SMART APPLICATION KIT FOR LIGHTWEIGHT MULTI-MATERIAL BODY STRUCTURES

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1 FlexBody ROADSHOW 2012 LIGHTWEIGHT TECHNOLOGY SMART APPLICATION KIT FOR LIGHTWEIGHT MULTI-MATERIAL BODY STRUCTURES Speaker: Dipl.-Ing. Gerhard von Kulmiz / Imperia GmbH October 2012

2 Agenda page2 Partners / Consortium Motivation for Body Structure Kit Methodology Application & Validation Projects Structural Validation Crash Material Concept Cost Calculations for Low Volume Cars Volume Dependent Manufacturing

3 Industry and Research Consortium page3 I N D U S T R Y P A R T N E R S R E S E A R C H P A R T N E R S

4 Motivation for a Smart, Lightweight Body-Structure-Kit page4 Satisfies the small series homologation needs (< car/year) Quick to market Low investment Limited engineering resources (high knowledge base) Dedicated and clear attributes management

5 Methodology - Geometrical and production-technological intelligence page5 Knowledge Base Geometry Manufacturing Structural Topology Profiles Joints Body Structure Kit

6 Methodology Development process page6 Vehicle Base Information Attributes Configurator Topology Configurator Vehicle Base Information H m v Topology Configurator Attribute Configurator Global Deformation & Stiffness Targets Section & Beam Configurator Options Choice Component Targets Section & Beam Configurator d Joint Configurator Validation (virtuel) Joint Configurator - Material Choice - Mfg. Restrictions - CAD Knowledge Base Final FEM-Validation b - Stiffness - Crash

7 Validation Vehicles page7 Lampo 3 (Concept) ec2go (carsharing) ego(golf Caddy) Central Pipe Integrated Frame Source: Body Integrated Frame

8 Structural intelligence Example Crash page8 frontcrash sidecrash roofcrash pole side pole front Final Evaluation using FEM Low speed

9 Materialmix page9 Aluminium HS Aluminium Stainless Steel CrNi HS-Steel(DP1000) Steel CFRP GFRP The right material at the right place! Combinations of different materials are possible Focused on lightweight design and functional requirements Combination of various cross sections due to modular construction system Body integrated frame for maximum battery protection

10 Material Concept: Joints page 10 A C A A B A B B A = Aluminium B = Steel-Aluminium-Hybrid C = Titanium

11 Example of cost calculation for low volume cars page 11 Specification Material supply Topology Manufacturing 3-armig Gesamtkosten 4-armig 3-armig Durchschnittskosten 4-armig 3-arms 4-arms Milling lost-wax-casting LP-sand-casting Milling lost-wax-casting low pressure-sand-casting Alu Alu No. Joints

12 Example of manufacturing concept: Joining Technology page 12 New process: Injection bonding Motivation: - tolerance friendly - no welding distortion -material combinations are possible

13 Example: Injection Bonding page 13 1.) Sealing inside via adhesive 2.) Sealing outside via adhesive 3.) Injection & leak test Adhesive seal o.k.

14 Volume dependent manufacturing technology page 14 Investment jig/ fixture technology partly automated jig/ fixture technology manuel jig/ fixture technology burn-out-templates Volume

15 Example: e-car project page 15

16 Summary page 16 FlexBodyconcept is giving the chance to realize low volume niche vehicles projects. Body integrated frame for maximum battery protection Injection bonding for cold body manufacturing and possible use of different materials. Reduced engineering efforts due to high degree of standardization and parametric design Hybrid casting technology to combine different materials and reinforce critical areas Volume dependent manufacturing technology

17 THANK YOU FOR YOUR ATTENTION Contact: Gerhard von Kulmiz, Imperia GmbH Soerser Weg 9, Aachen, Germany Phone: ++49 (0) October 2012