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    06 - The BIW of The New BMW 5 Series Gran Turismo

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    Silverio Acuña
    The document discusses the body structure of the new BMW 5 Series Gran Turismo. It has a coupe-like exterior and interior design that provides personal space in the rear seats. Lightweight materials like aluminum and high-strength steels are used to improve efficiency while maintaining passenger safety, as demonstrated through crash test results. Hot stamped boron steels and aluminum are emphasized for structural components to achieve weight savings of over 60 kg compared to conventional steel grades.

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    06 - The BIW of The New BMW 5 Series Gran Turismo

    Uploaded by

    Silverio Acuña
    77 views25 pages
    The document discusses the body structure of the new BMW 5 Series Gran Turismo. It has a coupe-like exterior and interior design that provides personal space in the rear seats. Lightweight materials like aluminum and high-strength steels are used to improve efficiency while maintaining passenger safety, as demonstrated through crash test results. Hot stamped boron steels and aluminum are emphasized for structural components to achieve weight savings of over 60 kg compared to conventional steel grades.

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    The BIW of the New BMW 5 Series Gran Turismo

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    06 - The BIW of the New BMW 5 Series Gran Turismo

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    The document discusses the body structure of the new BMW 5 Series Gran Turismo. It has a coupe-like exterior and interior design that provides personal space in the rear seats. Lightweight materials like aluminum and high-strength steels are used to improve efficiency while maintaining passenger safety, as demonstrated through crash test results. Hot stamped boron steels and aluminum are emphasized for structural components to achieve weight savings of over 60 kg compared to conventional steel grades.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    77 views25 pages

    06 - The BIW of The New BMW 5 Series Gran Turismo

    Uploaded by

    Silverio Acuña
    The document discusses the body structure of the new BMW 5 Series Gran Turismo. It has a coupe-like exterior and interior design that provides personal space in the rear seats. Lightweight materials like aluminum and high-strength steels are used to improve efficiency while maintaining passenger safety, as demonstrated through crash test results. Hot stamped boron steels and aluminum are emphasized for structural components to achieve weight savings of over 60 kg compared to conventional steel grades.

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    w w w . a u t o s t e e l .

    o r g

    Great Designs in Steel is Sponsored by:


    AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
    Nucor Corporation, Severstal North America and United States Steel Corporation
    www.autosteel.org
    The Body in White of the new
    BMW 5 Series Gran Turismo.
    Duane Copeland
    BMW AG
    Markus Pfestorf
    BMW AG

    www.autosteel.org
    Contents

    www.autosteel.org
    Introduction

    Coupe-Like Exterior
    - Coupe-Like Silhouette
    - Frameless Doors
    - High-Quality Appearance of Exterior
    Personal Space - (ex. chrome and high gloss black elements)
    - Semi Command Position
    - Perfect Entry
    - Rear Leg Room
    - Sedan-like Separated Trunk
    - Panoramic Roof

    Functionality
    - Twin-Trunk Lid
    Modern, Elegant Interior - Trunk Volume
    - New Type of High-Quality Interior - Flexible 2nd Seat Row / Trunk Size
    - Extended Ambient Light
    - Single Rear Seat Configuration (option)

    www.autosteel.org
    Relative Product Dimensions

    1678 1456 1555

    2933 3070 3070

    BMW X6
    BMW 7 series
    BMW 5 series Gran Turismo

    www.autosteel.org
    Technical Components for EficientDynamics

    Integral-V-Multilink
    Lower CO2 Emissions Suspension

    Efficient TwinPower
    Turbo Engines

    Runflat Tires

    Eight Gear Automatic


    Transmission with Steptronic

    Double-Wishbone Light Weight


    Front Axle Body in White Design

    www.autosteel.org
    Torsional Stiffness and Lightweight Coefficient
    40.000 4,0

    Nm/° 3,5
    31,500 cT
    3.0
    30.000 3,0
    2.6 27,500
    25.000 2,5

    Lightweight coefficient L
    20.000 2,0
    Torsional stiffness cT

    15.000 L L 1,5

    10.000 1,0

    5.000 0,5

    0 0
    Closed Roof Sun Roof
    L Lightweight Coefficient
    mGer Kg mGer. Weight of Body-in-White
    L= [ x 10³ ]
    CT x A Nm/° x m² cT Torsional Stiffness
    A Area (wheel base x track width)

    www.autosteel.org
    Increase of Stiffness in the Front and Rear End

    High Pressure Cast


    Aluminum Shock Tower

    Struts Torsion Frame

    Aluminum Struts Steel


    Aluminum

    www.autosteel.org
    Passive Safety
    Driving
    Warning
    Correction
    Crash Unavoidable Post Crash

    Active safety Crash Passive safety

    Stiffness Strength

    cT

    www.autosteel.org
    Load Path of Side Impact

    B-Pillar

    Impact

    Hot Stamped Components

    www.autosteel.org
    USNCAP Barrier

    •Passenger Values OK
    •Doors Remain Closed

    Barrier Weight = 1368 kg

    8 Cylinder 4-Wheel Drive


    (incl. simulated luggage)
    Load = 2555 kg

    www.autosteel.org
    Materials
    Steel
    DC04
    DX54D
    DX56D
    HC180BD, HC180YD
    HC220BD, HC220YD
    HC260BD, HC260LAD, HC260X(D)
    HC300BD, HC300LAD, HC300X
    HC340LAD, HC340X(D)
    HC380LAD
    HC400T
    HC420LAD, HC450X
    HC600C, HD680C
    HC700X
    HC1000W (+TE), HC1000WD+ZF
    Aluminium

    AlMg3,5Mn
    AlMg4,5Mn0,4
    AlMg1/AlMg5,7/AlMg1
    AlMg0,4Si1,2
    AlSi0,6Mg0,5
    AlSi10MgMnFe
    AlMgSi

    Others
    Other metallic materials

    www.autosteel.org
    Materials of the Structure
    180 MPA 200 – 220 MPa
    7% 9%

    Deep Drawn Steel 260 MPa


    19% 10%

    Others
    5%
    300 - 340 MPa
    21%
    AlSi Aluminum
    2%

    1000 MPa
    12%

    600 - 700 MPa 380 - 450 MPa


    1% 14%

    www.autosteel.org
    Weight Savings Compared to Conventional Steel Grades

    Hot Stamped Parts: -20,7 kg

    Tail Gate: -13,2 kg


    Shock Tower: -4,0 kg

    Hood: -7 kg
    Doors: -16 kg

    Total weight savings due to lightweight material design: 60,9 kg


    www.autosteel.org
    Hot Stamped Parts
    B-Pillar Reinforcement B-Pillar Reinforcement Inner
    Material: HC1000WD+ZF Material: HC1000W
    Thickness 1,80 Thickness 1,60
    Longitudinal Side Member Inner
    A-Pillar Reinforcement Material: HC1000WD+ZF
    Material: HC1000W Thickness 1,50
    Thickness 1,60
    Hinge Carrier Reinforcement
    Material: HC1000WD+ZF
    Thickness 1,60

    Longituidinal Side Member Outer


    Material: HC1000WD+ZF
    Thickness 1,00

    Tunnel Reinforcement
    Material: HC1000W+TE Uncoated Material
    Thickness: 1,50 Zinc Coated Material

    www.autosteel.org
    Press Hardening Process for Zinc Coated Boron Steel

    Hot dipped Cold forming Austenizing + Annealing Cleaning Oiling


    galvanized coil press hardening (optional) (optional) (optional)

    1. Form and Trim in a conventional cold forming process.

    2. Heat up the part to Austenitizing Temperature.

    3. Pressharden by Quenching in a cooled die.

    4. Cleaning of the parts to remove Oxide Layer (optional).

    www.autosteel.org
    Press Hardening Process for Zinc coated Boron Steel

    Film

    www.autosteel.org
    Press Hardening Process Window
    Increase of Oxide Layer

    min. Time for Process Window max. Time for


    Mechanical • Welding
    Properties • Corrosion Protection
    (austenitization of the • Paint Adhesion
    material) • Glue Adhesion
    (Oxide layer and Fe
    content)

    Oxide Layer
    Zn Fe Coating

    Basic Material

    www.autosteel.org
    Barrier and Cathodic Protection
    A. Overview Picture:
    • Zinc Coated Hot Formed
    Steel after 10 weeks of
    testing

    B. Region along the Scratch:


    • Cathodic Protection
    • No Base Material Corrosion
    • Corrosion Creep of Paint:
    100µm
    0,4mm

    Iron Zinc C. Undamaged Region:


    • Barrier and Cathodic Protection
    Zn Fe Coating

    22MnB5 50µm

    Conclusion:
    • Protection exists even with damaged surface and along cut edges
    • Application in wet areas without supplementary support

    www.autosteel.org
    Coating Properties – Zinc Distribution

    22MnB5

    Zn-Fe-
    Layer

    10µm 10µm

    Zinc-, Iron- Distribution

    Conclusion:
    • no zinc within the base material
    • no Embrittlement of grain
    boundaries by zinc
    Zn-Fe Layer 22MnB5

    www.autosteel.org
    Other Applications of Zinc Coated Boron Steel

    BMW 7 series (SOP 2008) BMW 5 series (SOP 2010)

    www.autosteel.org
    Application of Dual Phase Steel

    Steel Grades

    HC260XD
    HC300X
    HC340X(D)
    HC400T
    HC450X
    HC600C, HD680C

    www.autosteel.org
    Dachrahmen innen hinten an Serienstand angepasst 14.09.09
    Work Hardening of Dual Phase Steel (HC450X)
    Thinning

    min. Specimen

    max.

    Measured Yield
    Strength Section 1 Section 2

    Bent Part 548 MPa 557 MPa


    Deep Drawn Part 767 MPa 580 MPa
    www.autosteel.org
    Thank You for Your Attention

    www.autosteel.org
    w w w . a u t o s t e e l . o r g

    Great Designs in Steel is Sponsored by:


    AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
    Nucor Corporation, Severstal North America and United States Steel Corporation
    www.autosteel.org

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