5 series biw

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The Body in White of the new The Body in White of the new The Body in White of the new The Body in White of the new BMW 5 Series Gran Turismo. BMW 5 Series Gran Turismo. BMW 5 Series Gran Turismo. BMW 5 Series Gran Turismo. w w w . a u t o s t e e l . o r g BMW 5 Series Gran Turismo. BMW 5 Series Gran Turismo. BMW 5 Series Gran Turismo. BMW 5 Series Gran Turismo. Duane Copeland Duane Copeland Duane Copeland Duane Copeland BMW AG Markus Pfestorf Markus Pfestorf Markus Pfestorf Markus Pfestorf BMW AG

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Page 1: 5 Series BIW

The Body in White of the new The Body in White of the new The Body in White of the new The Body in White of the new

BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.

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BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.

Duane CopelandDuane CopelandDuane CopelandDuane CopelandBMW AG

Markus PfestorfMarkus PfestorfMarkus PfestorfMarkus PfestorfBMW AG

Page 2: 5 Series BIW

Contents

I) Introduction

II) Concept of the Car

III) Materials and Manufacturing Technologies

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Page 3: 5 Series BIW

Introduction

Personal Space- Semi Command Position- Perfect Entry- Rear Leg Room- Sedan-like Separated Trunk- Panoramic Roof

Coupe-Like Exterior- Coupe-Like Silhouette- Frameless Doors- High-Quality Appearance of Exterior - (ex. chrome and high gloss black elements)

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- Panoramic Roof

Modern, Elegant Interior- New Type of High-Quality Interior- Extended Ambient Light- Single Rear Seat Configuration (option)

Functionality- Twin-Trunk Lid- Trunk Volume- Flexible 2nd Seat Row / Trunk Size

Page 4: 5 Series BIW

Relative Product Dimensions

1678 1456 1555

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BMW X6

BMW 7 series

BMW 5 series Gran Turismo

2933 3070 3070

Page 5: 5 Series BIW

Technical Components for EficientDynamics

Lower CO2 Emissions

Efficient TwinPower Turbo Engines

Integral-V-MultilinkSuspension

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Runflat Tires

Turbo Engines

Eight Gear Automatic Transmission with Steptronic

Double-WishboneFront Axle

Light Weight Body in White Design

Page 6: 5 Series BIW

Torsional Stiffness and Lightweight CoefficientTo

rsio

na

l stiffn

ess c

T

L

27,5003.0

L

31,500

2.6

15.000

20.000

25.000

30.000

Nm/°

40.000

Lig

htw

eig

ht co

effic

ien

t L

1,5

2,0

2,5

3,0

4,0

3,5cT

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To

rsio

na

l stiffn

ess c

L = mGer

CT x A[ x 10³ ]

Kg

Nm/°x m²

L Lightweight CoefficientmGer. Weight of Body-in-WhitecT Torsional StiffnessA Area (wheel base x track width)

LL

0

5.000

10.000

15.000

Sun RoofClosed Roof

Lig

htw

eig

ht co

effic

ien

t L

0

0,5

1,0

1,5

Page 7: 5 Series BIW

Increase of Stiffness in the Front and Rear End

High Pressure Cast Aluminum Shock Tower

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Struts Torsion Frame

Steel

AluminumAluminum Struts

Page 8: 5 Series BIW

Passive Safety

Passive safetyActive safety Crash

Correction

Driving

Warning

Crash Unavoidable Post Crash

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cT

Stiffness Strength

Page 9: 5 Series BIW

Load Path of Side Impact

B-Pillar

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Impact

Hot Stamped Components

Page 10: 5 Series BIW

USNCAP Barrier

Barrier Weight = 1368 kg

•Passenger Values OK

•Doors Remain Closed

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Barrier Weight = 1368 kg

8 Cylinder 4-Wheel Drive

(incl. simulated luggage)

Load = 2555 kg

Page 11: 5 Series BIW

Materials

Aluminium

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

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Others

Other metallic materials

Aluminium

AlMg3,5Mn

AlMg4,5Mn0,4

AlMg1/AlMg5,7/AlMg1

AlMg0,4Si1,2

AlSi0,6Mg0,5

AlSi10MgMnFe

AlMgSi

Page 12: 5 Series BIW

Materials of the Structure

180 MPA7%

200 – 220 MPa9%

260 MPa10%

AlSi Aluminum

Others5%

300 - 340 MPa21%

Deep Drawn Steel19%

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380 - 450 MPa14%

600 - 700 MPa1%

1000 MPa12%

AlSi Aluminum2%

21%

Page 13: 5 Series BIW

Weight Savings Compared to Conventional Steel Grades

Hot Stamped Parts: -20,7 kg

Tail Gate: -13,2 kg

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Shock Tower: -4,0 kg

Hood: -7 kg

Doors: -16 kg

Tail Gate: -13,2 kg

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

Page 14: 5 Series BIW

Hot Stamped Parts

B-Pillar ReinforcementMaterial: HC1000WD+ZFThickness 1,80

B-Pillar Reinforcement InnerMaterial: HC1000WThickness 1,60

A-Pillar ReinforcementMaterial: HC1000WThickness 1,60

Longitudinal Side Member InnerMaterial: HC1000WD+ZFThickness 1,50

Hinge Carrier ReinforcementMaterial: HC1000WD+ZFThickness 1,60

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Uncoated Material

Zinc Coated Material

Tunnel ReinforcementMaterial: HC1000W+TEThickness: 1,50

Longituidinal Side Member OuterMaterial: HC1000WD+ZFThickness 1,00

Page 15: 5 Series BIW

Press Hardening Process for Zinc Coated Boron Steel

Hot dipped galvanized coil

Cold forming Austenizing + press hardening

Cleaning(optional)

Oiling (optional)

Annealing(optional)

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

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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).

Page 16: 5 Series BIW

Press Hardening Process for Zinc coated Boron Steel

Film

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Film

Page 17: 5 Series BIW

Press Hardening Process Window

min. Time for Mechanical Properties (austenitization of the

material)

Process Window max. Time for • Welding• Corrosion Protection• Paint Adhesion• Glue Adhesion(Oxide layer and Fe

Increase of Oxide Layer

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(Oxide layer and Fe

content)

Oxide Layer

Zn Fe Coating

Basic Material

Page 18: 5 Series BIW

Barrier and Cathodic Protection

B. Region along the Scratch:

• Cathodic Protection

• No Base Material Corrosion

• Corrosion Creep of Paint:

A. Overview Picture:

• Zinc Coated Hot Formed

Steel after 10 weeks of

testing

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100µm

50µm

Conclusion:

• Protection exists even with damaged surface and along cut edges

• Application in wet areas without supplementary support

• Corrosion Creep of Paint:

0,4mm

C. Undamaged Region:

• Barrier and Cathodic Protection Zn Fe Coating

22MnB5

Iron Zinc

Page 19: 5 Series BIW

Coating Properties – Zinc Distribution

22MnB5

Zn-Fe-

Layer

10µm 10µm

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Conclusion:

• no zinc within the base material

• no Embrittlement of grain boundaries by zinc

Zinc-, Iron- Distribution

22MnB5Zn-Fe Layer

Page 20: 5 Series BIW

Other Applications of Zinc Coated Boron Steel

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

Page 21: 5 Series BIW

Application of Dual Phase Steel

w w w . a u t o s t e e l . o r gDachrahmen innen hinten an Serienstand angepasst 14.09.09

Steel Grades

HC260XD

HC300X

HC340X(D)

HC400T

HC450X

HC600C, HD680C

Page 22: 5 Series BIW

Work Hardening of Dual Phase Steel (HC450X)

Specimen

1

Thinning

min.

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2

Bent Part

Deep Drawn Part

Section 1 Section 2

548 MPa 557 MPa

767 MPa 580 MPa

Measured Yield

Strength

max.

Page 23: 5 Series BIW

Thank You for Your Attention

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