material related design with tailor rolled products/media/files/autosteel/great designs in... ·...

Material Related Design

With Tailor Rolled Products

Markus Zoernack

Mubea, Inc.

Benefit of Flexible Rolling

$

$

Idea:

Lightweight parts with load and function-optimized

material usage

Implementation of Idea / Targets / Benefits:

Flexible Cold-Rolling Process

Flat material with repeated, varying thickness runs

and harmonious transition zones

An increased number of thickness zones for an

optimized TRB solution results in minimal

lightweight cost

Targets / Benefits:

Weight Reduction

Part Integration

Functional Improvement

Costs

Customer’s

Benefit

Integration of Mubea

Weight

Reduction

+ Functional

Improvement

+ Part

Integration

$

Load Path Front Crash

Example

Longitudinal Member

TRB Application in BIW

Transition Zone

Constant Thickness

Load Path Side Crash

Example

B-Pillar Reinforcement

TRB Application in BIW

Transition Zone

Constant Thickness

Mubea Tailor Rolled Blanks Technology

Main requirements

Security of passenger cell

Market related requirements

Euro-NCAP / IIHS

Narrow design of the upper area

Benefits with TRB®

Ideal load distribution due to

harmonic transition zones

(no notch effect)

Tuning of crash performance by

adjusted gauges

Cost reduction by part integration IIHS Side Impact*

* source: Insurance Institute of Highway Safety

Standard B-Pillar


weight reduction per vehicle:

> 2.0 kg

Standard B-Pillar

closing plate: m = 2.0 kg

Patch-Reinf.: m = 1.9 kg

Reinf.-B-Pillar: m = 5.4 kg

total weight: m = 9.3 kg

Mubea B-Pillar TRB®



total weight*: m = 8.3 kg

- 1.0 kg

Objective

Weight and function optimization

Innovation

Thickness variation along the length of a

part

Advantages

Weight reduction of up to 10%

Integration of reinforcements lead to

decreased efforts for logistics and

joining

Weight and function optimized body

structures

Status

Serial application


weight reduction per vehicle: > 2.0 kg

- 1.0 kg


22MnB5 / 1.8 mm 5.4 kg

Closing Plate DP590 / 1.2 mm

2.0 kg

Patch 22MnB5 / 2.2 mm

1.9 kg


2.0 kg

TRB B-Pillar Reinforcement

22MnB5 / TRB 6.3 kg

2.5 mm

2.0 mm

2.9 mm

2.5 mm

2.0 mm

1.45 mm

Section A - A

Joining Outer by 3 panel spot welding

Standard concept


Welding Condition Standard B-Pillar

Reinf. B-Pillar Closing Plate

Patch

A - A

Reinf. B-Pillar 22MnB5 / 1.8 mm



Outer Panel Mild Steel / 0.7 mm

Detail B

3 panel spot welding condition

Detail B

1.8 mm

1.2 mm

0.7 mm

Spot welding Closing Plate 1.2 mm, Reinf. B-Pillar 1.8 mm and Outer Panel 0.7 mm

Section A - A


TRB® B-Pillar concept


Welding Condition TRB® B-Pillar

Reinf. B-Pillar

Closing Plate

A - A




Detail B


Detail B

2.9 mm

1.2 mm

0.7 mm

2.5 mm

2.0 mm

2.9 mm

2.5 mm

2.0 mm

1.45 mm

Spot welding ratio leads to a smaller process window for the up gauged area

Mubea Flange Technology (MFT)

Objective


Innovation

Welded assembly body structure with

single-layered flanges in combination

with TRB®

Advantages


Improved connectivity to body

structure due to single-layered flange

Highly efficient solution due to

building closed section (like tubes)

while improving performance

Status

Serial development

MFT Mubea Flange Technology


Reinf.-B-Pillar: m = 5.8kg


- 1.5 kg

Constant B-Pillar






> 3.0 kg

TRB® MFT Assembly

Joining Closing Plate & Reinf. B-Pillar

TRB® MFT Concept

New trimming of flange area

Section A - A

Continiuous laser welding

Concept and Assembly TRB® MFT B-Pillar

New trim line Laser welding

Continuous laser welding leads to higher stiffness along the length of the B-Pillar

A A

Detail A

2.9 mm

1.2 mm

Laser welding Detail A

TRB® MFT B-Pillar


Section A - A


Welding Condition TRB® MFT B-Pillar

Reinf. B-Pillar

Closing Plate

A - A




Detail A


Detail A

2.9 mm

1.2 mm

0.7 mm

2.5 mm

2.0 mm

2.9 mm

2.5 mm

2.0 mm

1.45 mm

Spot welding Closing Plate with 1.2 mm to the Outer Panel with 0.7 mm

Laser welding

Mubea B-Pillar Slim Foot Design

Objective


Innovation

Introducing a slim foot design to get

a parallel nesting within the max. coil

width of TRB®

Advantages


High material utilization

Independent thickness run without

requiring a symmetry line

Status

In serial production soon

Mubea B-Pillar Slim Foot Design TRB®


Reinf.-B-Pillar: m = 5.7kg


- 1.6 kg


> 3.2 kg

Constant B-Pillar






Mubea B-Pillar TRB®

Mubea B-Pillar

Slim Foot TRB®

Material Utilization

63 % T

hic

kn

es

s

Th

ick

nes

s

Length / mm

Length / mm

Material Utilization

69 %

2.5 mm

2.0 mm

2.9 mm

2.5 mm

2.0 mm

1.45 mm

1.8 mm

1.6 mm

2.7 mm

2.2 mm

2.0 mm

1.6 mm

2.0 mm

Nesting

Nesting

B-Pillar Slim Foot Design

Side view with spot welds

B-Pillar Slim Foot Design

Closing Plate and Reinf. B-Pillar


Reinf.

B-Pillar Closing

Plate

Detail A

Closing Plate for joining Outer Panel

Detail A

No spot welds at the high deformation area to prevent initial cracks

Spot weld


IIHS Side Crash template


22MnB5 / 1.8 mm 5.4 kg


2.0 kg


1.9 kg

Standard B-Pillar concept fulfills the rating “good” for IIHS Side Crash


IIHS Side Crash template B-Pillar

Reinforcement 22MnB5 / TRB®

5.7 kg


2.0 kg

Mubea B-Pillar Slim Foot TRB® concept fulfills the rating “good” for IIHS Side Crash

1.8 mm

1.6 mm

2.7 mm

2.2 mm

2.0 mm

1.6 mm

2.0 mm


Analysis Baseline Design Slim Foot TRB

Design % Difference

Global Torsion Stiffness

(KN-m/Deg) 23.34 23.05 -1%

Global Bending Stiffness

(KN/mm) 10.94 10.77 -1.6%

Global Stiffness Analysis

Analysis Baseline Design Slim Foot TRB Design % Difference

Torsion Mode(Hz) 32.43 32.45 0%

Frontal Lateral Bending

Mode(Hz) 34.29 34.31 0%

Overall Bending

Mode(Hz) 43.81 43.43 -1%

Normal Mode Analysis

Material related design with TRB®

Mubea Flange Technology


Improved connectivity to body structure

Highly efficient solution due to building closed section

Increased process window for spot welding due framing

Ready for serial production



For parallel nesting and increased material utilization

Independent thickness run without symmetry conditions

No spot welds at the high deformation area

In serial production soon

Mubea: Supporting supplier of lightweight solutions

material related design with tailor rolled products/media/files/autosteel/great designs in... ·...

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