Funded by

InnoMateria 2012

Cologne, 22 Mai 2012 Collins Ntchouzou, Volkswagen AG Alexander Schiebahn, ISF

Funded by

Light-eBody Objectives & Design Approach

Development of an innovative multi-material lightweight car body Intensive use of profiles made from (ultra) high strength steel for the vehicle load bearing structure Lightweight panels from low density materials (aluminium, plastics, metalplastic-hybrids or sandwich material) Integration of the battery structure in the vehicle structure as load bearing element Details analysis of the used materials, manufacturing technologies and joining technologies CAE method development to enable a reliable simulation of the material combination and the joining Life Cycle Analysis investigations

C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Slide No. 2

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Light-eBody consortium 2012

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Light-eBody Objectives & Design Approach

Ultra high strength steel vehicle structure in profile intensive design

Lightweight panels from material with low density (aluminium or plastics)

Source: Ford
C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

Load bearing battery structure

Slide No. 3 22.05.2012 Light-eBody consortium 2012

Funded by

Light-eBody Consortium
Altair Engineering Bllhoff Dow Ford Fraunhofer LBF Hydro Aluminium Institut fr Kraftfahrzeuge Institut fr Schweitechnik & Fgetechnik Laboratorium fr Werkstoff- & Fgetechnik LINDE + WIEMANN Rchling Automotive ThyssenKrupp Steel Volkswagen Werkzeugmaschinenlabor
C. Ntchouzou, A. Schiebahn/ InnoMateria 2012 Slide No. 4 22.05.2012 Light-eBody consortium 2012

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Light-eBody Basic Specifications

Use case: Seats: Range: vmax: Weight: Production: Segment: urban/commute 2+3 > 150 km (NEDC) 150 km/h 1,250 kg large volume (1,000/d) C

C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012

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Light-eBody Topology Optimisation Load Paths

Determination of material distribution within a specified design space Objective: minisation of complaince Constraint: 80% volume reduction
Frontal impact IIHS Side impact Global stiffness

Load cases
Side impact Pole impact FMVSS 301 Rear impact

Design space

Material distribution

C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012

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Light-eBody Materials & manufacturing technologies

Materials Manufacturing technologies
Casting Rolled forming

Plastics Aluminium Magnesium Steel

Form-Blow-Hardening Tailored Tempering Extrusion T3 Technology

C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012

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Research in innovative, high-volume capable joining technologies for multi-material design

Examples (1/2): High-speed bolt joining

LWF

Boellhoff

Spotwelding with elements

LWF

Selfpiercing riveting

C. Ntchouzou, A. Olfermann, A. Schiebahn/ InnoMateria 2012 T. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012

Funded by

Research in innovative, high-volume capable joining technologies for multi-material design

Examples (2/2): Laser beam welding

Indirect spot-welding

Adhesive bonding / hybrid joining with new structural epoxies

C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012

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Life Cycle Analysis based on ISO 14040

Input
Energy Raw materials

Production Recycling Use

Output
Emission Waste

C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012

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Conclusions
Topology optimisation was conducted to identify the main load paths The load bearing structure was split into car body structure and battery structure Suitable joining techniques for the realisation of this approach are now analysed and developed. CAE methods for the simulation of the joining of the material combination are in development Development accompanying LCA The integration of the battery structure as load bearing part of the vehicle structure helps reducing the vehicle weight. The intensive profile design approach is very promising concerning light weight and modularity, but the joining remains a big challenge.
C. Ntchouzou, A. Schiebahn/ InnoMateria 2012 Slide No. 11 22.05.2012 Light-eBody consortium 2012

Funded by

Innovation beginning of the 20th century

Worldwide demand for motor vehicles will not exceed one million
solely due to the lack of available drivers.

Gottlieb Daimler, 1901

Worldwide sold vehicles in 2010:

> 60 Mio.

Worldwide sold battery electric vehicles in the next decades:> ? Mio. Faith in the future innovation !
C. Ntchouzou, A. Schiebahn/ InnoMateria 2012 Slide No. 12 22.05.2012 Light-eBody consortium 2012

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C. Ntchouzou, A. Schiebahn/ InnoMateria 2012

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Light-eBody consortium 2012