THE USE OF CARBON COMPOSITES FOR AUTOMOTIVE APPLICATIONS. · CFK-Valley Stade Convention | 15-16 June 2016 | The use of Carbon Composites for Automotive Applications - Opportunities

Dr. Lutz-Eike Elend | EK-8 | 15-16 June 2016

THE USE OF CARBON COMPOSITES FOR AUTOMOTIVE APPLICATIONS.

OPPORTUNITIES AND CHALLENGES.

THE USE OF CARBON COMPOSITES FOR AUTOMOTIVE APPLICATION.

AGENDA.

Page 2

Introduction

Conclusion

The all new BMW 7 series

1.

4.

3.

The structural concept of the BMW i2.

CFK-Valley Stade Convention | 15-16 June 2016 | The use of Carbon Composites for Automotive Applications - Opportunities and Challenges | Dr. Lutz-Eike Elend | BMW AG

Electrification

Legislation

Comfort

Safety+ kg

Fuel Consumption

Transverse Dynamics

Driving Range

Acceleration

Design Method

Increasing demands in comfort, safety, electrification and legislation cause a weight gain.

INTRODUCTION.

LIGHTWEIGHT OFFERS A DIRECT CUSTOMER BENEFIT.

- kg

Page 3

- kg



AGENDA.

Page 4

Introduction

Conclusion


1.

4.

3.



BMW I3 – SOP 2013.

MIXED MATERIAL DESIGN ON A MODULE LEVEL (LIFE-/DRIVE-MODULE).

Key Facts:

approx. 67kg CFRP

approx. 27,000 units per year

CFK-Valley Stade Convention | 15-16 June 2016 | The use of Carbon Composites for Automotive Applications - Opportunities and Challenges | Dr. Lutz-Eike Elend | BMW AG Page 5

BMW I8 – SOP 2014.

MIXED MATERIAL DESIGN ON A MODULE LEVEL (LIFE-/DRIVE-MODULE).

Key Facts:

approx. 67kg CFRP

approx. 27.000 units per year

Key Facts:

approx. 136kg CFRP

approx. 6,500 units per year


Carbon fibreLife module

LIGHTWEIGHT CONSTRUCTION.

BMW I3 AND BMW I8. LIFE/DRIVE ARCHITECTURE.

Page 7

Aluminum drive module

Electric engine

High-voltage-battery (Lithium –ion)

Twin power turbo engine


Page 8

BMW I8 – HIGHLIGHTS.

ARCHITECTURE AND STRUCTURAL CONCEPT.

Hood

Aluminum, painted in two colors

Integration of cooling air outlet

Full-LED headlight

Laser light (optional)

Active regulated air vents

Optimized cd-value

Acoustic insulating panel

Chemical hardened glass (2,2 mm

thickness) with embedded acoustic

foil

Interior with sustainable materials

Recycled materials

Avoidance of PVC materials

Olive tanned leather

High absorption acoustic concept

Body rear end in aluminum

Lightweight aluminum-shell design

CFRP Body-in-White

Lightweight

optimized functional performanceThermoplastics body skin

Unique Design

Aerodynamic performance

Lightweight wing doors

CFRP door structure

Aluminum door outer panel

E-latch

Outer mirror with translucent

indicator


Page 9

BMW I8 – HIGHLIGHTS.

MATERIAL CONCEPT OF THE LIFE-MODULE.

Stainless Steel1%

HSS10%

CFRP61%

AlMg-sheets9%

Al-Extrusion Profiles

9%

Thermoplastics3%

Others7%

Life-Module: approx. 168 kg

Drive-Module: approx. 59 kg

42 CFRP components:

14 monolithic RTM parts, incl. 3 integrated braided

parts with foam core

5 parts of recycled carbon fibers

23 monolithic fabric compression molding parts



AGENDA.

Page 10

Introduction

Conclusion


1.

4.

3.



When a body gets a name, it must be something special!

The lightest car in the segment

with extensive use of CFRP

through technology transfer

from BMW i.

Page 11

THE ALL NEW BMW 7 SERIES – DRIVING LUXURY.

SPECIFIC AIMS OF THE DEVELOPMENT.


Page 12

THE ALL NEW BMW 7 SERIES – CARBON CORE.

WEIGHT REDUCTION BY UP TO 130 KG.

+70 kg*

Weight

Increase

Measures

Needed

200 kg*

Body Carbon Core -40 kg

Mounted Parts -10 kg

-50 kg

Unsprung Masses -40 kg

Acoustic Concept -10 kg

Optimization of Details -35 kg

Other Concepts -40 kg

Supplier Selection -25 kg

Reduction

Target

-130 kg*

1870 kg

Pre

de

ce

sso

r

* The given example is valid for 750Li xdrive, weight, unladen. to DIN

2000 kg


Page 13


INTELLIGENT COMBINATION OF CARBON FIBER, STEEL AND ALUMINUM.

First time to combine 3 Materials in the painted body

4 different CFRP technologies

3 different Alu technologies

Carbon Fibre with 100 % renewable energy

Alu with 50 % recycled material

Highlights

Facts and Figures- Neues Bild ? -

Weight body structure: 323 kg (331 kg LWB, Pan.roof)

Weight reduction: 40 kg

CFRP parts numbers: 16

Alu part numbers: 11

CFRP parts per day: > 4.000


Page 14


INTELLIGENT COMBINATION OF CARBON FIBER, STEEL AND ALUMINUM.

16 CFRP parts 4 different technologies CFRP Wet Compression

Molding

CFRP Resin Transfer Molding

CFRP-Steel Hybrid

CF Sheet Molding Compound


CFRP Steel Hybrid

Page 15


CFRP STEEL HYBRID.


Page 16


CF SHEET MOLDING COMPOUND.

CF Sheet MoldingCompound


Page 17


RECYCLED MATERIAL CF-SMC.

Dry waste material

• Roving / Fabric

• Stack

• Preform waste

Fibre preparation

• Punching / cutting of the material

• Separating the fabric into fibres

Fleece production

• Generating max. fibre orientation

• Fixation / stabilization

Multi-layer fleece

• Processing of the

fleece to a

multilayer complex

Return of the recycled carbon fibres into 3 CFRP parts in the BMW 7 series

Reinforcement C-Pillar (left/right), Trunk partition wall


Page 18


WET COMPRESSION MOLDING AND RESIN TRANSFER MOLDING.

CFRP Resin Transfer Molding

CFRP Wet CompressionMolding


Page 19


CFRP WET COMPRESSION MOLDING AND CFRP MILLING MACHINE.



AGENDA.

Page 20

Introduction

Conclusion


1.

4.

3.



CONCLUSION.

FUTURE CFRP BODY IN WIGHT CONCEPTS.


2015: BMW 7 series

2013: BMW i3

2014: BMW i8

THANK YOU FOR YOUR ATTENTION.


Documents

THE USE OF CARBON COMPOSITES FOR AUTOMOTIVE APPLICATIONS. · CFK-Valley Stade Convention | 15-16 June 2016 | The use of Carbon Composites for Automotive Applications - Opportunities