Material Related Design With Tailor Rolled Products

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:
Costs
$
$
$
Weight
Reduction
+ Part
Integration
+ Functional
Improvement
Integration of Mubea
Customer’s
Benefit

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
TRB Application in BIW
Load Path Front Crash
Transition Zone
Constant Thickness
Example
Longitudinal Member
TRB Application in BIW
Load Path Side Crash
Transition Zone
Constant Thickness
Example
B-Pillar Reinforcement
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
Standard B-Pillar
IIHS Side Impact*
* source: Insurance Institute of Highway Safety
Mubea Tailor Rolled Blanks Technology
Objective

Weight and function optimization
Innovation
- 1.0 kg

Thickness variation along the length of a
part
Advantages
Standard B-Pillar
Mubea B-Pillar
closing plate:
Patch-Reinf.:
Reinf.-B-Pillar:
m = 2.0 kg
m = 1.9 kg
m = 5.4 kg
closing plate:
Reinf.-B-Pillar:
total weight:
m = 9.3 kg
total weight*:

Weight reduction of up to 10%

Integration of reinforcements lead to
decreased efforts for logistics and
joining

Weight and function optimized body
structures
TRB®
m = 2.0 kg
m = 6.3 kg
m = 8.3 kg
Status
weight reduction per vehicle:
> 2.0 kg

Serial application
Mubea Tailor Rolled Blanks Technology
Closing Plate
DP590 / 1.2 mm
2.0 kg
Closing Plate
DP590 / 1.2 mm
2.0 kg
2.0 mm
2.5 mm
- 1.0 kg
2.9 mm
2.5 mm
B-Pillar
Reinforcement
22MnB5 / 1.8 mm
5.4 kg
Patch
22MnB5 / 2.2 mm
1.9 kg
2.0 mm
TRB B-Pillar
Reinforcement
22MnB5 / TRB
6.3 kg
weight reduction per vehicle: > 2.0 kg
1.45 mm
Welding Condition Standard B-Pillar
Standard concept
Closing Plate
Reinf. B-Pillar
Section A - A
Closing Plate
DP590 / 1.2 mm
Patch
22MnB5 / 2.2 mm Detail B
A-A
Detail B
1.2 mm
1.8 mm
Reinf. B-Pillar
22MnB5 / 1.8 mm
Patch
Joining Outer by 3 panel spot welding
0.7 mm
Outer Panel
Mild Steel / 0.7 mm
Joining Outer by 3 panel spot welding
3 panel spot welding condition
Spot welding Closing Plate 1.2 mm, Reinf. B-Pillar 1.8 mm and Outer Panel 0.7 mm
Welding Condition TRB® B-Pillar
TRB® B-Pillar concept
Closing Plate
2.0 mm
Section A - A
Detail B
Closing Plate
DP590 / 1.2 mm
2.5 mm
Detail B
1.2 mm
A-A
2.9 mm
2.9 mm
2.5 mm
2.0 mm
Reinf. B-Pillar
1.45 mm
Joining Outer by 3 panel spot welding
Reinf. B-Pillar
22MnB5 / 2.9 mm
0.7 mm
Outer Panel
Mild Steel / 0.7 mm
Joining Outer by 3 panel spot welding
3 panel spot welding condition
Spot welding ratio leads to a smaller process window for the up gauged area
Mubea Flange Technology (MFT)
Objective

Weight and function optimization
Innovation

- 1.5 kg
Welded assembly body structure with
single-layered flanges in combination
with TRB®
Advantages
MFT
Constant B-Pillar
Mubea Flange Technology
closing plate:
Patch-Reinf.:
Reinf.-B-Pillar:
m = 2.0 kg
m = 1.9 kg
m = 5.4 kg
closing plate:
Reinf.-B-Pillar:
m = 2.0 kg
m = 5.8kg
total weight:
m = 9.3 kg
total weight*:
m = 7.8 kg
weight reduction per vehicle:
> 3.0 kg

Weight reduction of up to 16%

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
Concept and Assembly TRB® MFT B-Pillar
TRB® MFT Concept
TRB® MFT Assembly
Section A - A
Detail A
A
A
Detail A
Laser welding
1.2 mm
2.9 mm
New trimming of flange area
Joining Closing Plate & Reinf. B-Pillar
Continiuous laser welding
Continuous laser welding leads to higher stiffness along the length of the B-Pillar
New trim line
Laser welding
Welding Condition TRB® MFT B-Pillar
TRB® MFT B-Pillar
Closing Plate
2.0 mm
Section A - A
Detail A
Closing Plate
DP590 / 1.2 mm
2.5 mm
Detail A
Laser welding
1.2 mm
A-A
2.9 mm
2.5 mm
2.0 mm
Reinf. B-Pillar
1.45 mm
Joining Outer by 2 panel spot welding
0.7 mm
Reinf. B-Pillar
22MnB5 / 2.9 mm
2.9 mm
Outer Panel
Mild Steel / 0.7 mm
Joining Outer by 2 panel spot welding
2 panel spot welding condition
Spot welding Closing Plate with 1.2 mm to the Outer Panel with 0.7 mm
Mubea B-Pillar Slim Foot Design
Objective

Weight and function optimization
Innovation

- 1.6 kg
Introducing a slim foot design to get
a parallel nesting within the max. coil
width of TRB®
Advantages
Mubea B-Pillar
Constant B-Pillar
Slim Foot Design TRB®
closing plate:
Patch-Reinf.:
Reinf.-B-Pillar:
m = 2.0 kg
m = 1.9 kg
m = 5.4 kg
closing plate:
Reinf.-B-Pillar:
m = 2.0 kg
m = 5.7kg
total weight:
m = 9.3 kg
total weight*:
m = 7.7 kg

Weight reduction of up to 17%

High material utilization

Independent thickness run without
requiring a symmetry line
Status

weight reduction per vehicle:
> 3.2 kg
In serial production soon
Mubea B-Pillar Slim Foot Design
2.0 mm
Nesting
Thickness
2.5 mm
2.9 mm
2.5 mm
Material Utilization
63 %
2.0 mm
1.45 mm
Length / mm
Mubea B-Pillar TRB®
1.6 mm
Nesting
1.8 mm
Thickness
2.7 mm
2.0 mm
2.2 mm
2.0 mm
Material Utilization
69 %
1.6 mm
Mubea B-Pillar
Slim Foot TRB®
Length / mm
Mubea B-Pillar Slim Foot Design
B-Pillar Slim Foot Design
B-Pillar Slim Foot Design
Detail A
Reinf.
Closing
B-Pillar
Plate
Detail A
Spot weld
Closing Plate and Reinf. B-Pillar
Side view with spot welds
Closing Plate for joining Outer Panel
No spot welds at the high deformation area to prevent initial cracks
Mubea B-Pillar Slim Foot Design
Closing Plate
DP590 / 1.2 mm
2.0 kg
B-Pillar
Reinforcement
22MnB5 / 1.8 mm
5.4 kg
Patch
22MnB5 / 2.2 mm
1.9 kg
IIHS Side Crash template
Standard B-Pillar concept fulfills the rating “good” for IIHS Side Crash
Mubea B-Pillar Slim Foot Design
1.6 mm
Closing Plate
DP590 / 1.2 mm
2.0 kg
1.8 mm
2.7 mm
2.0 mm
2.2 mm
2.0 mm
1.6 mm
B-Pillar
Reinforcement
22MnB5 / TRB®
5.7 kg
IIHS Side Crash template
Mubea B-Pillar Slim Foot TRB® concept fulfills the rating “good” for IIHS Side Crash
Mubea B-Pillar Slim Foot Design
Global Stiffness Analysis
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%
Normal Mode 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%
Material related design with TRB®
Mubea Flange Technology

Weight reduction of up to 16%

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
Mubea B-Pillar Slim Foot Design

Weight reduction of up to 17%

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