Technologies for economical and functional lightweight design: Conference proceedings 2018

224 Pages·2019·33.343 MB·English

by  Klaus Dröder, Thomas Vietor

Zukunftstechnologien für den multifunktionalen Leichtbau
Klaus Dröder
Thomas Vietor Editors
Technologies for
economical and functional
lightweight design
Conference proceedings 2018
Zukunftstechnologien
für den multifunktionalen Leichtbau
Reihe herausgegeben von
Open Hybrid LabFactory e. V.
Ziel der Buchreihe ist es, zentrale Zukunftsthemen und aktuelle Arbeiten aus dem Umfeld des LeichtbauCampus
Open Hybrid LabFactory darzustellen. Es werden neue Denkansätze und Ergebnisse aus der Forschung zu unter-
schiedlichen Bereichen hybrider und multifunktionaler Bauteile vorgestellt. Dazu zählen Publikationen aus For-
schung, Entwicklung, Produktion und Prüfung dieser materialh ybriden Komponenten. Die Anwendbarkeit und
der Nutzen für den industriellen Einsatz stehen im Vordergrund der Beiträge und sichern nachhaltige Fortschritte
in der Fahrzeugentwicklung. Ebenfalls Ergebnisse und Berichte von Forschungsprojekten im Rahmen des durch
das Bundesministerium für Bildung und Forschung geförderten ForschungsCampus werden veröffentlicht und
Konferenzbände von Fachtagungen im Kontext der Open Hybrid LabFactory werden erscheinen.
Die Bände dieser Reihe richten sich an Wissenschaftler aus den Bereichen der Material-, Produktions- und
Mobilitätsforschung und an industrielle Experten der Branchen Technik, Anlangen- und Maschinenbau, Auto-
mobil & Fahrzeugbau sowie Werkstoffe & Werkstoffverarbeitung. Der Leser profitiert davon, dass ihm durch diese
Buchreihe ein konsolidiertes Angebot der öffentlichen Beiträge zu aktuellen Forschungsprojekten dargeboten wird.
The aim of this new book series is to present key future topics and current work from the LeichtbauCampus Open
Hybrid LabFactory. It presents new approaches and research findings from different areas of hybrid and
multifunctional components, including publications from the research, development, production and testing of
material hybrid components. The contributions focus on applicability and benefits for industrial use and ensure
sustainable progress in vehicle development. It also publishes the results and reports from research projects
within the framework of the ForschungsCampus scheme funded by the German Federal Ministry of Education
and Research, as well as the proceedings of conferences in the context of the Open Hybrid LabFactory.
The volumes in this series address scientists from the fields of materials, production and mobility research and
industrial experts in the fields of technology, plant engineering and mechanical engineer ing, automotive & vehicle
construction and materials & materials processing, offering readers a consoli dated range of public contributions
to current research projects.
Weitere Bände in der Reihe http://www.springer.com/series/16103
Klaus Dröder • Thomas Vietor (Eds.)
Technologies
for economical and functional
lightweight design
Conference proceedings 2018
Editors
Klaus Dröder Thomas Vietor
Technische Universität Braunschweig Technische Universität Braunschweig
Braunschweig, Germany Braunschweig, Germany
ISSN 2524-4787 ISSN 2524-4795 (electronic)
Zukunftstechnologien
für den multifunktionalen Leichtbau
ISBN 978-3-662-58205-3 ISBN 978-3-662-58206-0 (eBook)
https://doi.org/10.1007/978-3-662-58206-0
Library of Congress Control Number: 2019935981
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Preface
Every two years, Technische Universität Braunschweig in collaboration with ITS Mobility, organises
the conference “Faszination hybrider Leichtbau”. The conference brings together experts from re-
search and industry, in order to address leading research priorities and future challenges of the industry
in the field of hybrid lightweight Design. The conference is held in the city of Wolfsburg, Germany.

Initiated in 2003, the conference was held for the seventh time in 2018. As in previous years, hybrid
and functional lightweight design continued to be the focus of the event. Lightweight design is a key
technology in the development towards sustainable and resource-saving mobility. This applies in par-
ticular to the automotive industry, as automobile manufacturers are operating in a field of tension be-
tween customer requirements, competition and legislation. Hybrid structures combine the advantages
of different materials (e.g. fibre-reinforced plastics and metals) and have a high potential for minimiz-
ing weight, while simultaneously expanding component functionality. The future efficient use of func-
tion-integrated hybrid structures in vehicle design requires major innovations in vehicle development
and production technology. This constitutes a great need for new methods and technologies for eco-
nomical lightweight design in mass production – in particular when taking into account the increasing
requirements in terms of variant diversity, safety and quality.

Consequently, the focus of the conference was on new methods and technologies for the development
and production of function-integrated, hybrid and high volume ready lightweight solutions in vehicle
design, as well as, the exchange of experience between experts from industry and science.

The program included 50 presentations and was framed by top-class keynotes, which broadened the
horizon of this conference to digitalization, electro mobility and autonomous driving. A particular
highlight was the opening lecture of Johann Jungwirth (Executive Vice President of Mobility Services,
Volkswagen Group of America). We would like to thank our speakers and the over 250 participants
and are pleased to present these conference proceedings.

Wolfsburg, 23rd November 2018

Prof. Dr.-Ing. Klaus Dröder Prof. Dr.-Ing. Thomas Vietor
Table of Contents
Projects within the Open Hybrid LabFactory ..................................................................... 1
Multi material design. A current overview of the used potential in automotive industries ............. 3
Benjamin Bader, Eiko Türck, and Thomas Vietor
Data mining applications in manufacturing of lightweight structures ............................................. 15
Sebastian Gellrich, Marc-André Filz, Johannes Wölper, Christoph Herrmann, and
Sebastian Thiede
Development and numerical validation of combined forming processes for production
of hybrid parts .................................................................................................................................. 29
Bernd-Arno Behrens, Sven Hübner, Alexander Chugreev, André Neumann, Nenad Grbic,
Henrik Schulze, Ralf Lorenz, Moritz Micke, and Florian Bohne
Functional Components ............................................................................................................. 41
Hybrid components with function integration for crash related applications
in electromobility ............................................................................................................................. 43
Sebastian Iwan, Frank Schettler, Wolfgang Nendel, and Lothar Kroll
Composite engine block – Challenges for design and material ....................................................... 51
Melanie Jauernick, Dr. Christine Schütz, Joachim Sterz, and Birte Horn
Development of a light-weight seat structure using a hybrid material approach ............................ 61
Claudia Creighton, Mandy de Souza, Russell J. Varley, and John Antony
Smart Production/Smart Components .................................................................................. 69
Smart system integration – Potentials and challenges in the integrated condition
monitoring of lightweight structures ................................................................................................ 71
Michael Heinrich, Ricardo Decker, Marco Walther, and Lothar Kroll
Potentials of load carrying conductor tracks in new vehicle structures ........................................... 79
Alexander Pototzky, Daniel Stefaniak, and Christian Hühne
Numerical and experimental investigation of fiber reinforced biocomposites as structural
parts in automotive applications ...................................................................................................... 91
Benedikt Lahl, Nikita Pyatov, Christian Busch, Stefan Hartmann, Hans-Josef Endres, and
Tim Andreas Osswald
VIII Table of contents
Design and Simulation of Hybrid Structures ....................................................................... 103
Innovative hybrid material concepts and their virtual safeguarding ................................................ 105
Henning Gleich, Frank Meißen, Kim Kose, and Christian Paul
Carbon carrier – Integrated concept for innovative interior structures ............................................ 111
Michael Hage, Benjamin Wagner, and Frank Preller
Tailored stacked hybrids – An optimization-based approach in material design for further
improvement in lightweight car body structures ............................................................................. 119
Alan A. Camberg, Ina Stratmann, and Thomas Tröster
A manufacture constrained design methodology application for a tailored forming
hybrid component ............................................................................................................................ 133
Renan S. Siqueira, and Roland Lachmayer
New Production Technologies .................................................................................................. 145
Material- and process characterization of fibre-metal-elastomer laminate components
with high forming degrees ............................................................................................................... 147
Sven Roth, Sven Coutandin, and Jürgen Fleischer
Material Concepts ....................................................................................................................... 155
Film-adhesives for polymer-metal hybrid structures – From laboratory to
close-to-production .......................................................................................................................... 157
Thorsten Schnettker, Philipp Dreessen, Klaus Dröder, Christian Vogler, David Koch,
Thomas Frey, Benjamin Poller, Andreas Wedemeier, Christian Vree, Jörg Kosowski, and
Daniel Riss
Testing of metal connections using adhesive bonding combined
with self-piercing riveting ................................................................................................................ 167
M. Reil, O. Knoll, D. Morin, and M. Langseth
Application of innovative material concepts for safety lightweight inside cars using
alternative powertrains ..................................................................................................................... 175
Stefan Lindner
Bio-based materials for exterior applications – Project BioHybridCar ........................................... 189
Ole Hansen, Christoph Habermann, and Hans-Josef Endres
Improving the durability of bio hybrid fiber reinforced plastics by plasma treatment .................... 201
Florian Bittner, Martin Bellmann, Madina Shamsuyeva, Hans-Josef Endres, and
Wolfgang Viöl
The best properties from thermoplastic and thermosetting resins combined in fiber
reinforced plastics for improved productivity and properties .......................................................... 213
Andreas Niepel, Woo Jin Choi, Thomas Kowalik, and Andreas Hartwig
FAUST: Material characterization of low-cost foam materials under real boundary
process conditions for RTM large-scale production ........................................................................ 221
Mark Opitz, Dominic Bertling, and Nico Liebers
Projects within the Open Hybrid LabFactory
MULTI MATERIAL DESIGN. A CURRENT OVERVIEW OF THE USED
POTENTIAL IN AUTOMOTIVE INDUSTRIES

Benjamin Bader1, Eiko Türck, Thomas Vietor

1 Technische Universität Braunschweig, Institut für Konstruktionstechnik, Open Hybrid LabFactory,
Hermann-Münch-Straße 2, 38440 Wolfsburg, [email protected],
www.tu-braunschweig.de/ik

Keywords:
Potentials, Multi Material Design, Automotive Engineering, Component Overview

ABSTRACT
Multi material design represents the current forefront of the lightweight design trend for automotive
mass production. The combination of different materials (such as metals and fiber reinforced compo-
sites) can be used to improve components in terms of various requirements (component properties,
manufacturability, costs, etc.). With the reduction of component weight, low costs and feasibility in
mass production, hybrid design approaches are the ideal compromise for the mass automotive light-
weight construction of the future. However, there is currently no selection strategy for a specific defi-
nition of potential hybrid component areas. The basis for developing a selection strategy for potential
vehicle sections in multi material design is a comprehensive overview of current examples. The acqui-
sition and analysis of more than 150 components from the automotive industry and research make it
possible to identify the main implementation features and drivers of hybrid design in automotive en-
gineering. This contribution shows that the potential of hybrid design approaches in vehicle technolo-
gy can usually be limited to a few arguments, such as cost-efficiency or weight reduction. The article
shows that the hybrid design is marketed as an innovation feature. A particularly suitable group of
components for the application of hybrid design could only be identified to a limited extent. A state-
ment about the “correct” use of multi material design based on the compilation of current examples
could not be identify clearly. This confirms the need for a targeted selection strategy for multi material
components or an improvement indicator.
1 INTRODUCTION
Today’s drivers of society, such as compliance with regulatory CO limits, comfort requirements of the
2
customer and an acute range problem of electric vehicles, causes the automotive industry to build their
vehicles in a lighter way. Additional weight due to larger accumulators, additional comfort features,
customization measures and multimedia equipment can be compensated by reducing weight elsewhere
in the vehicle. The predominant mass shares of the vehicle are after Schöpf [1] the vehicle body and
the drive technology. These provide the best basis for applying lightweight design in the vehicle. For
implementing lighter vehicles, the example of automotive body in-in-white is followed by two signif-
icant approaches. In the field of high-class vehicles, with low and medium quantity (<200,000 pcs/
annum), light metals and fiber reinforcement plastics are increasingly used. Vehicle bodies, such as
these of the Mercedes AMG GT or the Audi A8, consist of a high percentage of aluminum. Partially
magnesium is used in the area of the outer skin and the attachments as well. Similar extremes are to be
noted in bodies with a high proportion of fiber reinforced plastics, as in the VW XL1 or the BMW i3 /
i8. The Body of these vehicles is characterized by spaceframe and monocoque design or a hybrid form
of it. In the high-volume mass production of automobiles, such as the Volkswagen Golf or the Toyota
Auris (> 1,000,000 pcs/annum), lightweight design measures are mainly characterized by the use of

© Springer-Verlag GmbH Germany, part of Springer Nature 2019 3
K. Dröder et al (eds), Technologies for economical and functional lightweight design,
Zukunftstechnologien für den multifunktionalen Leichtbau, https://doi.org/10.1007/978-3-662-58206-0_1