Data-based Process-Integrated 3D-Measurements of Magnesium Parts for Lightweight Car Body Construction

2021 ◽  
Author(s):  
Christian-Andreas Schumann ◽  
Jens Baum ◽  
Eric Forkel ◽  
Thomas Klein
Author(s):  
Woo Geun Lee ◽  
Jung-Seok Kim ◽  
Seung-Ju Sun ◽  
Jae-Yong Lim

While magnesium alloys have the attractive attributes of low density, the application of the metal in transportation industries has been restricted by its low stiffness and strength. The aim of this study was to examine the possibility of lightweight railway car body construction using magnesium alloys from the structural and manufacturing perspectives. Extruded members, making up a car body, were designed employing a gradient-based optimization algorithm. And then, numerical simulations were conducted to confirm the structural performance of the newly designed car body. In addition, one of the designed members was extruded and joined with another via friction stir welding in order to verify its fabrication potential. The work demonstrated that, with just 85% of the weight of an aluminium car body currently in operation, a magnesium-based railway car body can be potentially constructed by extrusion followed by friction stir welding for the next generation rolling stocks; that is to say, the weight saving amount is 10% of the total bare frame weight, or 2% of its total rolling stock weight.


1971 ◽  
Author(s):  
Keiji Kobayashi ◽  
Keiji Yamaguchi ◽  
Takayuki Ikejiri

1982 ◽  
Vol 2 (2) ◽  
pp. 110-113
Author(s):  
S. Muller
Keyword(s):  
Car Body ◽  

2020 ◽  
Vol 896 ◽  
pp. 127-132
Author(s):  
Gabriela Monica Pană

With ASF (Audi Space Frame) technology, Audi has completely reinvented the body construction using aluminum as a material and a concept adapted to light metal. ASF technology has undergone developments that efficiently exploit the knowledge accumulated from the efficient use of aluminum alloys, the optimization of casting and profiling processes, to the most appropriate techniques for joining components. The paper analyzes the main technical and technological developments adopted by Audi in designing and manufacturing the aluminum space frame for the car body.


2015 ◽  
Vol 651-653 ◽  
pp. 932-937 ◽  
Author(s):  
Dirk Landgrebe ◽  
Patrick Ackert ◽  
Raik Grützner ◽  
Johannes Weber ◽  
Reinhard Mauermann ◽  
...  

The use of FEM (finite element method) to assistant in ramp-up processes of car body construction lines is increasing, thanks to developments in recent years [1-3]. Car body manufacturing begins with sheet metal forming, while in subsequent steps the inner structures of the vehicle are assembled and connected to the outer skin by hemming. With reference to the current state of the art, there is no methodology which can reliably predict the dimensional accuracy of body parts through metal forming [4].Additionally, several methods to predict the distortion of joining and the dimensional effect of clamping during the assembly process were presented and validated [4-11]. Dimensional effects of the clamping process are basically the result of a deliberate alignment, other than the given values of construction to compensate dimensional inaccuracy of single parts from the body shop. These deliberate alignments are generally effected through a translation of clamps and pins in the clamping device. Until now, most of the methods of clamping and joining simulation presented have been verified using academic samples.In this report, the quality of forecasting in real problems during a ramp-up process will be verified and expanded. As part of a national project, co-funded by Sächsische Aufbaubank (SAB), the potential of FEM to assist in the ramp-up process were reviewed in a cooperative effort between Porsche Leipzig GmbH and Fraunhofer Institute for Machine Tools and Forming Technology (IWU). Furthermore, it will be shown that developed methods are able to represent the influence of deliberate positioning of clamps in complex samples. For the first time the quality of forecasting through the translation of locating pins is numerically and experimentally qualified.


2011 ◽  
Author(s):  
A. Eckert ◽  
R. Neugebauer ◽  
M. Rössinger ◽  
M. Wahl ◽  
F. Schulz ◽  
...  

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