P 244 - New solutions with steel in lightweight automotive construction

FEM calculations, structural analyses, crash calculations and deep-drawing simulations were carried out on the basis of existing and newly developed mechanical-technological material parameters. In conjunction with laser-welded tailored blanks and alternative joining methods to resistance spot welding, a new concept and design was developed for the following components: Door tube assembly of the two-door VW Polo, suspension strut mount of the VW Polo, front subframe of the Audi A 4 and console wishbone bearing of the Mercedes-Benz C Class. The usability of the components pressed with appropriately adjusted tools was tested in a practical test. As part of the research project, extensive new data material was compiled on the mechanical and technological properties of the steel grades analysed. Forming simulation has proved to be a useful and cost-saving tool for the design work carried out on the components and tools as well as for the implementation and planning of pressing tests. It was shown that optimisation of the component to suit the material not only leads to a reduction in weight but also to a reduction in the number of parts and thus to cost-effective solutions. With the use of modern, higher-strength steels, a weight reduction of 11 to 15 % was achieved under the specified conditions of the vehicle parts currently in series production. A further weight reduction can certainly be realised with a completely new design. STUDIENGESELLSCHAFT STAHLANWENDUNG e.V.