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DDM 2 > Advanced Car Production > Flashcards

Advanced Car Production Flashcards

(61 cards)

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1
Q

Customer requirements

A

Impression
Comfort
Dynamics
Safety
Economic efficiency
Robustness

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2
Q

Car body components

A

Component properties
Production process

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3
Q

Optics

A

 Surface geometry, design
 Surface Structure

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4
Q

Functionality

A

 Dimensional accuracy
 Stiffness
 Weight
 Aerodynamics
 Corrosion resistance
 Temperature behaviour

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5
Q

Technical Producibility

A

 Assembly sequence
 Measurability
 Dimensional accuracy
 Paintability
 Temperature behaviour

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6
Q

Economic Producibility

A

 Material usage
 Energy usage
 Productivity
 Rework
 Scrap rate

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7
Q

Typical car body metal composition

A

75% steel
25% aluminum

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8
Q

Sheet metal parts

A

 Produced mainly by drawing processes
 Joining by complex nesting
 Overall load-bearing structure

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9
Q

Profile-shaped components + node elements

A

Connected to a load-bearing structure

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10
Q

Functional and planking parts

A

 Usually sheet metal parts, which supplement this frame
 No significant contribution to the structural behaviour

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11
Q

Structural Parts

A

 Components which contribute to the structural
properties of the vehicle body.
 Not visible with closed hoods and doors.
 Visible surfaces that were often still present in
the interior are nowadays usually covered, e.g.
cockpit covers or pillar covers.

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12
Q

Outer Body Parts

A

 Body parts that are visible from the outside
and therefore have to meet the highest
demands on the visual appearance (Class A).
 Increasingly contribute to the clear visual
identification of cars.
 Special focus with regard to the quality in
the method planning of the manufacturing
process as well as in the production of the
forming tools and the joining devices.

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13
Q

Gigacasting

A

Giga- or megacasting refers to the die casting of large aluminium
components instead of the individual production of various components

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14
Q

Gigacasting advantages

A

 Technical and labour costs for welding the components are eliminated
 Multiple forming tools no longer necessary
 Reduced complexity in production, assembly and supply chain
 Use of secondary aluminium
 Higher material utilisation through direct melting down of unused material
elements on site

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15
Q

Gigacasting disadvantages

A

 High initial investment in plant technology required
 Five to six million parts can be produced with forming tools, whereas a die-casting mould can
only produce up to 150,000 “shots”.
 No variety of materials
 Large components require longer cooling and curing times. Uniform cooling is crucial to avoid
distortion and material defects.
 Accident damage: Replacement of large, one-piece cast parts significantly higher repair costs

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16
Q

Typical sheet metal sequence of operations

A

Cutting blank
Drawing
Trimming/Piercing (multiple steps)
Calibration

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17
Q

Purpose of blankholder

A

Prevents the scrap material wrinkling/springing up

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18
Q

Is the sheet metal blank clamped before drawing?

A

No, allowing the blank to flow freely in the die/mould allows for uniform thickness of final product

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19
Q

Purpose of addendums

A

For sharp geometries that cannot be drawn/pressed into the blank

Addendum is drawn initially but cut off later

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20
Q

Why have multiple trimming steps for a large piece?

A

So that the scrap can easily fall away

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21
Q

Method Planning

A

The task of the method planning is to determine the operational contents which
are necessary to form a component without machining, with the aim of giving it
the prescribed final shape and function as a whole of the later assembly.
The individual process steps, the operational sequences, are defined depending
on the method contents.

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22
Q

„Surplus“ Sheet Material

A

 Volume elements in the
flange move from larger
to smaller diameters.
 If the sheet thickness
remains constant, each
volume element becomes
longer in radial direction
and smaller in tangential
direction ( compressive
stresses).
 The surplus material is
thereby displaced
outwards towards the
flange edge.

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23
Q

Local control of material flow

A

Blankholder force
Blank outer contour (shape of blank)
Amount of lubricant
Draw beads (resist material flow)

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24
Q

Punching (cutting) phases

A

1 Contact of the punch
2 Elastic deformation
3 Plastic deformation
4 Abrupt material separation
5 Breakthrough and reverse drawing

Cutting is drawing until fracture occurs

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25
Profile vs shell construction methods
Profile parts are extruded through a die as a single piece Shell parts are pressed out parts that are fastened together
26
Extruded parts post processes
Joined Bent Machined
27
Forming by Internal Pressure
Extruded part is placed in a die and filled with fluid. The fluid is compressed and the part expands to fill the die
28
Mechanical joining technologies
Self-piercing riveting Flow-drill screws Solid self-pierce riveting Clinching
29
Thermal joining technologies
MIG welding Laser welding Resistance spot welding MAG welding Stud welding
30
Bonding technologies
Bonding
31
Clinching
 In clinching, a force-fit and form-fit connection is created by a cold extrusion process.  The undercut relevant for the positive fit is realised by a ring channel in the die.  The material on the die side flows into the die due to the transverse expansion of the material on the punch side and forms a raised edge.
32
Flowdrill Forming Sequence incl. Screw Insertion
 Positioning the screw  Increase the speed and contact pressure until the hole is formed.  When the insertion torque is reached, at which all threads are formed in the material, the speed and the contact pressure are reduced.  The screw is then screwed through until the screw head rests on the clamping part, followed by tightening to a predetermined torque.  Complete process sequence: approx. 3 seconds.
33
Hybrid Connections: Self-adhesive Riveting, Screw Connections with Adhesives
On the one hand, the rivet or the screw creates a “cold” positive connection, which prevents the formation of intermetallic phases. On the other hand, the use of an adhesive also leads to a material connection, in which the adhesive layer serves as protection against corrosion (no direct contact between steel and aluminum) and which additionally increases the strength of the connection.
34
Process Chain Die Hemming
Insert the inner part into the outer part Pressing the blankholder Pre-Hemming Final Hemming
35
Description Roller Hemming Process
During roller hemming, the flange is incrementally formed and closed by means of a robot-guided roller.
36
Measure of body panel gap
The human eye sees a gap from start of radius to start of radius between body panels
37
Forming Mechanism Movement of Edge Dislocation
When an external force is applied, the dislocation moves step by step from atom row to atom row and finally emerges as a slip step. Only a single bond has to be "flipped" at each atomic distance for the dislocation to move through the material or for the plane to slide off.
38
Overview Strengthening Mechanism
The yield strength, i.e. the resistance to the onset of plastic deformation, is increased by obstacles to the dislocation movement. There are four basic types of these  Solid solution  Strain hardening  Grain boundaries  Precipitations
39
Strengthening Mechanism
Substitutional solid solution - different element replaces atom in the lattice Interstitial solid solution - different element is trapped between atoms in the lattice Both strengthen the material against dislocation of the atom planes
40
Interstitial Mixed Crystals (steel)
"alpha"-MC (Ferrite) Type of lattice: Body centered cubic (BCC) Stable at RT Maximum solubility of carbon at 723°C: 0.02% magnetisable "gamma"-MC (Austenite) Type of lattice : Face centered cubic (FCC) Not stable at RT Maximum solubility of carbon at 1147°C: 2.06%
41
Material with highest strength and formability
Stainless steel
42
Purpose and mechanism of alloys
To strengthen a pure metal by adding different elements that can replace atoms in the lattice or be trapped in the lattice. These hinder the movement of dislocations which creates a stronger material that is more resistant to plastic deformation
43
What does Pearlite consist of?
Layers of ferrite and cementite (Fe3C)
44
What are carbides and nitrides?
Carbide is a carbon atom bonded with a metal atom and nitride is a nitrogen atom bonded with a metal atom
45
Solid solution formation
Homogeneous alloy formation with complete or partial solubility
46
Precipitations
Temperature dependent solubility of individual elements
47
Austenite stabilizing
Displacement of the solidification range and the α and γ range. Done by alloying.
48
Martensite Formation
The cooling that leads to the transformation in the martensite stage is so rapid that diffusion processes can no longer take place. This leads to a formation of the -lattice (fcc) into a tetragonal distorted -lattice (martensite).
49
Bainite Formation (Intermediate Stage)
Bainite forms between the lower and upper critical cooling rate. In contrast to pearlite, which forms directly from the austenite by diffusion, the diffusion of carbon in the austenite is more hindered in the intermediate stage. Smaller austenite areas change into a distorted -lattice, usually starting from grain boundaries.
50
Precipitation Hardening Aluminum
Alloy forms sold solutions with an alloying element at elevated temperature. Solubility of one or more alloying elements decreases with decreasing temperature
51
Al hardening Solution annealing (Diffusion annealing Homogenize)
Heating of the alloy until all the alloying elements necessary for the precipitation are in solution
52
Al hardening Quenching
Diffusion and precipitation of coarse particles is prevented. Mixed crystal remains in the supersaturated single-phase state.
53
Al hardening Tempering
Conversion into a 2 phase alloy
54
Can non-alloyed aluminum be hardened? Does the process require quenching?
No, it must be alloyed first. Just like how you can't harden iron (steel) w/o carbon content (needed to create martensites) Yes
55
What does quenching do to the grain boundaries in Al?
It keeps them small
56
How many axes does tensile stress have and how many axes does the strain response have?
Tensile stress is uniaxial and the strain response is triaxial
57
What can a bending test show that a tensile test can't in terms of deformation? What is the reason for this?
A bending test will produce around 40% more deformation w/o fracture due to the failure mechanism being intercrystalline (stronger) instead of transcrystalline (weaker)
58
What allows for more deformation of sheet metal w/o fracture
A cut edge or a drilled hole since cutting the sheet strain hardens the edge
59
What is the relation between hardness and formability?
They are inversely related i.e. as hardness goes up the material becomes less formable
60
How should sheet metal be tested?
With tests that are similar to the forming processes that will be used to make the part
61
What is the difference between engineering, true , and flow stress
Engineering stress plateaus in the plastics range until fracture. True stress the stress keeps increasing in the plastic range as the cross-sectional area decreases Flow stress is only valid in the plastic range and is similar to the engineering stress but doesn't curve down to fracture

DDM 2 (5 decks)

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