EuroCarBody 2006

EuroCarBody 2006
The new Audi TT body
Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

EuroCarBody 2006 The new Audi TT body function-integrated lightweight design

Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The world is changing global trends

Increasing urbanisation (USA, Asia, South America) Shortage of resources, Fuel prices are increasing Increasing reliance on imports

Environmental issues make negotiation essential (China) CO2 taxes

The European industrial society is ageing

Transport infrastructures are changing

Progressive policies of innovation (China, India)

Innovations drive public image

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body

A trendsetter The hybrid body construction

(Alu) casting (Alu) profile (Alu) plate (Steel) plate

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body Function-integrated lightweight design

A sports car must have the following characteristics: - low centre of gravity - product-optimised axle load distribution - high body stiffness - low mass

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

Function-integrated lightweight design Low centre of gravity

Lightweight aluminium construction - low centre of gravity
Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

EuroCarBody 2006

Function-integrated lightweight design Product-optimised axle load distribution

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

Light front end Product-optimised axle load distribution

EuroCarBody 2006

Function-integrated lightweight design High body stiffness

Static torsional rigidity Natural frequency of body shell

Topologically optimised Audi Space Frame (ASF) structure

Nm/degree

Audi TT Coup Predecessor dyn. deflection of body shell dyn. torsion of body shell

Audi TT Coup Predecessor

Natural frequency of trimmedbody

Lightweight components

Kg/(Nm/degrees x m2) x 10 E-3

43 % improvement

Audi TT Coup dyn. deflection of trimmed shell dyn. torsion of trimmed shell Predecessor

Predecessor

Audi TT Coup

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

Function-integrated lightweight design low mass

Weight saving of approx. 100kg
Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

69% alu 31% steel

EuroCarBody 2006

The new Audi TT body A trendsetter for virtual processes

Tasks of the simulation
To ensure and optimise function and weight of vehicle structure

To ensure the producibility of components

To ensure the producibility/joinability of components and assemblies

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body Examples of virtual process chains for the TT ASF
rolling rolling process process sheet sheet metal metal drawing drawing sheet metal part

extrusion extrusion process process

hydroforming hydroforming mech. mech. bending bending extrusion profile

heat heat treatment treatment

joining joining

Cataphoretic Cataphoretic dip dip painting painting

casting casting process process die casting mould

heat heat treatment treatment

function function

: virtual process at Audi : virtual process at supplier : virtual process at Audi/supplier

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body Example: Casting simulation on side member 2

The casting simulation is today already in standard use at Audi and its suppliers in the development of aluminium die cast moulds. Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body Example: Heat transfer simulation on side member 2
Simulation of air quenching using (FLUENT) air flow simulation Thermo-mechanical analysis as a means of determining heat transfer (ABAQUS)

Flow field

Variance analysis

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body Topology of cast moulds and extruded profiles
Topology of A column Topology of sill

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body An example of economic derativisation

Potential: - inexpensive tools - identical fittings and fixtures - identical connection technology
Sill 1

Floor structure based on alternative superstructure

Sill 2

Dimensioning adapted to product in common outer contour

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body light but also quiet

Insulation: PUR 7 PUR-RIM

End wall insulation: PUR-RIM

Reinforcement: epoxy resin mesh Wheel arch: PUR RIM

Suspension: Plastic film/ laminated aluminium Carpet: (PUR) fibre-flocks

An optimised lightweight insulation and suspension concept. Despite aluminium Body, car is quieter than previous model with less insulator (kg).

Aluminium and Lightweight Design Centre

26 October 2006, H. Timm, N/EL

EuroCarBody 2006

The new Audi TT body Sporty, progressive, sophisticated ...

... and with cutting-edge production technology
Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

EuroCarBody 2006

Thank you!
Aluminium and Lightweight Design Centre
26 October 2006, H. Timm, N/EL

EuroCarBody 2006

EuroCarBody 2006
The new Audi TT body
Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006

Agenda The new Audi TT compared with

its predecessor The body construction for the new Audi TT Corrosion-proofing in hybrid structures Manufacturing technologies used for the first time in the TT

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The new Audi TT compared with its predecessor Degree of automation in building the body

100% Degree of automation

appr. 98%
80% 60% 40%

appr. 30%
20% 0%
New TT Coup TT Coup neu Previous TT alt Coup TT Coup

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The new Audi TT compared with its predecessor Thermal joining methods (incl. attached parts)
Process MIG welding MAG welding Seamless laser welding Laser welding two layers Laser brazing Flame brazing RSP resistant spot welding Welded studs Al Welded studs St New TT Coup 21462 mm 809 mm 1779 mm 3530 mm ----1287 items 148 items 93 items Old TT Coup --3620 mm ----640 mm 120 mm 4646 items --188 items

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The new Audi TT compared with its predecessor Mechanical joining methods and adhesives (incl. att. parts)
Process Punch-riveting with semi tubular rivet Punch-riveting with solid Al rivet Punch-riveting with solid St rivet FDS Clinching Adhesive application Roll hemming Flanging in a fold bed New TT Coup 1606 items 48 items 48 items 229 items 172 items 97156 mm 26737 mm --Old TT Coup 37 items --------45040 mm --25865 mm
26 October 2006, Dr. K. Koglin, I/PG-6

Aluminium and Lightweight Design Centre

EuroCarBody 2006 The body construction of the new Audi TT Key manufacturing data
Cycle time 220 sec (3.7 min) 276 units / day 3-shift operation Degree of automation appr. 98 % Mixed production betw. TT Coups and TT Roadsters (of which max. 150 TT Roadsters)

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body construction of the new Audi TT Production flow
Front section (Al) B000 Front chassis member
(Al)

Tunnel (Al) B100

Lower groups

Undercarriage 1

Rear wheel arch

(Steel)

Welded assembly car rear (Steel) Rear floor (Steel)

Undercarriage 2 B200

B pillar (Al) Outer roof frame (Al) front/rear front/rear B500 Rain channel
(Al)

Inner side Outer side

(Al) (Al)

Inner roof frame (Al)

Assembly 1

Assembly 3 Doors
(Steel) (Steel)

B400

Assembly 2 Hood
(Al)

B300

Trunk lid spoiler

C00 0

Fine finish/Assembly

CC

To Paint Shop

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body structure of the new Audi TT Undercarriage assembly

Rear assembly (steel and aluminium) Front assembly (all aluminium)

Centre section (all aluminium)

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body structure of the new Audi TT Upper assembly
Roof (aluminium) Front roof frame assembly (aluminium) Rear roof frame assembly (aluminium) Upper and lower trunk sections (steel)

Inner side assy. (aluminium)

Outer side assy. (aluminium)

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body structure of the new Audi TT Shell assembly

Framing station, assembly of body shell without outer sides Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body structure of the new Audi TT Add-on parts
Trunk lid assy. (steel)

Hood assembly (aluminium)

Wing (aluminium)

Door assy. (steel)

Spoiler assy. (steel)

Aluminium and Lightweight Design Centre

26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body structure of the new Audi TT Add-on parts / Finish

Finishing line at the end of the body assembly Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 The body structure of the new Audi TT Product and process monitoring
Function measurement Perceptron in-line measurement, static and robotic systems Torque control for screw operations ATM Vision (image processing for control: parts present (yes/no))
Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6

Process monitoring Soudronik SCA (glued seam) Weld watcher 4D (Laser seam inspection)

Process control TCP (Tool Center Point) correction (MIG, brushes) Image evaluation (fine positioning of solid rivets in visual range)

EuroCarBody 2006 Corrosion-proofing in hybrid structures Examples of corrosion-proofing concept - aluminium / steel
Area around rear lamp shell Process: Adhesive (insulation adhesive) + PVC seal Rear outer wheel arch flange to outer side section Process: Adhesive (structural adhesive) + PVC seal in wheel arch + wax preservative from inside Rear chassis member to chassis connecting piece / sills Process: Adhesive (structural adhesive) + wax preservative Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006 Manufacturing technologies used for first time in the Audi TT
Laser cleaning of aluminium sheets coated with dry lubricant Zerogap laser joint Punch-riveting with solid rivets Hole and thread forming screws (FDS) Arc welding of aluminium studs using AC to aluminium sheet coated with dry lubricant Extension of the lean Audi aluminium process Co-operating industrial robots
Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6

EuroCarBody 2006

Thank you.
Aluminium and Lightweight Design Centre
26 October 2006, Dr. K. Koglin, I/PG-6