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1、BMWService TrainingE65 BodyshellCourse Contents/Background MaterialInformation status:May 2001E65 BodyshellChapter1-2Course contents/Background material BMW AG, Service TrainingContentsPageCHAP 1E65 Bodyshell1 Introduction1 Requirements of body structure3 - Static performance3 - Dynamic performance4
2、 - Crash performance4 - Weight optimisation4 Materials5 - Cold-rolled deep-drawing steel6 - Isotropic steel7 - Phosphorus-alloyed steel8 - Higher-tensile IF steel9 - Complex-phase steel10 Surface treatment12 - Galvanizing12 - Painting13 Joining techniques14 - Body joining techniques14 - Joining tech
3、niques for aluminium parts15 - Tailored blanks16 - Bonding17 Body structure25 - Front end25 - Side carcass34 - Underbody41 - Rear end50 - Outer skin panel56 Passive safety64 - Requirements of structure64 - Properties of engine carriers64 - Properties of sills64 - Properties of B-pillar64 Body repair
4、s65 - Body measurement65 - Repair requirements68 - Body repairs of high-tensile steel69 - Body repairs of aluminium69 - Body repairs of galvanized sheets70 - Painting during repairs70CHAP 2Glossary1E65 Bodyshell Chapter 1 P.1Course Contents/Background Material BMW AG, Service TrainingE65 BodyshellIn
5、troductionThe E65/E66 comes in 8 body variants. There are the following different variants for the models:- Normal version E65 left-hand drive with/without sliding sunroof - Normal version E65 right-hand drive with/without sliding sunroof - Long version E66 left-hand drive with/without sliding sunro
6、of - Long version E66 right-hand drive with/without sliding sunroofThe long version E66 has a body which has been extended in length by 140 mm.Fig. 1: BodyshellKT-8894E65 Bodyshell Chapter 1 P.2Course Contents/Background Material BMW AG, Service TrainingThe body of the E65 has been manufactured in t
7、he form of a lightweight design.The design takes into consideration the latest demands with regard to competition, customer requirements and crash performance. The design has essentially been determined by styling, ergonomics, comfort and quality as well as functional demands made of the body.Sheet
8、panels of different material thicknesses and different steel types have been used. These factors together with strength bonding produce the following advantages:- The unladen weight of the vehicle is reduced, thereby lowering energy consumption. - Improved crash performance results in increased pass
9、ive safety. - Increased body rigidity results in improved directional stability. - A reduction of vibrations and acoustic noises provides the driver with increased driving comfort.Through the use of higher-tensile steels and the increased use of spot-weld-bonded joints, it has been possible to avoid
10、 a marked body weight increase. The weight is currently 326 kg.E65 Bodyshell Chapter 1 P.3Course Contents/Background Material BMW AG, Service TrainingRequirements of body structureThe body structure is designed in accordance with the following standpoints:- Static performance - Dynamic performance -
11、 Crash performance - Weight optimisationCompared with the E38, the fully galvanized body has been clearly optimized in its static and dynamic rigidity.- Static performanceStatic configuration primarily involves the optimisation relevant to rigidity and strength of the body design for quasistatic veh
12、icle handling.Good static rigidity serves as the basic prerequisite for good dynamic performance.The flexural strength, torsional resistance and transversal rigidity of the body are all determined by the design. The strength is determined by the choice of materials used (high-tensile steels) and by
13、the additional bonding of welding flanges.E65 Bodyshell Chapter 1 P.4Course Contents/Background Material BMW AG, Service Training- Dynamic performanceThe aim of dynamic configuration of the body structure is to achieve the vibrational and acoustic comfort objectives.In order to ensure “vibration-fre
14、e“ operation, it is essential for the natural body frequencies to lie within a limited frequency range. This is limited by the exciting frequencies of the engines used.- Crash performanceStatic and dynamic performance forms an outstanding basis for crash optimisation, which in turn serves to improve
15、 passive passenger protection.- Weight optimisationNext to aerodynamics, vehicle weight is the most important factor in reducing fuel consumption and improving handling performance.E65 Bodyshell Chapter 1 P.5Course Contents/Background Material BMW AG, Service TrainingMaterialsThe choice of materials
16、 for the bodyshell is geared towards the design objectives.Roughly 90% of the sheet panels used in the bodyshell consists of higher-tensile steels. In comparison, only roughly 30% of higher-tensile steels was used in the E38 while only 5% was used in the E32.In addition to the benefits of reduced weight and increased strength, the use of higher-tensile sheet panels provides the possibility of a more efficient deployment of materials in the manufacture of the vehicle.The properties of
