EuroCarBody 2010
12th International Car Body Benchmark Conference
Car body benchmarking data summary
Aston Martin Rapide
1. Weights
Total weight body-in-white: 408kg 1)
1) Includes bolt-on structural braces & shear panels and tailgate (all T&F).
Defined as the total weight of the car body including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint.
Corresponding view:
(The colour scheme of the parts shown makes use of the RGB colour code for the material classification, see section 2.)
Extra parts:
Weights of separate subframes, front end modules, etc.
Part description Corresponding view Weight
Hot-cure bonded tub: 195 kg
(includes NVH pads,
sealant & foam)
Front structure, front sub-frame 71.0 kg
and other bolt-on structural components:
Bodyside, roof and composites: 59.0 kg
Body-in-white weights of doors, closures (including hinges) and fenders
Front doors (both): 24.0 kg
Rear doors (both): 25.0 kg
kg Bonnet: 10.8
kg Tailgate: 10.6 Front fenders (both): 12.6 kg
Front end modules: see above
Total weight body-in-white without doors, closures and fenders:325.0 kg
Based on metallurgical/chemical material classes
Materials: corresponding metallurgical classes
RGB colour code
%S t e e l s
Low Strength Steels: Mild steels
R 153, G 204, B 255 4.5High Strength Steels (HSS):
High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA) R 051, G 102, B 255
0.9 Advanced High Strength Steels (AHSS):
Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP)
R 255, G 153, B 204 Stainless steels: Austenitic stainless steels R 051, G 051, B 153 1.1Ultra High Strength Steels (UHSS):
Complex Phase Steels (CP), Martensitic Steels (MS) R 204, G 153, B 255
Press Hardened Steels (PHS) R 128, G 000, B 128 A l u m i n i u m
Aluminium sheets: 7xxx series R 051, G 204, B 153 Aluminium sheets: 6xxx series R 000, G 255, B 000 4.6Aluminium sheets: 5xxx series R 204, G 255, B 204 22.0Aluminium extrusion profiles R 153, G 204, B 000 37.5Cast aluminium R 051, G 153, B 102 12.6 Magnesium R 255, G 255, B 000 P l a s t i c s
Fibre reinforced plastics
R 255, G 000, B 000 5.6Duroplastics, including Sheet Molding Compound (SMC) R 255, G 153, B 000 5.5Thermoplastics
R 153, G 051, B 000 0.4Other materials, namely: Adhesives, sealant, foam, NVH pads
R 192, G 192, B 192
5.3
The following graph may serve as a guide to locate the properties of the metallurgical steel classes:
0400
8001.2001.6002.000
200
400
600
800
1.000
1.200
1.400
T e n s i l e S t r e n g t h /M P a
Yield Strength /MPa
HSLA
BH
Low Strength Steel
High Strength Steel
Ultra High
Strength Steel
Advanced High Strength Steel CP
MS PHS Press Hardened Steel
Mild
TRIP DP
HSIF
Measured / Calculated
1st Eigenfrequency trimmed body: 25.4 Hz
2nd Eigenfrequency trimmed body: 33.7 Hz
1st Eigenfrequency body*: 37.0 Hz
2nd Eigenfrequency body*: >50 Hz
*Parts included in the measurement/calculation of the body frequencies:
Tub, front structure and front subframe only (no bolt-on braces or shear panels)
(1st mode for glazed BIW using FE model correlated to 37Hz 'tub' test above:51.2 Hz)
Static torsional stiffness 28,390 Nm/°
N/mm Static bending stiffness 16,000
4. Contact area
= track (1.565 m) x wheelbase (2.99 m) = 4.68 m2
5. Joining processes
used in the body shop, including all bought-in parts and sub-assemblies (BIW less
closures)
Joining technique Number of joints Weldspot Calculation
or length of seams equivalents
(WSE)
Spot welds 1:1
Arc welding 3.2 m 16020 mm = 1 WSE
Laser welding 15 mm = 1 WSE
Conventional brazing 20 mm = 1 WSE
Laser brazing 30 mm = 1 WSE
Adhesive joining 251 m 502050 mm = 1 WSE
(Monobolts) 610 610 1 joint = 1 WSE
Rivets
Clinch-spots (SPRs) 239 239 1 joint = 1 WSE
Screws (incl. flow drills) 1 joint = 1 WSE
6029
Total
WSE:
Process stability/availability: 99.52 % = total up-time in the body shop
Re-tooling or re-use factor:
0 %
= [1 – Project investment excluding operational costs / “all new“] x 100
with …all new“ = Value of the total installed investment
Degree of mechanisation:
31 %
= Automated Work Content* / Total Work Content*
* Work Content refers to the sum of Standardized Work Contents in the Body Shop, calculated according to the Harbour Report system, excluding lay-in operations, handling of parts, logistic operations
Bodyshop-Index BSI n. sp.
*
model the of WSE Total ]units/hour [car model the of production net [€]model specific the for investment additional [€]re architectu ,investment project ×+=
* as calculated in section 5
No. of production sites: 1 namely in: Graz, Austria Intended production volume: circa 2000 units/year
Car body production lead time: 33 hours = the time spent by the unit in the body shop, from the start of the first underbody parts to the handing over of the body-in-white to the paint shop, including car body interim storage**
** More accurate definition (Harbour):
? Start counting when work begins at the first station of the underbody (motor compartment or
rear floor, whichever station begins first).
? The end of the measurement is the beginning of the delivery from body in white to the paint
shop. If the vehicle changes skids or pallets, the process ends as soon as the vehicle leaves the original pallet. If the vehicle is going on a lift to transfer to the paint shop, the process ends as soon as the body in white is in final position to begin transfer.
Cycle time (mainline bodyshop): 105 minutes
Degree of material utilisation/scrap rate: n. sp.
Total number of parts in the BIW (including closures):
362 Number of parts, including external parts, in weight classes < 100 g: n. sp. 100 g - 1 kg: n. sp. 1 kg - 5 kg: n. sp. > 5 kg:
n. sp.
(all assemblies broken down into their component parts)
7. Targeted market regions and origin of build…
….of the vehicle presented at the EuroCarBody:
Targeted market region(s): worldwide
Origin of build: Austria
8. Development strategies /initial propositions
Specific aims of the development:
First 4-door sportscar and the realisation of the Aston Martin Rapide Detroit Showcar
Vehicle dynamics, refinement, package, style
Specific improvements reached compared to the predecessor:
4 door vehicle, exceeding stiffness of 2 door coupe (DB9) whilst minimising weight
increase. Structure designed to be compatible with meeting forthcoming FMVSS214 side
impact (pole and EuroSIDII re) legislation.
Specific comparisons to direct competition in the market:
Lightweight Index = 2.45
9. Damage and repair strategy
Qualitative description of the repair strategy:
All structurally bonded components can be replaced using a repair adhesive, according
to a prescribed AML process at appointed specialist repair centres.
Engine variant Insurance classification
applicable Not
RCAR basket of parts*:
n. sp.
* Parts to be repaired after a standardised RCAR low speed (15 km/h) offset insurance crash (front and
rear, respectively). See https://www.doczj.com/doc/e23912790.html,/Papers/Procedures/rcar_test_protocol_angled_barrier.pdf
If other tests (e.g. special in-house tests) are referred to, please specify them.
10. Additional information:
Crash performance data:
NCAP
Euro
applicable
Not
results:
test
Other
Legal compliance in all world market legislative tests. European front impact legal sign-off (56km/h ODB) carried out at EuroNCAP speed (64km/h).
Development time: 15 months = time from design freeze to SOP/job one
Life cycle analysis data:
n. sp.