BMW

Group

The mixed Material Concept of the

new BMW X5
Markus Pfestorf
BMW Group

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Content

BMW
Group

Technical Features
Stiffness
Passive Safety
Materials
Components
Driving Performance
Conclusion

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Technical Features
Dimension of the Car
Track width
1644mm/64.7in (+ 61/+2,4)

BMW
Group

Wheelbase 2933mm/115.5in (+ 113/+4.5)

Total length 4854mm/191.1in (+ 187/+7.4)

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Technical Features
Unique Chasis Technology

BMW
Group

Variable
steering
ratio

Double
wishbone
front axle

Integral IV
rear axle

50 %

Wide track
Low centre
of gravity
50 %

Excellent handling and roadholding capabilities

and a comfortable ride without compromise
Handles like a true BMW

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BMW
Group

Technical Features
Intelligent Light Weight Contruction

Runflat tyres 4th

generation fitted
as standard

Aluminium
engine hood
Magnesium
carrier for
instrument
panel

Intelligent use of ultra

high strength steel

Cast aluminium
front strut tower

15 per cent higher torsional stiffness ~27.000 Nm/

Almost the same weight in spite of enlarged dimensions
Innovative technologies for optimum active and passive safety

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Stiffness
Torsional Stiffness

BMW
Group

40.000

4,0
3,3

Torsional Stiffness cT

30.000
25.000

3,0

27.000
23.500

2,5

20.000

2,0

15.000

1,5

10.000

1,0

5.000

0,5

0
L=

Previous X5
mGer
Ct x A

New X5
Kg

Nm/ x m

x 10

cT

3,5

Lightweight Coefficient L

3,7

Nm/

L
Lightweight coefficient
mGer. Weight of body in white
(without doors and closures)
ct
Static torsion
(including screens)
A
Area (wheel base x track width)

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Stiffness
Design Solutions

BMW
Group

Stiff Front End by

Diagonal Strut
(Aluminium)

Stiff Rear End due to

the Torsion Ring

Additional Stiffness by
bracing the trunk lid
between the D-pillars
(Weight Saving: 6 kg)

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Passive Safety
Most Important Crash Tests

BMW
Group

Rear Impact:
Others:

FMVSS 301: 80 km/h, 70% overlapp, undeformable Barrier

AZT Frontcrash: 15 km/h, 10, 40% overlapp,

undeformable Barrier

AZT Rear-Crash: 1000 kg Barriere, 15 km/h, 10,

40% overlapp, undeformable Barrier

Roll Over

Side Impact:

Front Impact:
EU-NCAP: 64 km/h, 40% overlap, deformable Barrier
US-NCAP 0: 35mph, 100% overlap, undeformable Barrier
US IIHS 40%: 64 km/h, 40% overlap, special Barrier

EU-NCAP Side: 950 kg Barrier, 50 km/h

EU-NCAP Side Pole: 29km/h to Pole
US IIHS Side: 1500 kg Barrier, 50 km/h

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Passive Safety
Loadpath for Front Crash

BMW
Group
Distribution of induced Forces

Deformation after the Euro-NCAP

Minimum Yield Strength

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BMW
Group

Passive Safety
EU-NCAP Front Crash

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BMW
Group

Body in White Materials

Overview of Materials
Steel Grades (min. yield Strength)
CR4 (DDQ) HD, CR4 (DDQ) HDG,
CR4 (DDQ) HSDG, CR5 (EDDQ) HD
CR 180B HD, CR 180B HDG,
CR 180A HD, CR 180AT HD
CR 210B HD, CR 210B HDG,
CR 210AT HD
CR 250B HD, CR 250B HDG,
CR 250 A HD, CR 250 AT HD
CR 280B HD, CR 280B HDG
CR 380X (HSLA) HD
CR 420X (HSLA) HD,
CR 420X (HSLA) HDG
CR 950DL (Dual Phase), HD 680C
22MnB5
Aluminum
AlMg3
AlMg4,5Mn0,4
AlSi9Cu3(Fe)
AlMgSi
AlMg0,4Si1,2
AlSi10MgMn
Plastics
Thermoplastic Resin

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Body in White Materials

Percentage of Steel Grade

BMW
Group
Minimum Yield Strength
Deep Drawing Steel
25%

Steel Grade

180 MPa
11%

Deep Drawing Steel

(25%)

200 -220 MPa

6%
260 MPa
6%
Others
4%
Thermoplatic
2%
AlMgSi Alloy
2%
AlMg Alloy
1%
> 900 MPa
3%
600-700 MPa
6%

300-340 MPa
13%

AlMgSi Alloy
(2%)
AlMg Alloy
(1%)
Others
(4%)
Thermoplastic
(2%)
Dual Phase Steel
(2%)

380-450 MPa
21%

Bake Hardening Steel

(24%)

Boron Steel
(3%)
Complex Phase Steel
(4%)

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IF-Steel
(13%)
Microalloyed Steel
20%

Body in White Materials

Average minimum Yieled Strength

BMW
Group
500
Average min. Yieled Strength Rp0,2

475

MPa
400
350
New X5

3series Sedan
3series Sports W.

300

3series Coup
1series
6series Convertible
6series Coup

3series
5series
Sports Wagon 7series
3series
5series
5series
Z4Coup
Sedan
Z4 Sports Wagon
3series
200
3series previous X5 Compact
7series 5series
Coup
3series
Sports
Wagon
150
Convertible

250

1994

1996

1998
2000
2002
2004
Start of Production

2006

Rp0,2 i * m i
Rp0,2 =

i=1
n

mi

n
number of parts
m
weight of the part
Rp0,2 min. yield strength

i=1

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2008

2010

Body in White Materials

Average Gauge

BMW
Group

1,7
mm

3series Convertible

1,5
Z4

1,4
Average Gauge

6series Convertible

1,3

6series Coup

1,2

3series Sports Wagon

previous X5

7series

1,1
5series

1,0
0,9
1992

New X5

5series Sports Wagon

1series

7series

1994

1996

1998

2000

2002

2004

2006

Start of Production

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2008

2010

Components
Max. Styling Freedom in Front End

BMW
Group
Pedestrian Safety
Fender (PP-EPDM)

Bonnet (Aluminum)

Washer fluid container

Front Head Lights

Crash Beam

Front End

Passive Safety / Stiffness

Fog light

Relocated
cooler

Benefits:
Flexible Design
Less Gaps / reduced Gap Dimensions
Weight Saving
Pedestrian Safety (ACEA, Japan, Europe)

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BMW
Group

Components
Cast Aluminum Front Strut Tower

Mechanical Values:
Yield Strength Rp0,2: 120 - 140 MPa
Tensile Strength Rm: 200 - 240 MPa

Benefits:
Weight Saving (-50% compared to Steel Sheet)
Optimized Package
Increased Stiffness

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BMW
Group

Components
Simulation of the Forming Process

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BMW
Group

Components
The B-Pillar Reinforcement
Thickness s
s = 1.2
s = 1.6

s = 2.2

Weight Saving: 2 kg/Side

s = 1.4

s = 1.2

(compared to a hot stamped Part

with a constant Thickness)

Mechanical Values:
Yield Strength Rp0,2: > 950 MPa
Tensile Strength Rm: > 1300 MPa

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BMW
Group
Roll gap
Control

Components
Manufacturing of the B-Pillar Reinf.
Correction

Longitudinal
profile check

1. Manufacturing of tailored rolled blanks

Advantages of a tailored rolled Blank
Compared to a tailored welded Blank
With many different thicknesses: Cost Benefit
Now weekening of strength level by a weld seem
Notch free transition at varying thickness

varying
thickness
Source: Mubea

2. Direct Hot Stamping

Tailored
rolled Sheet
22MnB5

Heating
> 900C

Hot Stamping +
rapid Cooling

trimming
By Laser
By Tool

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Scale
remocal

BMW
Group

Driving Performance
Racetrack Nuerburgring Nordschleife
Power to
weight ratio
[kg/HP]

time
taken
[s]

Previous X5

9,3

9,07

New X5

9,9

8,54

Length of the Racetrack

Nuerburgring Nordschleife:
20,8 km

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Conclusion

BMW
Group

Higher functional Requirements in the new BMW X5 are met

by a consequent Implementation of innovative Light-Weight
Design

Process-suitable Design of structural Components allow for

the use of Multi Phase Steels, hot formed Materials and
Aluminum Castings

Due to new Design of Carrier Structure Torsional Stiffness

raised from 23500 Nm/ to 27000 Nm/

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