E-mobility: FLB GmbH uses Z100 and HTM 5020 for flexibility in materials testing
Case Study
- Customer: FLB Gesellschaft für Fahrzeugleichtbau mbH
- Location: Siegen, Deutschland
- Industry: Automotive, plastics
- Topic: Testing and validation of structure components for battery electric vehicles (BEV)
November 2024
FLB Gesellschaft für Fahrzeugleichtbau mbH (lightweight engineering) focuses on the material characterization of metals and fiber-reinforced plastics in order to develop simulation material data sheets for crash calculations. These data cards are validated to accurately simulate and improve underride protection systems in battery electric vehicles (BEVs). FLB GmbH uses the ZwickRoell HTM 5020 and Z100 high-speed and tensile testing machines for this purpose.
FLB Gesellschaft für Fahrzeugleichtbau mbH
FLB GmbH is a leading development service provider in the field of automotive structural components, specializing in the creation of sustainable, lightweight solutions, particularly for new energy vehicles. As a spin-off of the Chair of Lightweight Vehicle Construction at the University of Siegen, the company has privileged access to the latest research and development trends. FLB GmbH offers comprehensive services ranging from benchmarking and reverse engineering to advanced product development and optimization using the latest CAD and FEM technologies. In addition to process simulation, the company offers flexible testing options to meet the high demands of the industry and efficiently validate innovative solutions.
ZwickRoell top competences
- Flexible: maximum adaptability of the testing machines with nearly unlimited possibilities for impactor geometries.
- Robust: testing machines are designed for daily use in harsh conditions.
- Versatile: ability to perform all types of materials testing including axial testing, 3-point bending and other methods.
- Proficient: reliable and fast service from ZwickRoell.
- Reliable: traceable test results.
The task
Development and validation of material data sheets for aluminum alloys via different strain rates
Precise material characterization is extremely important in the automotive industry for the development of safe and efficient vehicles. The FLB Gesellschaft für Fahrzeugleichtbau was faced with the task of creating material data sheets for aluminum alloys that cover a wide range of strain rates - from quasi-static conditions to highly dynamic crash scenarios. These material data sheets are crucial to precisely predict the behavior of aluminum in different load situations and help to continuously optimize vehicle safety and efficiency.
Specific challenges:
- Material characterization at high strain rates: the first major challenge was to obtain accurate and reliable data on the behavior of the aluminum alloys at high strain rates. At these speeds, materials behave differently than under slower, quasi-static conditions. Measuring precise data in this field requires specialized equipment and expertise in order to adequately record the fast and often enormous loads.
- Validation of the material data sheets under the same conditions: another critical task was the validation of the developed material data sheets through component tests that can simulate both quasi-static and highly dynamic conditions. This validation must ensure that the material data sheets function consistently and reliably under different load conditions.
The challenge: create test environments that can accurately replicate these different conditions so that the material data sheets can be effectively tested and released for practical use.
The ZwickRoell solution
Solve complex testing requirements with the Z100 and HTM 5020
To meet these challenges, the company implemented two specialized machines: the Allroundline Z100 and the HTM 5020 high-speed testing machine. These machines played a decisive role in solving the complex testing requirements.
- Quasi-static material characterization with the Z100: the Z100 was primarily used for quasi-static tests. Its ability to precisely apply slowly increasing loads made it ideal for the detailed investigation of material behavior under lower speeds and loads. These tests were crucial in establishing a basic understanding of how the aluminum alloys would behave under everyday operating conditions.
- Highly dynamic material characterization with the HTM 5020: to extend the quasi-static material data into the highly dynamic range, further tensile tests were carried out on the HTM5020. This machine enabled FLB GmbH to test material behavior under extremely fast and high loads, such as those that occur in a vehicle crash. The HTM 5020 provided important data that is essential for the development of material data sheets in order to predict the behavior of the material in critical and safety-relevant situations.
- Quasi-static validation and intrusion testing: one innovative aspect of the solution was the additional use of the Z100 to set up an intrusion test on an underride protection system. This is done in the same way as the highly dynamic tests on the drop tower. The drop tower is a separate test setup in which underride protection systems for BEVs are tested - thus “intrusion” refers to the penetration of a foreign object/impactor into the battery pack of a vehicle. This scenario is reproduced and tested both statically with the Z100 and dynamically on the drop tower. This allowed FLB GmbH to validate the material data sheets under identical conditions for both test types. By using the same test setups in the Z100 and the drop tower, consistent and comparable data was generated, which significantly improved the reliability and accuracy of the material characterization.
The result
Lighter underride protection systems thanks to precise testing
FLB GmbH's decision to use highly specialized testing systems such as the Z100 and HTM 5020 led to outstanding results, both in terms of scientific data quality and product development speed. The combined use of these devices made it possible to precisely characterize materials across the entire spectrum of load velocities, from quasi-static to dynamic, and to validly describe their behavior at component level.
The generated database not only enabled FLB GmbH to significantly improve the accuracy of its material characterization, but also to accelerate the development of innovative products. One clear result of these improved testing and development processes is the initiation of a pre-development project for underride protection systems that are up to 20 percent lighter than existing series products. This represents significant progress in the area of lightweight construction and increased efficiency, which is directly attributable to the improved testing procedures.
Customers of FLB GmbH were extremely satisfied with the progress made. Improved material characterization and product development enabled them to implement more advanced and lighter components that increase vehicle safety and performance while helping to reduce overall weight.
“The reliable and, in the case of the Z100, highly flexible ZwickRoell machines enable us to carry out extremely effective tests for our customers. The ability to map a wide range of strain rates in the material characterization and at the same time display validations at component level also enables our customers and us to identify new lightweight construction potential time and time again”
Max Bisch, Managing Director FLB Gesellschaft für Fahrzeugleichtbau mbH
ZwickRoell testing machines at FLB GmbH
