16th Global Car Body Benchmarking Conference
Bad Nauheim, 21st – 23rd October 2014
Audi TT Coupé
EuroCarBody 2014
Ghibsy Seehafer Daniel Schmid
Development – Body Structure Technology Development – Joining
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Audi TT Audi TT
Technology Production
Ghibsy Seehafer Daniel Schmid
Development – Body Structure Technology Development – Joining
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AUDI AG
around the world
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AUDI AG | Expansion of the model range
• Year 1992: 3 series, 10 models Year 2014: 12 series, 50 models
A1 A3 Q3 A4 A5 Q5 A6 A7 Q7 A8 TT R8
A3 Q3 A4 Sedan A5 Coupé A6 Sedan TT Coupé
A1 Q5 A7 Sportback Q7 A8 R8 Coupé
A3 Sportback A4 Avant A5 Sportback
A1 Sportback RS Q3 SQ5 A6 Avant S7 Sportback A8 L TTS Coupé R8 Spyder
A3 Sportback A4 allroad A5 Cabriolet
S1 g-tron A6 allroad RS7 Sportback A8 L W12
S4 Sedan S5 Coupé
A3 Sedan S6 Sedan S8
S1 Sportback
S4 Avant S5 Sportback
A3 Cabriolet S6 Avant
RS4 Avant S5 Cabriolet
S3
RS6 Avant
RS5 Coupé
S3 Sportback
RS5 Cabriolet
S3 Sedan
S3 Cabriolet
A3 Sportback
e-tron
Trend is unbroken!
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AUDI AG | Globalization
• Conflict of interests
World of product World of production
► Individualization ► Worldwide production network
► Derivatization ► Standardization
► Increasing demand for function ► Avoidance of complexity
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AUDI AG | Production plants
Neckarsulm (Germany) Brussels (Belgium) Ingolstadt (Germany) Kaluga (Russia) Bratislava (Slovakia)
Martorell (Spain) Changchun (China)
San José Chiapa Foshan (China)
(Mexico) (from 2016) (from 2013)
Barcelona (Spain) Chiang Mai (Thailand)
(Italdesign) (Ducati)
Manaus (Brazil) Jakarta (Indonesia)
(Ducati)
São José dos Pinhais Moncalieri (Italy) Bologna (Italy) Sant‘Agata (Italy)
(Brazil) (from 2015) Győr (Hungary) Aurangabad (India)
(Italdesign Giugaro) (Ducati) (Lamborghini)
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AUDI AG | Győr plant expansion
• June 2011: Foundation stone laid for plant expansion
• May 2012: Topping out ceremony for the new car plant
• June 2013: Opening of the new car plant with full process chain
• Body shop
• Paint shop
• Assembly
• Press shop
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Audi TT Coupé
The vehicle
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Audi TT Coupé | High product expectations
Safety and comfort Lower mass
Performance Lower CO2 emissions
Reliability Innovations
Value for money Sophistication and attractiveness
Compact exterior dimensions Large interior
Economical production Individual vehicle
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Audi TT Coupé | Mass reduction
- 90 kg
1.370 kg - 50 kg
1.280 kg
1.230 kg
(2.0 TFSI HS front)
1998
2006
2014
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Audi TT Coupé | Lightweight construction
• The key details (Substantial weight reductions)
onboard supply -2,6 kg
Doors and tailgate
TFSI engine -3,6 kg
made out of aluminium -17 kg
TDI engine -1,9 kg
quattro drivetrain
-1,5 kg Fixed calliper brake -5 kg
Exhaust manifold -2 kg
Aeorodynamic underbody panels Seat structure -5 kg
-1 kg
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Audi TT Coupé | Customer benefits
Torsional stiffness Higher-quality Lightweight
increased by 23 % construction
higher local
rigidity Centre of gravity
lowered by 10 mm
Greateragility thanks to
targeted lightweight Better
construction crash characteristics
The new TT is stiffer and lighter than its predecessor
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Audi TT Coupé | Engines
2.0 TDI 2.0 TFSI 2.0 TFSI
with S tronic In the Audi TTS
• Power output 135 kW (184 hp) 169 kW (230 hp) 228 kW (310 hp)
• Torque 380 Nm 370 Nm 380 Nm
• 0-100 km/h 7,2 sec 5,3 sec 4,6 sec
• Top speed 235 km/h 250 km/h 250 km/h
• Consumption per 100 km 4,2 l 6,8 l 7,1 l
• CO2- emission 110 g/km 158 g/km 164 g/km
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Audi TT Coupé | Dimensions
TT TT ∆
3rd gen. 2nd gen.
• Length 4.177 mm 4.178 mm - 1 mm
• Width 1.832 mm 1.842 mm - 10 mm
• Height 1.353 mm 1.353 mm +/- 0 mm
• Wheelbase 2.505 mm 2.468 mm + 37 mm
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Audi TT Coupé | Matrix-based development
Platform strategy: Matrix–module strategy:
Top Modules
Platform
Audi vehicle categories
Sport Sport
Q D
D C
C B
B A
A A0
A0 A00
Body form Body form
Synergies within Synergies covering
similar classes of vehicle all classes of vehicle 15
Audi TT Coupé | Modular car body development
• Coupé
A3 family • Electrified/PHEV
• Sportback • CNG drive
• Saloon based on
• …
• Cabriolet Modular Transverse Matrix
• S/RS models MQB–A
• …
Cost-effective, flexible body concept
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Audi TT Coupé | Brand-specific requirements
• Usage of design freedom in the MQB platform
COP items
► Longitudinal member structure, front
► Wheel arches
► Bulkhead
► Member system, rear
• Specific modifications for TT3:
Brand- and project-specific degrees of freedom
► Cross-beam below the windscreen
► Spring strut mount, front
► Floor, front
► Floor, rear
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Audi TT Coupé | Body design/Requirements
• Body concepts for segment-specific lightweight construction
• The right amount of the right material in the right place for optimal functions
Audi A3: MQB A series
Audi TT: MQB A series
Audi A6: MLB C series
Audi A8: MLB D series
Die-cast aluminium
Aluminium profile
Sheet aluminium
Hot-pressed steel
Conventionally pressed steel
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Audi TT Coupé | Joining technique – cell
FDS Laser
SW FR
MAG Clinching
SR Folding
Adhesives PR
Three hot and six cold joining techniques for constructing the cell
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Audi TT Coupé | Joining technique – add-on parts
SW
Folding
Adhesives
Clinching
SR
One hot and four cold joining techniques for constructing the add-on parts
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Audi TT Coupé | Joining technique
Short form Long form
Adhesives Structural, relining and fold bonding
SR Semitubular rivet
MAG Metal active gas welding
SW Spot weld
FDS Flow drill screws
Laser Laser welding
FR Full rivet
Clinching Clinch connection
Folding Roller hemming
PR Blind rivets
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Audi TT Coupé
Production
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Audi TT Coupé | Győr plant
Analysis and
Pre-Series Centre
Assembly
Body shop
Quality
Paint shop
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Audi TT Coupé | Joint sequence
SG tail panel
SG wheel arch, rear,
outside left
SG wheel arch, rear,
inside left
SG side section,
SG side wall frame, left Tail panel
SG A-pillar, inside left inside left
Z: body construction Z: body construction Z: body construction
SG underbody 1 SG Runderbody 2
Insert station 1 + 2 Insert station 3 Insert station 4 + 5
SG A-pillar, inside right SG side section,
SG side wall frame, right Roof – full roof
inside right
SG wheel arch, rear,
inside right
SG wheel arch, rear,
outside right SG Welding Group
Z Assembly
SG bulkhead
Die-cast aluminium
Aluminium profile
Sheet aluminium
Hot-pressed steel
Conventionally
pressed steel
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Audi TT Coupé | Platform concept and globalisation
• Derivatives on an underbody line
A3 Sedan A3 Cabriolet TT Coupé
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Audi TT Coupé | Systems layout
Release to paint
Pillar Wheel arch Wheel arch Finish
A Rear Rear UB1
A1
Underbody 1
Underbody 2
Weld 2:
Geo joints 1
Body 2
Body 1
Wheel Pillar A Pillar A
Underbody 2
arch Wheel arch
Body 3
Body 1
Body 2
Body 3
Weld 1
Rear Rear
Wheel arch Wheel arch
Body 4
Wheel arch
Outer rear Outer rear
Finish line
Geo joints 1a
Underbody 2
Front
Rear cross
VEWA Undergr. panel
Bulkhead
Bulkhead
VBT/ attachment strip
D Ra.
ET
Side, inner left
member, rear
Pillar A
Longitudinal
member, front left
Longitudinal
Body washer
right
Side, outside right
Side, outside left
Floor, rear
Complete Side Pillar
member, rear
Floor
Longitudinal
Inside A+B
Feed belt
TGST Floor
Front Rear
left
Bypass
TGST
Longitudinal
left/right
member
Rear
Rear panel Underbody 1
Side, outside Side, outside
Geo joints 1
Left Right
Online
measurements
Doors
Instrument cluster, A3 and TT Doors
Primary line
Tailgate
Specific TT Coupé
Gelling drier
Secondary line
Bonnet
Doors
Bonnet
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Audi TT
Thank you.
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