宝马5系E60手册技术资料：mfp-brk-e60-rohhk-basic-update_en

BMW Service

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NOTE

The information contained in this participant manual is intended for participants of the Aftersales Training.

Refer to the relevant "BMW Service" information for any changes/ supplements to the Technical Data.

© 2003 BMW AG

München, Germany. Reprints of this manual or its parts

require the written approval of BMW AG, München

VS-12/Vs-42 MFP-HGK-BRK-0210_update

Contents

Page Introduction1

Bodyshell2

Joining techniques3

- Side panel, front4

Weight-reduced aluminium front end GRAV7

- Front wheel arch10

- Engine support16

- Bulkhead20

- Welds for EMC24

Side frame and roof26

Substructure34

Rear end38

Crash characteristics40

Introduction

In recent years all automobile manufacturers have been increasingly faced with the problem of spiralling weight in today's motor vehicles.In view of constantly increasing engine performance,both the chassis and the body must absorb and transmit ever higher forces.

In addition, cars and their interior are generally larger. The reason for this development is that the vehicle size is based on the95%man.The 95% man is derived from the average height of the population. This means only 5% of the population exceed the size of the 95% man. Furthermore,in the past few decades comfort demands have increased continuously resulting in ever more comfort systems either fitted as standard or available as optional equipment.

All these factors have lead to an increase in vehicle weight.

The objective during the development of the E60 was to stop or even reverse this trend.

Consequently, the E60 is the first vehicle to feature a mixed aluminium-steel construction. The front end of the vehicle is made of aluminium with a steel passenger cell and rear end.

Thanks to this mixed construction and the use of high strength steels, the body weight was reduced to 255kg (not including doors, bonnet, boot lid and flaps) while weight distribution was substantially improved.

Bodyshell

KT-11776

Fig. 1:Bodyshell (yellow = steel, blue = aluminium)

Body rigidity

Joining techniques

In E60 series production, the following joining methods are used in the steel section of the body:

-MAG welding

-MIG braze-welding

-Laser welding

-Spot-weld bonding

-Bordering

Static rigidity, bodyshell

Values Framework (carcass)

(not including doors, bonnet, rear lid, flaps, front end, front side

panels)

255kg Flexion 1 tunnel

6500N/mm Flexion 1 sill

7500N/mm Flexion 2 rear centre

1900N/mm Flexion 2 rear frame side member

1000N/mm T orsion 1

18500Nm/ºT orsion 2

17000Nm/ºT ransverse flexion 5500N/mm Dynamic rigidity, overall vehicle

Values Flexion 1

26Hz T orsion 1

29Hz T orsion 237.5Hz