Production processes change the properties of vehicle components in view of crash performance. For example, stresses, strains and thickness changes of a deep drawing operation lead to a response change of a component in a crash event compared to a stress and strain free structure with evenly distributed sheet thickness. Different materials, geometries and production methods were investigated in terms of magnitude of this property change. In view of an early stage of the vehicle design process the capability of one-step solvers to estimate the results of forming processes was analysed. It could be shown that the use of such one-step solvers is not sufficient in order to estimate the influence of deep drawing on the crash result. Further on it was shown that compared to most cases of cold stamping, the inclusion of hot stamping simulation results in a crash simulation leads to softer component response. The individual die design of the forming tool also has some influence on the crash performance of sheet metal parts. Finally it was shown how the topic forming to crash can be implemented into the process chain of an automotive development process and how relevant parts for which forming simulations have to be performed can be chosen.
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