The digital connection of production processes is a promising approach to minimize CO2-emissions and maximize the material effectiveness for lightweight constructions. Especially for modern and complex lightweight concepts a digital twin of the complete process chain can improve the process design, lead to a shorter time-to-market, save money and reduce the error probability. Tailor Welded Blanks (TWBs) – laser welded metal sheets with customized properties – which are formed into car body parts have a huge lightweight and material saving potential.

Due to the complex process chain, difficulties in designing and simulating parts appear. This lack of process knowledge and prediction hinders the use of advanced high strength steels for the application in car body parts. Combined with high-strength steel, the potential for lightweighting and material savings is increased while maintaining at least the same level of occupant protection.

The challenge in producing these parts is the heat input and geometrical changes caused by the welding process, which affect the forming properties of the sheet metal. To evaluate the potential and adjust the welding or forming process, a high number of expensive experiments must be repeated. These experiments are replaced by simulations connected with a blockchain-based transformation platform, which exchanges information from these two simulations between different companies securely and semi automatically.

In the presentation the setup and validation of a welding and forming simulation is shown as well as the connection between these simulations to build a bidirectional digital twin. The digital optimized parts are produced and compared to the parts with initial parameters.