Abstract. Welding distortion is one of the major concerns of the industrial joining practice. In order to obtain optimal welding parameters many experiments have to be carried out. Numerical simulation enables a virtual examination of the welding distortion without performing expensive experiments. In this contribution some industrially applicable methods of weld modeling are discussed. They enable the fast distortion assessment in the pre-development stage. The application of these methods on a complex automotive part is conducted followed by a comparison of computed distortion with measured values. Furthermore, aspects of integration of weld modeling into the virtual product chain are addressed.

Abstract.Several measures are applied in order to reduce springback but it is not always possible to reduce springback sufficiently. Therefore techniques have been developed to counter springback by modification of the tool shape (overbending). In this paper the smooth displacement adjustment method (SDA) for springback compensation is presented. The discrete springback displacement field is approximated by an L2-projection of suitable continuous smooth functions. Multiplied by a compensation factor the approximating continuous displacement field is applied to the tool surface including the addendum. An application of the new method on an industrial part is demonstrated. The main advantage is the easy handling of the method.

WORLDWIDEManufacturing and Characterisation of Highstrength Plastic-metal Hybrids Metals and plastics have long since been rival materials when it comes to "plastic substituting metal". Well-known exceptions to this rule include insert and outsert technology. This is primarily based on integrating locally arranged elements of the single material component into associated structures of the other material.

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