Utilization of damage controlled forming processes -a case study on the design of airbag pressure bins

In order to benefit from damage-controlled forming processes in terms of high-performance lightweight components with known safety margins, a new design strategy is suggested that is based on the application of probabilistic safety concepts. Since we postulate that damage-controlled forming processes will lead to a significantly reduced scatter of critical loads, we can derive significantly reduced safety factors without changing the component´s geometry. Demonstration of the underlying strategy in a case study on airbag pressure bins will quantitatively reveal the possible utilization of damage-controlled forming processes.