Web-based material properties for use with metalforming simulation packages

Commercial pressures are forcing metalforming companies to embrace technologies that enable the development of high value added designs. One of these technologies is metalforming simulation normally based on the finite volume or finite element method. The use of simulation enables innovative designs to be examined and modified before execution. However, the precision of the results from any simulation depends on the quality of the input data. This data must accurately describe every aspect of the forming process being examined and can include the behaviour of the tools, the workpiece and the interface between the two. The mechanical and thermal data required must be valid over the temperature, strain and strain rate ranges applicable to the process. This type of data differs greatly from the data normally available in design handbooks and in many well-publicised databases. This paper demonstrates the importance of accurate material data for simulation and discusses the issues of available data and their relationship with real process temperature and strain rate ranges. In addition, the limitations associated with testing conditions as well as the work being undertaken by Brunel University in conjunction with the UK metalforming industry in developing a web-enabled database of materials properties is discussed.