How to - Assess the Importance of Material Data Quality

The NAFEMS Manufacturing Process Simulation Working Group (MANWG) would like to commission a How-To guide titled "How to - Assess the Importance of Material Data Quality".

Introduction

The simulation of manufacturing processes requires the use of many different materials (e.g. metals, plastics, composites, etc.) described by constitutive models and equation of state models in the simulation. These models are controlled by user-supplied input parameters which characterise the material response to loads, pressures, temperatures, etc. during manufacturing. While it is recommended to use validated data, often the quality of these model input parameters is not known since the modeller may use easily obtained values without caring too much about their origin. Another fact that is often underestimated is that some parameters are more important for simulation accuracy than others, dependent too on the development or design stage. This document is intended to provide insights to managers and practitioners as to best practices in assessing material model input quality and the relationship to simulation accuracy and outcome.

The document is intended to complement the existing publication that has been developed by MANWG, specifically “Material Characterisation for Metal Forming Simulation (TG01)”. The new document is expected to be completely generic and should not focus on one specific manufacturing process.

Scope

This document is expected to provide generic insights to a range of typical questions and topics, for example:

  • Which material models are important (and may be required) for manufacturing process simulation? This should consider cost, lead-time, quality and design stage.
  • What material parameters are required for these models? What are their specific temperature, loading, physical structure, process sequence, etc. ranges?
  • What are the sources of material input parameters? How generally reliable are these sources?
  • What approach should be used for determining the quality of material input parameters?
  • How could one assess which constitutive model parameters are most important to the simulation outcome?
  • How should one assess the sensitivity of simulation outcomes to material input parameters?
  • What is constitutive model and material input parameter uncertainties and what methods may be used to quantify this?

The document is expected to make the reader aware of these key issues for general manufacturing simulation and provide examples and demonstrations of material model input consequences on simulation outcomes. If possible, the document should also indicate where there are current knowledge gaps and industrial demand to improve model accuracy that may currently be insufficient. It is envisaged that this document would spawn a number of more detailed process- and/or sector specific publications to be created in the future.

Intended Readership

The intended readership consists of managers, engineers and scientists responsible for analysis and modelling activities within their organisation. The document is expected to provide these decision makers and practitioners with a guide to the key issues that need to be considered when implementing a manufacturing process simulation requiring specific material data input, that may be part of a fuller manufacturing simulation process.

Format / Cost / Timescale / Expected Length

The key issues may be expressed as a series of questions that the practitioner may ask themselves in preparing and performing a manufacturing process simulation and analysis.

The total cost is not expected to exceed £4,000 (GBP) which should include responding to a single set of consolidated comments from the review team.

The first draft for review must be complete within 12 months of placement of contract. Interim work-in-progress drafts may be requested by the review panel.

The publication is anticipated to be approximately 50 A5 pages in length.

Proposals

Potential authors should submit the following:

  • A brief description of the main topics to be covered
  • Chapter and section headings with an approximate number of pages per chapter
  • Timescale for completing the book
  • Cost
  • CVs of the authors (Maximum  two-pages per author) 

Proposal should be sent to NAFEMS at manufacture@nafems.org  for a 1st of January 2021 submission deadline. 

Further details are available by contacting the NAFEMS Technical Officer technical@nafems.org