Research involves

Developing advanced numerical tools to simulate metal forming processes.

Research relevance

The research is providing more accurate numerical tools to simulate metal forming operations, which will help develop more cost-effective manufacturing processes.

Keeping the Edge in Canada's Automotive Metal Forming Industry

With 20 percent of Ontario's workforce directly employed in the automotive industry, keeping the Canadian auto industry both competitive internationally and ecologically responsible cannot be overemphasized. One way to do this is to support researchers, like Daniel Green, who are involved in pushing the envelope of Canada's metal forming manufacturing processes.
As a Canada Research Chair, Green works on the modelling capabilities of the metal forming manufacturing processes. What makes his work unique is that it covers the full spectrum of activities, from theoretical research to use in industry.

Green is particularly interested in the development and experimental validation of more accurate constitutive models for material behaviour, friction behaviour, and failure prediction. By embodying the core science within finite element codes, he ensures that it is applied to optimize metal fabricating processes and develop more advanced metal forming manufacturing strategies.

Green's work is also unique in that it looks at manufacturing solutions that accelerate the use of lightweight materials. This technology helps to optimize the performance of fabricated parts and sub-assemblies.

Green's research will have immediate benefits for industry, particularly in the area of hydroforming. Hydroforming is a mass-saving technique for producing lightweight steel components, which uses fluid pressure (instead of the punch) to form tubular metal parts within a die cavity. Lightweight materials translate into lighter weight vehicles; savings on materials and energy lead to more environmentally friendly products. Canada is a leader in hydroforming technology and production, and we'd like to keep it that way.

Green's research not only strengthens the Canadian auto-parts supply industry, but is also expected to spill over into other key sectors, such as the aerospace and appliance industries. And, of course, its contribution to the manufacture of lightweight components is helping to reduce vehicle mass and thus contribute toward reducing greenhouse gas emissions.