Waterloo Forming and Crash Lab
E3-2105, 2106 & 2121G
University of Waterloo
200 University Avenue West
Contact Michael Worswick, Co-director, Waterloo Forming and Crash Lab
Michael Worswick is a Professor in the Department of Mechanical and Mechatronics Engineering of the University of Waterloo and holds a Tier 1 Canada Research Chair in “Light Weight Materials Under Extreme Deformation: Forming and Impact”. He leads a research program in automotive stamping, warm forming, hot die stamping and crashworthiness, as well as impact behaviour of materials. His research activities encompass structural crash worthiness, high-strain-rate material behavior and sheet forming for auto weight reduction, within one of the largest academic laboratories for such research. The major thrust of his research is the response of materials and structures under the gross deformation conditions associated with forming and impact.
Professor Worswick has published over 100 papers in refereed journals and has more than 300 conference publications and industrial reports. He has trained/is training more than 95 graduate students, post-doctoral fellows and research associates. He has led more than $100 million in funded research projects and conducts research with companies across the auto-sector supply chain. He is a member of the Editorial Board of the International Journal of Impact Engineering and an Associate Editor of the International Journal of Material Forming. He was the Founding Director of WatCAR, the Waterloo Centre for Automotive Research. He is a Fellow of the Canadian Academy of Engineers and was recently made a Fellow of the Society of Automotive Engineers (SAE).
- Computational Mechanics
- Automotive Metal Forming & Crash Simulations
- Advanced/Ultra High Strength Steels
- Aluminum Alloys
- Magnesium Alloys
- Warm Forming & Hot Stamping
- Diploma of Technology from Conestoga College (Electronic Technician)
- 35 years work experience in mechanical testing environment and high technology fabrication.
- Strong background in prototyping, and building electrical and mechanical designs
- Experienced in organizing processes.
- Experienced in interfacing and working with people.
- Knowledgeable and experienced with instrumentation, mechanical testing and electrical wiring.
- Good working knowledge of safety standards and procedures.
- Ability to work independently and as a team member.
Research Interests & Lab Activities:
- Hot stamping of Ultra High Strength Steels
- Elevated temperature forming of Aluminum Alloys
- Tool and Die design
- PLC, Robotics, and Automation
- Mechanical and electrical design and integration
- High strain rate behaviour of materials
- Impact testing
- Sheet metal forming of steel, aluminum and magnesium
- Finite Element Analysis of sheet metal forming
- Digital Image Correlation (DIC) applied to constitutive and fracture characterization
- Electromagnetic forming
- Sheet metal forming of steel and aluminum
- High strain rate behavior of materials
- Finite element modeling of forming and impact
- Constitutive and Fracture characterization of sheet metal, castings and forgings
- Digital Image Correlation (DIC) applied to constitutive and fracture characterization
- Finite Element Modelling of Forming and Crashworthiness Applications
- Constitutive and Fracture Characterization of Automotive Alloys
- Thermo-mechanical Fracture Behaviour of Materials under Dynamic Strain Rates
- Fracture Response of Materials under Non-proportional Loading Conditions
I am a postdoctoral fellow at the University of Waterloo within the Forming and Crash lab. My research has been focused on the development and characterization of lightweight composite-metal hybrid material systems. I hold a MSc degree in structural engineering with particular interest in structural health monitoring and a BSc degree in Civil engineering from Shiraz University of Iran. I have completed my PhD at Dalhousie University within the Advanced Composite and Materials Engineering Lab. My PhD research was focused on development of a novel hybrid composite material for application in automotive industry. Throughout my PhD research, I introduced a newly developed 3D fiber metal laminate. I have conducted an extensive research (both experimentally and computationally) on the mechanical behaviour of the proposed material under static and impact loading conditions. In particular, the low velocity impact response of the material has been systematically investigated.
- Fiber reinforced composite materials
- Composite-metal hybrid materials
- Mechanical testing experiments
- Nonlinear finite element method
- Failure analysis of materials
- Dynamic and crash behaviour of materials
Abdelbaset Midawi is a post-doctoral fellow at the University of Waterloo. Dr. Midawi was a former lecturer at the University of Benghazi-Libya (2008-2012). He joined the Centre of Advanced Materials Joining (CAMJ) at the University of Waterloo in 2013 since then his focus was to develop a novel technique to estimate the strength for welded structures. The technique successfully developed, which is based on an instrumented indentation approach to measure strength in local zones across the weld. In January 2019, Dr. Midawi joined Forming and Crash Lab at the University of Waterloo since then he is working on spot welding characterization for automotive steel components and testing state-of-the-art advanced high strength steels, that are targeted for use in future vehicles to reduce weight and gas consumption. This research aimed to improve industrial competitiveness and reduction of the environmental footprint of new vehicles.
Areas of interest:
- Welding processes optimization such as GMAW, GTAW, and RSW
- Physical metallurgy and welding metallurgy of engineering alloys.
- Instrumented Indentation (Macro and Nano-indentation) and its applications.
- Material characterization (Advanced High Strength Steels and Line Pipe Steels) using advanced techniques such as digital image correlation, SEM, EBSD, and XRD.
- Stress analysis for mechanical systems, such as pipelines and pressure vessels.
- Experimental formability characterization of advanced high strength aluminum and steel alloys under warm and hot stamping conditions using digital image correlation (DIC) techniques.
- Constitutive characterization of advanced high strength sheet alloys using DIC techniques from room temperature to ~900°C.
- The study of initial temper effects on the formability and final strength of precipitation hardenable aluminum alloys in warm forming processes.
- Application of finite element modelling techniques to temperature dependent forming processes.
- Craft beer
- Vegetable gardening
- Multi-scale fracture characterization of next generation steels
- Fracture characterization and damage accumulation modeling of Advanced High Strength Steels and lightweight alloys
- Characterizing material under proportional and n0n-proportional loading conditions in forming and fracture
- Finite element modeling of forming and fracture
- Non-linear strain path evaluation in fracture and forming process
- Resistance spot welding of hot stamping steels
- Mechanical and material characterization of spot welds
- Failure analysis and fracture characterization
- Spot weld performance modeling and simulation
- Sheared edge fracture characterization of stretch webs in a progressive die.
- Development of fracture models for the stretch web based on its geometry, material, shearing conditions and forming history.
- Formability characterization and prediction with through-thickness strain and stress gradients
- Fracture characterization of 3rd Gen AHSS
- Springback characterization and modeling
- Friction characterization at room and elevated temperature
- Constitutive and fracture characterization of advanced high strength sheet metal alloys
- High strain rate behavior of 6000- and 7000-series aluminum alloys
- Finite element modelling of sheet metal forming and impact processes
- High strain rate behavior of fiber reinforced polymers
- Strain rate dependent constitutive modelling of composite materials
- Multi-scale structural modelling of heterogeneous materials
- Non-linear finite element analysis
- Hot stamping/forming of advance high strength steels (AHSSs)
- Flow, formability, and fracture characterization of sheet metal alloys
- Microstructure-based modelling of deformation behavior of materials
- Finite element simulation of forming processes
- Finite element modelling of elevated temperature forming
- Die quench (hot stamping) process optimization for aluminum alloys
- Mechanical and material characterization of die quench aluminum alloy candidate
- Tribology characterization of aluminum alloys during elevated temperature forming
I am a MASc student at the University of Waterloo's Forming and Crash Lab. I received my BASc from the University of Waterloo's Mechanical Engineering Department. I have an interest in how machine learning can be applied to optimize manufacturing processes. My research focuses on the development of a Digital Twin to be used in the control of a progressive die. In particular, I am interested in investigating how active actuation can be used to increase the stroke rate of a press while maintaining stability in the process. The goal of this research is to use finite element modeling and machine learning to develop a Digital Twin of a progressive die.
- Digital Twins
- Finite element modeling of forming
- Machine learning applications in manufacturing
- Formability characterization of 3rd Generation AHSS steels
- FEA forming and crash modelling of automotive B-pillar
- Springback analysis
- Numerical simulation of sheet metal forming operations
- Finite element modelling of hot stamping processes for ultra-high strength steel
- Formability characterization under various strain types
- Constitutive testing and modelling of tribology characteristics for ultra-high strength steel
- Constitutive characterization of high strength steels and aluminum alloys
- Finite element analysis and numerical methods
- Yield surface modelling and calibration
- Coupled thermal-mechanical finite element analysis
- High temperature tensile testing and non-contact strain measurement techniques
- Constitutive behaviour of ultra high strength steels
The goal of my research is to introduce a precipitation and strain hardening route for ultra-high strength aluminum alloys, exhibiting optimal forming behavior in its pre-aged condition, and with further precipitation hardening, reaching the desired ultra-strength conditions. This will help to promote such alloys to be further implemented into the automotive industries.
The following list includes the major tasks being undertaken for this study:
- Evaluation of the precipitation and work hardening behavior of the alloys in a Fast Forming process at elevated forming temperatures
- Characterization and Constitutive modeling
- Control system studies on the existing equipment
- Assist with the development of a fast forming apparatus
- Performing runnability studies
- Finite element modeling of the forming processes its evaluation with the lab experiments
I began working towards my MASc after completing my BASc in Mechanical Engineering here at the University of Waterloo in 2017. Under the supervision of Prof. Michael Worswick I am working on developing a new specimen design for testing group spot weld failure. My work focuses on characterizing and modeling spot weld in die-quenched UHSS materials. Numerical models are created to aid vehicle designers through powerful simulation software such as LS-DYNA to build safe and fuel-efficient vehicles. As the base metal strength and ductility improves there is more emphasis on understanding the strength of the joints used to construct a vehicle with these materials and how joint failure affects the overall structure behaviour in a crash scenario. Single spot weld tests are used to characterize the strength of the joint under various loading conditions and calibrate a numerical spot weld model. To validate the numerical models, the model needs to be able to accurately predict the results of component level testing that incorporates multiple spot welds interacting together as the structure deforms. Previous work has begun developing new group weld specimens for spot weld model validation and I am further working on this, towards the goal of building accurate and reliable spot weld models that are used in full vehicle simulations.
- Spot weld finite element modelling for crash analysis
- Spot weld failure characterization
- Die-quenched UHSS processing