Digital twin framework for load-dependent volumetric error modelling of metal-cutting machine tools

About the Project

Machine tool accuracy is typically assessed under no-load or quasi‑static conditions, as reflected in existing ISO 230 standards. However, real machining operations involve cutting forces, thermal effects and structural compliance that introduce load‑dependent deviations and significantly affect volumetric accuracy. This project addresses this gap by developing a metrology‑integrated digital twin capable of predicting volumetric performance of metal‑cutting machine tools under realistic operating conditions.

The research will begin by developing a baseline kinematic model using established geometric error modelling approaches. This model will then be extended to incorporate load‑induced effects through compliance modelling and cutting‑force estimation, enabling representation of structural deformation during machining. A key element of the work is the integration of high‑precision experimental data from advanced metrology systems, such as laser interferometry and multi‑axis measurement instruments, to calibrate and validate the digital twin. Environmental influences, including thermal variation, will also be considered to improve model fidelity.

A major novelty of the project lies in its emphasis on experimentally validated, traceable digital twins rather than purely simulation‑based approaches. The project will also investigate new strategies for characterising machine tool compliance under load, with the potential to inform future developments of international standards. The expected outcomes include improved understanding of load‑induced error mechanisms, a validated digital‑twin framework, and a pathway towards standardised testing methods for machine tools under operational conditions.

Entry Requirements

• Qualifications: A good honours degree (minimum 2:1) in Mechanical Engineering, Manufacturing Engineering, Mechatronics or a closely related discipline. A Master’s degree in a relevant area is desirable but not essential.
• Skills & Experience: A strong understanding of dimensional metrology and geometric tolerancing, together with an interest in machine tools and precision engineering.
• Additional Knowledge: A strong understanding of dimensional metrology and geometric tolerancing, together with an interest in machine tools and precision engineering. An interest in digital manufacturing, machine tool performance, and applied research with industrial and standardisation relevance.

Application Details

• A motivational email as to why you wish to apply for the scholarship, stating which project you are applying for.
• Full CV
• Provide copies of transcripts and certificates of all relevant academic and/or any professional qualifications.
• Provide references from two individuals – please contact your referees and ask them to send your reference directly to gs.pgradmissions@hud.ac.ukfrom their email address. (references can be submitted late but must be received by 17th May 2026)
• Proof of eligibility – e.g. scan of passport photo page
• International applicants must be able to provide an IELTS 6.5 (with no element below 6) *or equivalent English Language certificate or proof of study in the UK within the past 2 years, for their application to be considered for shortlisting.

Please email gs.pgradmissions@hud.ac.uk with queries regarding eligibility and submitting documents. Informal enquiries about individual projects should be directed to the lead supervisor listed for each project.

Funding Notes

3 years full-time research covering tuition fees and a tax-free bursary (stipend) starting at £21,805 for 2026/27.