EngD: Multi-scale analytical modelling of turning processes for digital optimisation of chip geometry for improved recyclability

About the Project

Machining is a key part of subtractive manufacturing which is used by almost all industries to shape components and remove unwanted material. A particular type of machining process used to make components that are generally cylindrical and spherical in nature is turning. The material is removed in the form of ‘chips’ (also called swarf). A key process response that must be controlled in turning processes is the geometry of these produced chips to enable them to be easily evacuated from machine tools without manual intervention and enable them to be easily compact into pucks for re-melting and recycling. These considerations are especially crucial when machining components from hazardous materials and materials that are limited in supply.

Machining process optimisation using modelling techniques is becoming widely adopted in the manufacturing industry, resulting in digital process optimisation that is less reliant on experimental testing and more informed data-driven decision making. This leads to more optimal machining processes resulting in right-first-time manufacturing with a reduced carbon footprint.

Project Objectives

The aim of this project is to integrate novel meso-scale analytical models of metal cutting, that can rapidly predict cyclic chip formation, into component scale virtual machining simulations for industrially relevant turning operations. This will enable the produced chip geometry (including stress, temperature, deformation in the chip and workpiece) to be optimised alongside process level responses such as cutting forces, cutting temperatures, spindle power, and minimise static deflections that result in component geometric errors.

A key component of this project will involve developing analytical modelling techniques grounded in solid mechanics, plasticity theory, and fracture mechanics.

Not only will this project involve developing new mathematical models to predict chip formation, stress, temperature, material damage and fracture; but you will perform experimental testing on state-of-the-art equipment at the AMRC and the University of Sheffield to better understand how materials deform and interact with cutting tools. You will generate and analyse large data sets that from both cutting trials (i.e. forces, temperatures, chip geometry, microstructure) and controlled mechanical testing of materials in the lab to build and validate your models.

Project Industrial Sponsor

The project is sponsored by AWE Nuclear Security Technologies who play a crucial role in delivering the UK’s nuclear deterrent and are at the forefront of nuclear technology and innovation. You will work with them throughout your degree and they will support you in developing the process models. Ultimately, your work will have real impact as they will use the models you develop to improve the sustainability of their machining processes.

NB: The project is subject to contract and the specific scope of research may change.

Benefits

• Earn While You Learn: Get a fully funded four-year postgraduate research degree (EngD or PhD) with an annual tax-free stipend of £28,000 (that’s equivalent to a £34,000 salary!). We’ve got your back so you can focus on your research.
• Serious Funding: You’ll have access to a £35,000 research training support grant over four years. Whether it’s for experimental work, conference travel, or the latest computing gear, we’ll make sure you have the resources to succeed.
• Work with the Best: Team up with industry giants. You’ll work on real-world projects that make a difference, gaining experience that sets you apart.
• Launch Your Career: Our graduates have landed senior roles in top industries, thanks to the hands-on experience and industry connections you’ll build here.
• World-Class Facilities: You’ll be working at the cutting edge, alongside experts in machining, assembly, and digital engineering. The tools and knowledge you’ll gain are second to none.
• Tailored Training: Benefit from both group-based and personalised training activities. We’ll help you craft an individual training plan that aligns with your career goals.
• Live in Sheffield: Enjoy life in one of the UK’s friendliest cities. With a vibrant social scene and supportive community, Sheffield is the perfect place to live and learn.
• Go Pro: We’ll support you in gaining Chartered Engineer (CEng) status, ensuring you’re recognised for your professional expertise.

Requirements

A first-class or strong 2:1 degree in a relevant science or engineering subject such as Mechanical Engineering, Aerospace Engineering, General Engineering, Mechatronics, Physics, Mathematics, or Computer Science

If you haven’t previously been educated in English, you’ll need an overall IELTS score of 6.5 with at least 6.0 in each section

Eligibility

This project is open to Home (UK) students. To be considered a UK Home student, you must have no restrictions on how long you can stay in the UK, and should have been ordinarily resident in the UK for at least 3 years prior to the start of the scholarship.