4 year Engineering Doctorate (EngD): Mechanics of deformation and induced surface integrity in micro-cutting (Sponsors: University of Sheffield AMRC)

Start date: 9 September 2018
Stipend: Tax free stipend of £18,000 per year, plus all tuition fees paid at UK/EU rates.

Project Description
Micro-cutting is increasingly used to modify the surface properties of functional surfaces as well as in the generation of mechanical systems for Micro Electro Mechanical Systems (MEMS). In the later, the quality of the generated surface can have a significant impact on the functional performance of the produced system. This is also influenced by the mechanics of deformation at the tool-workpiece interface which is related to the micro-cutting tool geometries and associated features. The size of the removed material during this process is in the same order as the microstructural constituents of most of metallic materials, therefore the mechanics of deformation during the chip separation and the produced surfaces are significantly affected due to this size scale. This highlights the importance of the performance of the cutting tools developed for micro-cutting and the interaction of the cutting edges with the deforming materials.

Therefore, in order to develop a predictive tool to simulate material deformation as well as cutting tool interactions during micro-cutting, a comprehensive knowledge on mechanics of deformation during micro cutting is required to understand these interactions. This will enhance the development of new cutting tools as well as provide better prediction of functional performance in micro mechanical systems.

The research program will focus on the following activities:

- Review of the state of the art knowledge in the field of micro-cutting with a focus on micro-milling processes
- Design a systematic study to conduct machining trials with the development of required in-house cutting rigs to investigate mechanics of deformation and quantify machining induced damage during micro-cutting
- Conduct a detailed investigation on the required material properties and modelling strategies for the development of micro-material removal modelling tool
- Develop a multi-scale predictive tool to simulate material deformation and cutting forces in the selected cutting regime

About the AMRC with Boeing
The University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing is a world-class centre for advanced machining and materials research for aerospace and other high-value manufacturing sectors. The AMRC with Boeing is a multi-million pound industry/university partnership which builds on the shared scientific excellence and technological innovation. It has internationally acknowledged research in developing innovative and advanced technology solutions for materials-forming and metal working and is housed in the Factory of the Future, a BREEAM-rated building with a zero carbon footprint. The AMRC with Boeing now employs around 500 highly qualified researchers and engineers from around the globe, in two purpose-built centres on the Advanced Manufacturing Park in South Yorkshire.

The University of Sheffield AMRC cluster also includes the Nuclear AMRC; AMRC Training Centre; and the AMRC Knowledge Transfer Centre. The AMRC with Boeing has over 70 partner companies and is part of the High Value Manufacturing Catapult network. The AMRC with Boeing machining group is the largest group, with over 85 R&D engineers across its flagship Factory of the Future and Factory 2050 facilities.

How to Apply for the Studentship
All applications should be submitted online. Please follow the instructions in the How to Apply section carefully, and ensure that you specify which project you are applying for and include in your statement why you are interested in the project and how you will contribute.

Applicants must have, or expect to get, a 1st or good 2:1 degree (or Masters with Merit) in a relevant science or engineering subject such as Mechanical Engineering, Aerospace Engineering, Materials Science, or Physics.

Candidates must also be able to show that their English language proficiency is at a level which allows them to successfully complete the EngD. All applicants require an English language qualification, typically a GCSE or an IELTS test (a score of 7 or above is required, with a minimum of 6 in each component).

For an informal discussion, in the first instance please contact the IDC Centre Team [Email Address Removed].