4 year Engineering Doctorate (EngD): Simulation and on-line measurement of temperature during milling processes (Sponsors: University of Sheffield AMRC, and University of Strathclyde AFRC)

Start date: 2 September 2019
Duration: 4 years
Stipend: Tax-free stipend of £18,000 per year, plus all tuition fees paid at UK/EU rates.

Please check eligibility requirements before applying.

Project Description

Milling process is one of the most common machining operations in the industry, which allows the use of higher speeds to improve productivity. However, the cutting temperature generated is one of the key factors that limits the process optimisation.

For example, it is widely recognised that the evolution and redistribution of induced residual stress during machining operations is directly influenced by the magnitude of applied loads and the experienced cutting temperature within the workpiece. Equipment for in-process measurement of cutting forces has reached a high level of maturity which has led to a greater understanding of what is occurring at the tool chip interface. However, this has exposed a fundamental lack of understanding regarding temperature profiles within both the cutting tool and the workpiece, particularly when milling using solid carbide tools.

This project will establish a greater understanding of the temperatures generated during machining leading to a step change:

- ​Within modelling capability for temperature prediction.

- Understanding of the thermal cycles within typical applications toolpaths leading to future work in toolpath optimisation driven by temperature.

- Improvements in the characterisation, evolution and redistribution of stresses in the material and related surface integrity.

It is envisioned that the candidate improves the current readily available hardware solution for a more robust measurement method for on line temperature measurement in milling process for solid carbide tools. It is proposed that the candidate revisits the method of placing the thermocouple sensor, the sensor selection itself, and the wireless system for further improvements.

This project offers a unique opportunity to work as part of a collaboration between both the University of Sheffield - Advanced Manufacturing Research Centre and University of Strathclyde - Advanced Forming Research Centre. This project will draw upon core specialisms from both institutions. Through the cross HVMC collaboration, the two centres will build upon the strengths of the AMRC’s process monitoring and process modelling teams; and the residual stress measurements and modelling capabilities at the AFRC. Due to the nature of this project operating between the two centres the candidate must therefore be comfortable with travelling between both research centres.

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 further information see the IDC website http://www.ms-idc.co.uk/vacancies