Machining induced surface integrity in aerospace components

Machining and mechanical material removal is one of the key manufacturing operations in the automotive and aerospace industries to generate functional surfaces. The interaction of the hard cutting tool with the workpiece materials affects the quality of the generated surfaces which be critical on the service life of the components. This project aims to better understand the effect of machining induced surface modification on a range of aerospace alloys produced by conventional and Additive Manufacturing techniques (AM) and its effect on the service life including the fatigue performance. The proposed research aims to utilise advanced modelling techniques to develop a predictive model of chip formation and machining induced damage in machining of the produced parts. A range of state of the art experimental methods will be used to investigate the mechanical properties of the parts as well as advanced modelling techniques to predict the components service life. The predicted results will be validated using the experimental findings and the outcome will be used to develop a more robust manufacturing approach for complex parts for aerospace applications.

Previous experience/requirements: Experimental methods, Finite element modelling, computer programming, Manufacturing