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Material monitoring for process control in the roll forming process

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  • Full or part time
    Dr V Janik
    Prof R Dashwood
  • Application Deadline
    No more applications being accepted
  • Funded PhD Project (Students Worldwide)
    Funded PhD Project (Students Worldwide)

Project Description

This PhD project is part of the Cotutelle arrangement between Coventry University, UK and Deakin University, Melbourne, Australia. The successful applicant will spend 2 years at Deakin and 1.5 years at Coventry, with a supervision team drawn from the two Universities.

This PhD project will be situated within the Sustainable Production and Consumption research cluster of the Centre for Business in Society (CBiS) which is the Faculty of Business and Law’s hub for specialist research which focuses on the ultimate goals of living within environmental limits and the attainment of social justice, through the delivery of responsible business and ethical consumption practices.

Our research takes a 'whole supply chain' approach, examining activities, attitudes and behaviours at different points in the lifecycle of products. We are especially interested in work which engages consumers through raising awareness of the imperative for more sustainable lifestyles and decision making.

Project Details

Roll forming, where a flat sheet is incrementally bent into shape in successive roll stands is increasingly used for the forming of high strength steels and light metal alloys to high end products for the construction and transport industry. For this achieving high and consistent part quality is important. With increasing material strength the effect of material property variations on the final component shape becomes more significant. In addition most roll forming metal grades are skin-passed or tension levelled to improve flatness. This results in residual stresses through the material thickness that can affect part shape. To achieve high component quality and process robustness in the forming of high strength metal sheet therefore new methods for in-line material property monitoring and part shape control need to be established.

The team at Deakin University has developed a simple bending test that can be used on the shop floor for the monitoring of material properties from coil to coil. Combined with numerical analysis and a simple inverse routine the bend test allows identifying residual stress profiles in the incoming strip; this information can be used in FEA to achieve an improved representation of material behaviour in the process. Deakin`s team also developed a new approach for in-line shape control. Here roll load and torque measurements in combination with FEA analysis are used to identify property variations in the incoming material and to link those with the final part shape. Using special roll tooling in-line part shape compensation is achieved. So far above methods have only been proven in a laboratory environment and for limited component shapes. A fundamental understanding of the effect of residual stress on part shape does not exists. It is likely that both, changes in material strength and residual stress influence the final shape and therefore need to be considered for final part shape adjustment.

The three main scientific objectives of this project are:
1) To investigate the range of material property variation observed in conventional roll forming and how it affects part shape quality and specific shape defects such as twist, flare and bow.
2) To separately understand the effect of residual stress and microstructure on roll forming process robustness and component shape.
3) Based on above to develop and experimentally validate techniques for material monitoring and part shape control.

Training and Development

The successful candidate will receive comprehensive research training including technical, personal and professional skills.
All researchers at Coventry University (from PhD to Professor) are part of the Doctoral College and Centre for Research Capability and Development, which provides support with high-quality training and career development activities.

Find out more about the institute here:

Entry criteria for applicants to PhD

Successful applicants will have:
• A minimum of a 2:1 first degree (second class honours upper division) in a relevant discipline/subject area with a minimum 70% mark in the project element or equivalent with a minimum 70% overall module average, and/or
• A Masters Degree in a relevant subject area will be considered as an equivalent. The Masters must have been attained with overall marks at 70%. In addition, the dissertation or equivalent element in the Masters must also have been attained with a mark at 70%.
• a minimum of English language proficiency (IELTS overall minimum score of 7.0 with a minimum of 6.5 in each component)
• Strong industrial experience is desirable.
• The potential to engage in innovative research and to complete the PhD within a prescribed period of study
• the potential to engage in innovative research and to complete the PhD within a prescribed period of study

Additional requirements:
• Hands-on experience with of Electron Microscopy and Electron Backscattered Diffraction is a plus
• Experience with FEA software such as ABAQUS or LS-DYNA is a plus.
Essential to be able to physically locate to both Coventry University (England) and Deakin University (Australia)

How to apply

To find out more about the project please contact Vit Janik ([Email Address Removed]) and Richard Dashwood ([Email Address Removed]).

To apply on line please visit:
All applications require full supporting documentation, a covering letter, plus a 2000-word supporting statement showing how the applicant’s expertise and interests are relevant to the project.

Funding Notes

• Bursary £15000 pa (TBC)
• Tuition fees (UK/EU/International)

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