Dr M Weiss
No more applications being accepted
Funded PhD Project (Students Worldwide)
About the Project
The use of carbon fiber as a structural reinforcement for body structure applications is currently under investigation at the Ford Motor Company. Recent results have shown that significant weight savings can be achieved with similar or enhanced component performance in static and crash tests. Roll forming is frequently used at Ford for the manufacture of structural and crash components from UHSS. In comparison to hot stamping, roll forming promises lower tooling costs at higher material utilization and output rates. The process is continuous and material is fed from a coil which reduces material handling. This project proposes the manufacture of long structural components from CFRMH by roll forming. A manufacturing scenario is anticipated that will establish the combination of carbon fiber composite with roll formed sheet metal structures with the main aims of the research to address the associated challenges of combining these dissimilar materials.
This will include the manufacture and analysis of CFRMH sheet at Deakin University’s Carbon Nexus (carbonnexus.com.au) followed by the investigation of forming limits of CFRMH in simple bending deformation and its effect on system properties. Based on the above, advanced numerical material models will be developed with major focus on the accurate prediction of potential error states and failure modes in forming. These models will be used to develop a process design for roll forming CFRMH followed by optimization and proof of concept with numerical analysis. The focus will be on the roll forming of structural members – prototype manufacture and experimental proof of concept will be performed on IFM’s world first flexible forming facility (https://blogs.deakin.edu.au/roll-forming/frf/).
Funding Notes
To be eligible for this scholarship you must:
- have a first class honours or 2a honours or equivalent (such as a Master) in materials, manufacturing or mechanical engineering, physics or chemistry
- provide evidence of good oral and written communication skills
- demonstrate ability to work as part of a multi-disciplinary research team.
- meet Deakin University’s entry requirements for the higher degree by research