EngD - Disruptive Machining Methods for Large Aerospace Wing Structures

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Over the next 10 years, major aerospace OEMs are expected to dramatically increase production rates for current short range aircraft, and develop new airframes including a mid-range platform and at least two new short range aircraft. Current production methods for large metal wing structures do not offer the cost, production rate and quality performance that will be required from future platforms.The UK Aerospace industry is the second largest in the world, second only to the US. GKN is a FTSE 100 business and one of the most important contributors to manufacturing in the UK, and thus economy. As the most comprehensive aerostructures Tier 1 supplier (worldwide), GKN has a diverse range of technical capability across the globe. The EngD candidate will become part of this community and contribute to GKN's vision to grow and maintain world-beating manufacturing processes for future aircraft.The candidate will become part of the GKN Technology Centre in Bristol, conducting research locally, at the AMRC, and will also have the opportunity to visit other global sites as required to support technical and personal development. In addition to the small experimental budget afforded by the EngD programme, the candidate will be aligned to much larger collaborative research programmes with GKN customers, giving them the opportunity to utilise greater budget and lead tasks that are complementary to their EngD theme.The main thrust of the work will be around large machined wing structures. Initially the candidate will work with GKN colleagues and customers to understand requirements of the future aircraft in terms of component geometry, tolerance requirements, cost targets, etc. The candidate will then define experimental studies that will explore the most effective way to process these new components (clean sheet, not constrained by existing equipment). The candidate will lead processing trials from small scale up to full scale wing components. Development work will be progressed and evaluated in accordance with GKN's Technology Readiness Level (TRL) process, and the candidate will have the opportunity to present their work across the business to colleagues and senior management.The candidate has the enviable opportunity to consider how to manufacture a part without any existing constraints on equipment. This will give the candidate the greatest opportunity and flexibility to address the two major research focus:A major focus of the scientific development will be in understanding the origin of part distortion in the target product(s) and how this could be minimised/mitigated.A second major focus will be in understanding how a step change in material removal rates can be achieved through development of advanced material removal methods for the target product(s).In support of the major research focus:The candidate will consider whether conventional 5-axis 'machining in a box' processes are the most effective, or whether other more radical machine architectures are the future. This will involve the candidate understanding processing dynamics and other considerations such as the influence of fixturing/part handling methods.The candidate will need to understand a range of material-in conditions from conventional billets to additively manufactured net-shapes. This will involve developing knowledge of material properties and microstructure for the respective material stocks, and their interaction with the chosen material removal methods.The candidate will develop understanding in the art of process control, with potential to consider adaptive processes.What are the potential benefits of the collaboration for the company and for the academic partners? Are there wider benefits that may result