Development of Innovative Instrumentation and Modelling for 21st Century CNC Machining

数控制造无处不在，机床市场规模接近1000亿美元。21世纪的制造材料带来了新的问题，我们需要在这些过程中发明传感器和测量的未来。这是一个尚未填补的研究空白，我们的目标是用我们令人兴奋的、资金充足的EngD计划来填补这一空白。工艺参数对成品零件的性能有很大影响。切削力的在线测量设备已经达到了高度成熟的水平，这使得人们更好地了解了刀具芯片界面上发生的事情。然而，这暴露了对刀具和工件内温度分布的根本缺乏了解。用户目前遇到无法解释的加工问题，我们需要找出原因。例如，当他们试图从合金中去除重金属时。对于我们正在开发的新合金来说，这种情况变得更糟，例如用于航空航天工业。刀具和加工表面的温度测量是非常有意义的，因为热集中在小接触区。这会加速刀具磨损，并导致包括工作表面完整性在内的许多问题。AMRC在车削应用、将热电偶嵌入工具和工作部件以及与热像仪进行测量比较方面拥有丰富的经验。已经取得了有用的结果；然而，热电偶的测量太慢了。我们还发现了一些红外波长，其中一种类型的冷却剂是透明的；原则上，这应该提供了一条通过这些流体成像温度的途径。目前还没有针对更困难的铣削应用的解决方案，在这些应用中，不可能嵌入热电偶，摄像机帧速率必须非常高，以及许多其他限制，如弹道碎片和碎屑，使热图像复杂化。我们设计了一个令人兴奋的新合作EngD项目，将通过结合新型在线光学仪器和对底层冶金的深入了解来解决这些重要问题。我们的CDT和目前由五名博士生、四名PDRA和一名技术人员组成的电子工程研究小组将为您提供高质量的冶金培训。这种培训将使你对未来的雇主具有极大的吸引力。您的项目源于最近的一项可行性研究，参见：Heeley et。美国，2018年https://doi.org/10.3390/s18103188.提供解决方案将引起制造商和许多AMRC合作伙伴的极大兴趣，包括劳斯莱斯、英国宇航工业公司和波音公司。该项目由谢菲尔德大学电子电气工程系的Jon Willmott博士和谢菲尔德先进制造研究中心(AMRC)的Sabino Ayvar-Soberanis博士负责监督。您还将与斯特拉斯克莱德的先进成形研究中心(AFRC)和工业合作者密切合作。因此，预计您将在谢菲尔德大学和AMRC以及其他合作者那里度过必要的时间。

CNC manufacturing is ubiquitous, with the market for machines approaching $100 billion. With 21st century manufacturing materials comes new problems and the need for us to invent the future of sensors and measurements in these processes. This is an unfilled gap in research that we aim to fill with our exciting, well-funded EngD programme. Processing parameters significantly affect the properties of finished components. 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. Users are currently experiencing unexplained machining problems and we need to find out why. For example, when they try to remove heavy metals from their alloys. This situation becomes worse for the new alloys we are developing, e.g., for the aerospace industry. Temperature measurement of tools and machining surfaces is of great interest because of the heat concentrated in the small contact zone. This accelerates tool wear and leads to many problems, including work surface integrity. The AMRC has considerable experience in turning applications, embedding thermocouples in tools and work pieces and comparing measurements with thermal cameras. Useful results have been achieved; however, thermocouple measurements are far too slow. We have also found some infrared wavelengths where one type of coolant is transparent; in principal, this should provide a route to imaging temperature through these fluids. There is no current solution for the more difficult milling applications, where embedding thermocouples is not possible, camera frame rate must be very high and many other constraints, such as ballistic chips and swarf, complicate the thermal image.We have devised an exciting new collaborative EngD project that will lead to solving these important problems through a combination of novel in-process optical instrumentation and a deep understanding of the underlying metallurgy. You will be supported through high-quality cohort training in metallurgy from our CDT and an electronic engineering research group currently consisting of five PhD students, four PDRAs and one technician. This will training make you highly attractive to future employers. Your project follows from a recent feasibility study, see: Heeley et. al., 2018 https://doi.org/10.3390/s18103188. Providing solutions will be of great interest to manufacturers and many AMRC partners; including Rolls Royce, BAE and Boeing. This project is supervised by Dr Jon Willmott in the Department of Electronic and Electrical Engineering at the University of Sheffield, and by Dr Sabino Ayvar-Soberanis at the Advanced Manufacturing Research Centre (AMRC) in Sheffield. You will also work closely with the Advanced Forming Research Centre (AFRC) in Strathclyde and industrial collaborators. It is expected that you will, therefore, spend time at the University of Sheffield and the AMRC, and other collaborators as required.