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

数控制造无处不在，机器市场接近1000亿美元。随着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未来的传感器和测量。这是研究领域的一个空白，我们的目标是用我们令人兴奋的、资金充足的工程博士项目来填补这一空白。加工参数对成品零件的性能影响很大。用于过程中切削力测量的设备已经达到了高度成熟的水平，这使得人们对刀具切屑界面上发生的事情有了更深入的了解。然而，这暴露了对切削工具和工件内温度分布的基本缺乏理解。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，例如用于航空航天工业的合金，这种情况变得更糟。刀具和加工表面的温度测量是非常有趣的，因为热量集中在小的接触区。这加速了刀具的磨损，并导致许多问题，包括工作表面的完整性。AMRC在车削应用，在工具和工件中嵌入热电偶以及与热像仪比较测量值方面具有丰富的经验。取得了有益的成果；然而，热电偶测量太慢了。我们还发现了一些红外波长，其中一种冷却剂是透明的；原则上，这应该提供了通过这些流体成像温度的途径。目前还没有更困难的铣削应用的解决方案，其中嵌入热电偶是不可能的，相机帧速率必须非常高，许多其他限制，如弹道芯片和屑，使热图像复杂化。我们设计了一个令人兴奋的新合作工程，将通过结合新颖的过程光学仪器和对潜在冶金的深刻理解来解决这些重要问题。我们的CDT将为您提供高质量的冶金队列培训，我们的电子工程研究小组目前由5名博士生、4名PDRAs和1名技术员组成。这种培训将使你对未来的雇主极具吸引力。您的项目遵循最近的可行性研究，参见：Heeley等人，2018 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、BAE和波音。该项目由谢菲尔德大学电子与电气工程系的Jon Willmott博士和谢菲尔德先进制造研究中心（AMRC）的Sabino Ayvar-Soberanis博士监督。您还将与Strathclyde的先进成形研究中心（AFRC）和工业合作者密切合作。因此，预计你将在谢菲尔德大学和AMRC以及其他必要的合作者那里度过一段时间。

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.