Optimised machining strategies for near net shape components

为了让高附加值制造业支持全球实现净零增长的努力，制造商需要迅速实现以更负责任和可持续的方式供应产品的方式的一步改变。目前业界已做好准备的解决方案包括：以近净形式提供零件，以便只需要最少的进一步加工过程；提供含有100%可回收原料的材料；以及实施适应性更强的系统，如机器人或并联运动加工中心。然而，这些解决方案在试图满足行业在质量、成本和费率方面的严格要求时，当被视为完整的一揽子方案时，会带来各自的挑战。当与可持续发展目标结合起来时，很可能不得不承认，目前最先进的解决方案实际上可能会导致生产率下降。目前市面上可用的仿真模型已经跟不上模具设计和加工策略的发展。因此，该博士项目的重点将是提高我们的模拟能力，同时考虑到固有的工艺变异性，如供应的材料条件、刀具几何和形状误差、机床运动学/动力学以及零件夹具，以提供可以在加工中心直接演示的解决方案。

In order for the high value manufacturing sector to support the global drive towards net zero, manufacturers need to rapidly implement a step change in how they can supply products in a more responsible and sustainable way. Current industry-ready solutions include providing parts in near-net forms such that minimal further machining processes are required; provision of material that contains 100% recycled feedstock; and implementing the use of more adaptable systems such as robotics or parallel kinematic machining centres. However, these solutions provide their own challenges when considered as a complete package when attempting to meet stringent sector requirements in terms of quality, cost and rate. When combined with sustainability targets it may well have to be accepted that current state of the art solutions may in fact lead to decreases in productivity. The current class of commercially available simulation models are not keeping pace with the developments of tooling design and machining strategies. Therefore the focus of this PhD project will be to advance our simulation capability taking into account inherent process variability such as material condition of supply, cutting tool geometry and form error, machine tool kinematics/dynamics, and part fixturing, to provide solutions that can be directly demonstrated on a machine centre.