EngD - Machinability of Titanium Alloys
Lead Research Organisation:
University of Sheffield
Department Name: Mechanical Engineering
Abstract
Sandvik Coromant are the world leader in cutting tools to the metals industry. To maintain our position, it is essential that we adapt and build our knowledge constantly to understand our customers' latest processes and materials.
This EngD is to work with the workpiece materials team within Sandvik Coromant, to build our knowledge of machining titanium alloys. Specific topics that have been identified for further consideration are;
- Ti-5-5-5-3 machinability, in comparison with Ti-6Al-4V. Although there has been some academic research on this topic in the past, this has tended to focus on finishing processes, to minimise costs. This makes the work of questionable relevance to the roughing applications seen in industry. This should be considered in scoping this aspect further if it is selected for study.
- Machining of the alpha case in as forged Ti-6Al-4V components. This should include an analysis of the extent to which alpha case is formed in near net shape components, and the implications that this will have on the finishing process.
- Dry drilling of Ti-6Al-4V
These initial studies would be a mixture of reviews of literature and experimental work.
Machinability of titanium alloys is a topic that has been widely examined in academic circles, but generally with a focus in Ti-6Al-4V based alloys produced through conventional processing routes. As new alloys have come into mainstream use, and as processing methods have changed towards near net and additive manufacture, we need to understand the implications of these changes. The way in which our customers use the tools may be different, but also the machinability knowledge of the actual materials structures may be incomplete.
This EngD is to work with the workpiece materials team within Sandvik Coromant, to build our knowledge of machining titanium alloys. Specific topics that have been identified for further consideration are;
- Ti-5-5-5-3 machinability, in comparison with Ti-6Al-4V. Although there has been some academic research on this topic in the past, this has tended to focus on finishing processes, to minimise costs. This makes the work of questionable relevance to the roughing applications seen in industry. This should be considered in scoping this aspect further if it is selected for study.
- Machining of the alpha case in as forged Ti-6Al-4V components. This should include an analysis of the extent to which alpha case is formed in near net shape components, and the implications that this will have on the finishing process.
- Dry drilling of Ti-6Al-4V
These initial studies would be a mixture of reviews of literature and experimental work.
Machinability of titanium alloys is a topic that has been widely examined in academic circles, but generally with a focus in Ti-6Al-4V based alloys produced through conventional processing routes. As new alloys have come into mainstream use, and as processing methods have changed towards near net and additive manufacture, we need to understand the implications of these changes. The way in which our customers use the tools may be different, but also the machinability knowledge of the actual materials structures may be incomplete.
Planned Impact
Novel, high-speed machining processes are central to the UK's economic vision with respect to manufacturing, and in particular high value manufacturing.
The Centre for Doctoral Training in Machining Science will provide trained individuals with skills and expertise at the forefront of knowledge in machining science to the labour market. In doing so, it will address a key skills gap in the High Value Manufacturing supply chain. In supporting the manufacturing sector in the UK the centre will deliver societal impact through job and wealth creation. Meanwhile, the outreach activities will aim to attract more widely skilled individuals into manufacturing.
Industrial impact is central to the training programme. All research engineers undertake doctoral training in conjunction with a sponsoring industrial company, which also provides the context for their research work. In some cases this context will reflect current manufacturing problems, and in other cases will consider future machining processes with respect to a company's technology roadmap and capability acquisition. Collaborating industrial companies will therefore receive machining science solutions to industrial problems investigated through the centre. Research engineers undertake their projects in close partnership with their sponsor, and ultimately they implement their research in an industrial context. In order to maximise this impact, training is provided in communication, dissemination and implementation, alongside research skills.
Our industrial partners consider the doctoral training programme as a mechanism through which to develop technical leaders within their organisations. As they move beyond their doctoral research into employment in industry, research engineers will have the opportunity to apply their machining science and industrial project co-ordination skills to solve manufacturing problems beyond the scope of their initial training project. As they embark on their professional careers, the Centre's graduates will have the skills and expertise to underpin manufacturing initiatives such as the re-emergence of the nuclear energy supply chain, where machining of single, long lead-time, high-cost castings is critical.
Longer term and on a broader level, as our alumni develop into leaders, they will also have organisational, cultural, and technical impacts on industry through the teams they create and mentor. This will have a wider industry impact wider industry as these individuals move around the labour market, stimulating the uptake of advanced machining science.
The centre will be based in the Advanced Manufacturing Research Centre (AMRC), itself a showcase for the resurgence in UK manufacturing capability. Through the Doctoral Centre's location, research engineers will contribute to outreach and engagement activities in the AMRC, with the aim of further attracting skilled individuals at all levels into the UK manufacturing sector.
The Centre for Doctoral Training in Machining Science will provide trained individuals with skills and expertise at the forefront of knowledge in machining science to the labour market. In doing so, it will address a key skills gap in the High Value Manufacturing supply chain. In supporting the manufacturing sector in the UK the centre will deliver societal impact through job and wealth creation. Meanwhile, the outreach activities will aim to attract more widely skilled individuals into manufacturing.
Industrial impact is central to the training programme. All research engineers undertake doctoral training in conjunction with a sponsoring industrial company, which also provides the context for their research work. In some cases this context will reflect current manufacturing problems, and in other cases will consider future machining processes with respect to a company's technology roadmap and capability acquisition. Collaborating industrial companies will therefore receive machining science solutions to industrial problems investigated through the centre. Research engineers undertake their projects in close partnership with their sponsor, and ultimately they implement their research in an industrial context. In order to maximise this impact, training is provided in communication, dissemination and implementation, alongside research skills.
Our industrial partners consider the doctoral training programme as a mechanism through which to develop technical leaders within their organisations. As they move beyond their doctoral research into employment in industry, research engineers will have the opportunity to apply their machining science and industrial project co-ordination skills to solve manufacturing problems beyond the scope of their initial training project. As they embark on their professional careers, the Centre's graduates will have the skills and expertise to underpin manufacturing initiatives such as the re-emergence of the nuclear energy supply chain, where machining of single, long lead-time, high-cost castings is critical.
Longer term and on a broader level, as our alumni develop into leaders, they will also have organisational, cultural, and technical impacts on industry through the teams they create and mentor. This will have a wider industry impact wider industry as these individuals move around the labour market, stimulating the uptake of advanced machining science.
The centre will be based in the Advanced Manufacturing Research Centre (AMRC), itself a showcase for the resurgence in UK manufacturing capability. Through the Doctoral Centre's location, research engineers will contribute to outreach and engagement activities in the AMRC, with the aim of further attracting skilled individuals at all levels into the UK manufacturing sector.
