Providing novel experimental methods to improve commercialisation of cutting fluids to apersopace manufacturing markets

The aim of this project is to establish a test regime(s) that allow rapid identification of superior fluid performance in an accurate and timely manner. Previous research shows that this is achieved by production representative machinery and equipment, with lab standard experimental control. State-of-the-art test method(s) require design and development, that statistically relates coolant and process parameters to machinability outputs (tool life mean and variance, surface integrity, productivity). Furthermore, the research should identify the operating conditions that production sites should apply in order to maximise productivity with respect to coolants, thus improving the service that Hangsterfers can offer to their customers.
The underlying questions that prevent these objectives being achieved today relate to our limited understanding of chemical and mechanical interactions between cutting tools, cutting fluids, and work piece materials. A major obstacle is tackling the large number of variables involved in this multi-disciplinary field. As such, a design of experiment approach is highly recommended. This research will require an understanding of mechanical processing of aerospace grade metal alloys, including knowledge of chip formation processes, tool wear mechanisms and, perhaps most crucially, the cutting fluid chemistry. A good knowledge of statistics, design of experiments, experimental control and in process measurement will be essential to be able to evidence the influence of coolants on machining.

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.