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Details of Grant 

EPSRC Reference: EP/P027555/1
Title: H2 Manufacturing: Hybrid-Hybrid machining of next generation aerospace materials
Principal Investigator: Roy, Professor A
Other Investigators:
Zhao, Professor L Silberschmidt, Professor V
Researcher Co-Investigators:
Project Partners:
BAE Systems Sandvik (Cormant/Steel)
Department: Wolfson Sch of Mech, Elec & Manufac Eng
Organisation: Loughborough University
Scheme: Standard Research
Starts: 01 October 2017 Ends: 30 September 2021 Value (£): 396,115
EPSRC Research Topic Classifications:
Manufacturing Machine & Plant Materials Processing
EPSRC Industrial Sector Classifications:
Aerospace, Defence and Marine Manufacturing
Related Grants:
EP/P027652/1 EP/P027563/1
Panel History:
Panel DatePanel NameOutcome
03 Mar 2017 EPSRC Manufacturing Prioritisation Panel March 2017 Announced
Summary on Grant Application Form
The application of laser assisted machining/processing has shown promise in reducing tool wear in the machining of difficult-to-machine aerospace materials, such as, metal matrix composites (MMCs). On the other hand, ultrasonically assisted machining has been successfully used to demonstrate essential reductions in cutting forces with an improvement of machined surface quality. This project is a fundamental research programme that aims to comprehensively study the two techniques in combination with a clear route to implementation. Through the transition to hybrid-hybrid manufacturing processes such as the one proposed, UK industries will be able to meet the growing needs of present and future sectors/customers by efficient and sustainable resource usage in the manufacture of future aerospace materials.

The research will focus on the influence of the thermal field-ultrasonic vibrations-mechanical deformation on the MMC material taking into consideration the initial underlying micro-structure of the material. Special attention will be paid to dynamic recrystallization and grain growth of the metallic matrix material due to the influence of the imposed thermal field and deformation-rates (due to machining).

In parallel, a laser-ultrasonically assisted machining system will be designed, developed and installed on an existing CNC machine, with the aim of cutting without coolants, using less force and machining-induced damage. Machining studies will be conducted at industrially relevant machining conditions. Comparisons will be drawn with current practice for

best machining outcomes. It is expected that the new hybrid-hybrid manufacture will lead to less machining forces with reduced tool wear and post machining (tensile) residual stresses.

Finally, several case studies will be conducted with the aim of developing next generation tools for optimal manufacture.
Key Findings
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Potential use in non-academic contexts
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Date Materialised
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Further Information:  
Organisation Website: http://www.lboro.ac.uk