This EngD/PhD project at the University of Sheffield, sponsored by Ceratizit, focuses on developing advanced real-time temperature monitoring systems for high-speed CNC machining in the context of smart manufacturing and Industry 4.0. The project addresses the critical challenge of excessive heat generation during high-speed milling, which leads to rapid tool wear, poor workpiece quality, and dimensional inaccuracies. By integrating novel wireless sensor systems and intelligent predictive models, the research aims to enable autonomous machine tools to monitor and adjust cutting temperatures in real-time, thereby enhancing productivity, reducing tool damage, and minimizing scrap rates in advanced manufacturing sectors such as aerospace and automotive.

The research involves a deep dive into digital engineering, combining powerful sensing technologies with predictive analytics. Key research questions include the implementation of non-intrusive, in-process wireless sensors in harsh milling environments, analyzing the relationship between high-frequency thermal events (using advanced Fibre Optic Infrared Radiation Thermometry) and tool wear/thermal stresses, and developing real-time predictive models to infer cutting temperatures in traditionally inaccessible areas. The successful candidate will be responsible for the full lifecycle of the smart system, from sensor design and calibration to integration, real-time data acquisition, and the creation and validation of predictive models using the AMRC’s 5G-enabled infrastructure.

The project offers significant impact by improving process efficiency through predictive maintenance and intelligent automation, enhancing part quality by reducing temperature-induced defects, and supporting digitalization goals across precision engineering industries. Students will benefit from a fully funded four-year scholarship, including tuition fees, an annual tax-free stipend of £28,000, and a £35,000 research support grant for equipment, travel, and consumables. The program provides access to world-class facilities, tailored training, and support for gaining Chartered Engineer (CEng) status. Graduates have a strong track record of securing senior roles in top industries.

Applicants should hold a first-class or strong 2:1 degree in a relevant engineering or science discipline (such as Electrical and Electronic Engineering, Mechanical Engineering, Aerospace Engineering, Materials Science, Physics, or Mechatronics and Systems Engineering). International and UK students are eligible, with specific residency requirements for UK Home status. English language proficiency (IELTS 6.5 overall, minimum 6.0 in each section) is required for non-native speakers.

Applications are made via the University of Sheffield admissions system, selecting the 'Doctoral Training Course' and 'MADE4 Manufacturing CDT' options, and must include transcripts, degree certificates, CV, personal statement, and evidence of English proficiency if applicable. For further information, applicants can contact Dr Matthew Hobbs at [email protected].