This project explores how to use CO ₂ efficiently in cryogenic machining, a technology that improves cutting performance and supports healthier, greener practices for workers and the environment.

Kennametal is a global cutting tool supplier, and many of their customers request outlet holes of just 0.2 mm diameter in their supercritical CO ₂ fluid-delivered tools, but this presents a challenge for manufacturers. The research will use Computational Fluid Dynamics and validation experiments to investigate the best ways to deliver CO ₂ , using novel fibre CFRP and metallic stack materials as case studies.

Key Questions :

Optimal Aperture Size

• What’s the optimal diameter of the supercritical CO ₂ and liquid CO ₂ outlet apertures to improve tool life and cutting performance while preventing ice crystal formation?

Coolant Flow Dynamics

• Investigate how the number and placement of coolant holes affect flow distribution and cooling efficiency. How does this change with larger hole sizes?

Heat Transfer Mechanisms

• Study how heat is transferred during cooling and how to make the process more efficient.

Chip Formation and Evacuation

• Look at how coolant delivery influences chip formation and removal during machining.

Why This Matters:

Optimised CO ₂ systems can transform machining by:

• Extending tool life and cutting costs.
• Improving machining precision and surface quality.
• Reducing energy use and boosting production speeds.

Your research will support modern manufacturing strategies by using data and advanced simulations to design better tools and processes. These improvements will benefit industries by cutting costs, increasing efficiency, and delivering higher-quality products.

Benefits

• Earn While You Learn: Get a fully funded four-year postgraduate research degree (EngD or PhD) with an annual tax-free stipend of £28,000 (that’s equivalent to a £34,000 salary!). We’ve got your back so you can focus on your research.
• Serious Funding: You’ll have access to a £35,000 research training support grant over four years. Whether it’s for experimental work, conference travel, or the latest computing gear, we’ll make sure you have the resources to succeed.
• Work with the Best: Team up with industry giants to work on real-world projects that make a difference, gaining experience that sets you apart.
• Launch Your Career: Our graduates have landed senior roles in top industries, thanks to the hands-on experience and industry connections you’ll build here.
• World-Class Facilities: You’ll be working at the cutting edge, alongside experts in machining, assembly, and digital engineering. The tools and knowledge you’ll gain are second to none.
• Tailored Training: Benefit from both group-based and personalised training activities. We’ll help you craft an individual training plan that aligns with your career goals.
• Live in Sheffield: Enjoy life in one of the UK’s friendliest cities. With a vibrant social scene and supportive community, Sheffield is the perfect place to live and learn.
• Go Pro: We’ll support you in gaining Chartered Engineer (CEng) status, ensuring you’re recognised for your professional expertise.

Requirements

A first-class or strong 2:1 degree in a relevant science or engineering subject such as Mechanical Engineering, Aerospace Engineering, Materials Science, Physics, Computer Science or Applied Mathematics.

If English isn’t your first language, you’ll need an overall IELTS score of 6.5 with at least 6.0 in each section

Find out more

MADE4Manufacturing CDT: www.sheffield.ac.uk/made4manufacturing

Kennametal: https://www.kennametal.com/us/en/home.html

Interested?

Contact Ellis Taylor ( [email protected] ) for more information or apply here: www.sheffield.ac.uk/made4manufacturing/how-apply

When applying, please make sure you select ‘Doctoral Training Course’ as the qualification you are applying for. You should then select ‘MADE4 Manufacturing CDT’ for the specific doctoral training course, choosing either EngD or PhD as indicated in the project title.