EngD: Fundamental understanding of the performance and suitability of tool coatings and lubricants at temperatures experienced during SCCO2 assisted machining (sponsored by Seco Tools and Hangsterfer's Laboratories) University of Sheffield in United Kingdom

Are you passionate about cutting-edge manufacturing technology? This PhD project offers an exciting opportunity to explore how tool coatings and lubricants perform in supercritical CO2 (scCO2) machining , a technique known for enhancing tool life, reducing friction, and improving machining performance.

The Challenge

Tool coatings are designed to withstand extreme heat in conventional machining, but SCCO2-assisted machining significantly lowers cutting temperatures. This raises important questions:

• Are current coatings optimized for these cooler conditions?
• Can alternative coating materials and lubricants, such as MoS2 (a known low-temperature lubricant), improve tool life?
• How do coatings and lubricants interact chemically in the cutting zone under cryogenic conditions?

Understanding these factors is essential for developing next-generation tool coatings that maximize efficiency and durability in scCO2 machining.

Your Goals

This project will provide fundamental insights into coating and lubricant performance in cryogenic machining by:

• Characterizing tool coatings at lower cutting temperatures to determine their suitability.
• Developing models to predict wear, friction, and chip formation, integrating coating, lubricant, and coolant effects.
• Building a data-driven AI model to analyze process parameters and optimize machining performance.
• Validating findings through experimental machining tests in collaboration with industry partners.

Industry Impact

ScCO2 machining is transforming manufacturing by extending tool life , increasing cutting speeds, and improving part quality . This research will contribute to enhanced coating and lubrication strategies , leading to more efficient and cost-effective machining solutions.

What’s in It for You?

• Work at the forefront of cryogenic machining, coatings, and AI-driven process optimisation .
• Collaborate with leading industry partners and OEMs to test coatings on real-world materials.
• Gain expertise in material science, tribology, surface engineering and advanced manufacturing technologies .
• Make a tangible impact on productivity, tool longevity, and sustainable manufacturing.

Be Part of the Future of Machining

This PhD is an opportunity to redefine tool coating technology for the next generation of advanced manufacturing. If you are excited about materials science, digital modelling, and industrial innovation, this project will put you at the forefront of machining research.

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, Chemistry or Chemical Engineering

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

Learn more

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

Seco Tools: https://www.secotools.com/

Hangsterfer’s Laboratories: https://www.hangsterfers.com/

Interested?

Contact Dr Thawhid Khan ( [email protected] ) if you have specific questions about the project, otherwise, please 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.