Research themes
- Micro/Nano Manufacturing
- Green/Sustainable Manufacturing
- High Speed Machining
- Materials Modelling
- Rapid Prototyping and Additive Manufacturing
- Bio-medical Manufacturing
- Composite Manufacturing and Materials Modelling
- Digital Manufacturing
- Micro/Nano Metrology
- High Precision, Micro/nano Machine Design
- Non-conventional Manufacturing Technology (Macro-scale)
Achievements
The group has made significant contributions in specific areas of micro/nano engineering: design, manufacturing and inspection. On the design front, with the help of an EU grant (I*PROMS), the group has built an ultra-precision µ-machining centre which not only serves as a demonstrator for 30 I*PROMS partners but also as a research test bed for studying the science of machining at the micro level.
In manufacturing at the micro/nano scale, the group has pioneered hybrid laser/sol-gel technology for the synthesis of nano-composite coatings including functionally graded TiN coatings, without the need for a vacuum chamber. With DTI/EPSRC funding, the group has been investigating the use of advanced nano-structured diamond-like carbon and Ti-based coatings for the machining of difficult-to-machine materials at micro and macro level. The group has also pioneered fibre laser techniques for the manufacture of nano-particles. The hybrid laser/EDM micro-drilling work funded by Delphi Automotive Systems has led to reduced cycle times in the manufacture of next generation fuel injection nozzles.
The challenges arising from the lack of precision instruments for inspecting mesoscale components are being addressed by the group. A novel vision system based on sub-pixel edge detection for inspecting micro-scale features has been developed. To enhance the precision of measurement at the nano-scale, new mathematical expressions for propagated uncertainties at higher orders for indirect measurements and calibration have been developed, filling a knowledge gap in nano-metrology. For the machining of precision components, a new in-process system, employing a Doppler-effect probe, for measuring the machining errors and compensating for them has been developed.
Research Themes
- Large area laser surface micro/nano patterning, texturing and structuring.
- Laser manufacturing of nano-particles, nano-wires and nano-carbon tubes.
- Laser processing of nano materials.
- Design and fabrication of nano optics and novel photonic crystals.
- Hybrid laser and sol-gel synthesis of novel nano-composite coatings.
- Laser enhanced PVD coating
- Laser activated electro-chemical micro machining
- ECM STEM drilling of deep micro-holes.
- Hybrid laser-EDM drilling of micro-holes.
- Electrochemical dressing of metal-bonded diamond grinding wheels.
- 3-D Electrochemical machining (ECM) in milling mode
- Ultrasonic EDM of micro-features
- Pulsed micro- ECM
- Advanced coating technology for micro-tools
- Micro-milling, turning and drilling
- Micro-CNC machining science
- 3D printing, direct writing of micro-parts
- Micro-forming
- Micro-shock peening
- In-process monitoring of micro-machining processes
- Precision machining using ultra-ECM for extremely hard materials and micro machining of aerospace parts using EDM
- Nano-machining of ceramic materials
Research Themes
- Cost efficient and ecologically sustainable forming of light weight sheet metals
- Laser surface cleaning
- Laser decontamination and decommissioning
- Laser paint stripping
- Repair of engineering components by laser additive manufacturing
- Dry (coolant-free) high speed machining
- Self-lubricating tool coatings CNC machining
- Novel Energy Reduction and Capital Optimisation for Rotomoulding
- Optimisation of Power Supply and Heat Management in LED-based Luminary Designs for Domestic and Industrial Lighting
- Forming of light weight metals
- Bi-metallic dies for rapid heat extraction
Research Themes
- Novel tool coatings for high speed machining
- High speed machining of light weight alloys
- Thermal and thermo-mechanical finite element modelling of high speed machining
- Determination and compensation of errors in machine tools
- Machining of hardended steels, difficult-to-cut alloys
Research Themes
- Production of functionally graded aerospace parts using hybrid additive and subtractive manufacturing.
- Novel selective laser melting process for multiple material component manufacture.
- Direct laser deposition using combined wire and powder feeding.
- Modelling of direct laser deposition process.
- Laser deposition of functionally graded components.
- Direct laser deposition with high efficiency powder usage.
- Powder recycling in direct laser deposition.
- Laser machining of powder composite materials for rapid manufacturing
Achievements
The research has pioneered the application of laser surface processing techniques for the modification of wettability of bio-compatible materials. Laser surface micro-texturing has been used for the improvement of cell integration (funded by GESCO Ltd, in collaboration with the Tissue Engineering Group, Faculty of Life Sciences). In collaboration with Electrosion Ltd, the group is investigating the stress-free machining of titanium knee-joint prostheses using 5-axes electrochemical milling (ECMilling). This experimental work is complemented by the development of a multi-axes ECMilling process model using boundary element to predict optimum electrode size and process parameters.Research Themes
- 3-D ECM milling of knee joint prostheses
- Laser surface modification of bio-materials for controlled wettability and cell adhesion
- Laser welding of thin foils for low temperature drug packging.
- Laser drilling of inhaler stems
- Laser processing of titanium alloys for medical implant manufacture
- Laser surface micro-texturing of medical implant materials
Achievements
The group has, in collaboration with aerospace and energy industries and the School of Materials Science, pioneered 3-D woven carbon composite techniques. Recently, the group has established collaboration with BAe Systems for the investigation of laser machining of carbon and glass composites. International collaboration has been established with Singapore Institute of Manufacturing Technology in the area of laser micro-machining of composite materials for the electronics industry. Collaborations with academics in USA, Exeter University, Manchester Material Science Centre and Manchester Computing Centre have been established, through two EPSRC grants (£295k and £288k), to investigate ultra-scalable modelling of advanced composite materials with complex architectures. The projects include material characterisation of composites and auxetic foams through the use of high performance computing which is expected to lead to the design of new materials with complex architectures in aerospace, nuclear and medical applications.
The group has responded to growing needs for mass-customised products in functional heterogenous materials through their research activities in rapid manufacturing. With £420K EPSRC funding (LASPRO project) and £250K EU funding (FANTASIA project) in laser additive manufacturing, the group has collaborated with 20 companies in Europe to develop next generation additive manufacturing technologies for aerospace components having variable material properties. This laser additive manufacturing technology has found application in the repair of aerospace components. Another research has investigated technological issues in the fabrication of multimaterial components.
In the area of continuum damage mechanics and modelling of composite manufacturing, a major EPSRC-funded development has taken place with British Energy on the analysis for design of weldments in high-temperature nuclear components. In addition, new EPSRC funding will research design/analysis techniques for components fabricated in ceramic matrix composites for advanced aerospace applications. The research will build on contacts with major US composites manufacturers, Rockwell International, and the University of California.
To realise flexible and multimaterial products, novel modelling techniques are being researched by the group. Interdisciplinary research with the Manchester School of Materials has taken a first step towards the mapping of woven tubular composite performs on to doubly-curved surfaces. The mathematical model devised allows the prediction of fibre alignment in order to improve the structural homogeneity and mechanical properties of composite based products.
Research Themes
- Moulding analysis and modelling of 3-D woven composites.
- High speed machining of composites.
- Laser drilling and cutting of composite materials.
- Development of robust principles for the design and constriction of radomes.
- Infrared, radio frequency, microwave and induction heating technology in composite manufacture.
- Thermal and mechanical models for ceramic matrix composites.
- Ultrascalable modelling of advanced materials with complex architectures
- Material characterisation of composites and auxetic foams through the use of high performance computing
- Computer aided modelling of materials in manufacture
- Modelling the pressure die-casting process
- Computational techniques for ceramic matrix composites from constituent materials to engineering components
- High-temperature creep Continuum Damage Mechanics modelling.
- Finite element modelling of non-linear material and geometric response of high-temperature component
Achievements
The Manchester manufacturing group is well known for its sustained contributions in areas of Digital Manufacturing such as product and process modelling, and manufacturing process planning.
With funding from EPSRC and industry, research in modelling the pressure die-casting process has led to optimum cooling channel shapes resulting in better quality products and reduced cycle times. A further EPSRC grant enabled research into improving the surface finish of these cast components by controlled vibration of the die.
The lack of success in applying process planning in industry has been addressed by developing systems that can be customised to suit the resources in a manufacturing environment. In addition to the adaptable architecture of these planning systems, a unique contribution has been made by considering both the geometric and technological aspects of the machining process. These considerations have resulted, for example, in toolpaths for milled components which are considerably more efficient than those generated by commercial systems.
The pioneering contributions to automatic feature recognition (AFR) have been strengthened in recent years through development of new algorithms with self-learning capabilities. Through funding from EU FP6 framework, the work on AFR has been applied to the detection of manufacturing defects (tears) from process signals obtained in deep drawing, thus enabling better process control. The group is also actively researching process control of the STEM drilling of turbine blades. This DTI funded research is a fundamental study of the effects of process parameters on product accuracy thus facilitating the development of a novel control strategy for STEM drilling.
Research Themes
- Software for logging design decisions and distributed design resources
- Automatic feature recognition (AFR) with self-learning capabilities.
- Computer aided process planning of machined components
- Determination of optimum toolpaths for machining of 2.5D milling features
- Optimum two-tool solutions for machining milling features
- CAD/CAM/CAE
- Lean manufacturing
Research Themes
- Vision system for meso scale inspection
- Modelling the propagation of uncertainties at high orders
- New probe for micro-systems inspection/calibration.
- Laser interferometer probe for in-process dimensional inspection.
- 3D surface profiling and roughness measurement
Research Themes
- Optimised design of micro-serial/parallel machines for better dexterity and higher accuracy. for micro manipulation and machining.
- Real-time error compensation in CNC machines.
- Design of ultra precision machine tools.
- Development of robust and/or reconfigurable kinematic systems for precision and micro machining applications.
- Actuators and nano-positioning
- Zero defect manufacturing using compensation techniques
Research Themes
- Laser cutting
- Laser welding
- Laser drilling
- Laser surface engineering (hardening, cladding, alloying, texturing)
- Laser marking and engraving
- Laser forming
- Laser milling
- Laser processing for art and creative industry
- Electro-chemical machining
- Electro-discharge machining
- Microwave, ultrasonic and radio wave production of polymer and composites
- Design of weldments in high-temperature nuclear components