Start date: 31^st August 2015. 

Duration: 4 years.

Project Summary

Tata Steel supplies low carbon free cutting steel bar to customers who manufacture machining intensive parts for a variety of applications. The value of the steel is controlled by its machining performance, with enhanced machining steels demanding a price premium.

A range of alloying additions can be used to enhance machinability, the most common being S, Pb, Bi, Te and Se. These influence the microstructure and mechanical behaviour of the material during machining, however some of these additions limit the attractiveness of the material for other production processes such as hot forming.

This project will optimise S containing grades to minimize the requirement for other machinability enhancing additions while retaining excellent machinability. This will improve the profitability of the product produced at the Tata Steel Speciality Steels’ Thrybergh plant.

The main objectives of the EngD project are to:

• Review factors controlling the machinability of low carbon free cutting steels.
• Determine the effect of MnS inclusion distribution and pearlite morphology on chip formation and cutting forces in machining processes
• Through FE modelling predict the optimum inclusion size and pearlite distribution to maximise machining performance.

Eligibility

Applicants must have, or expect to get, a 1st or good 2.1 degree or Masters (with Merit) in mechanical engineering, materials science and engineering, physics or other relevant subject. 

Due to EPSRC residency requirements, this project is open only to UK/EU applicants resident in the UK for at least 3 years immediately preceding the start of the course.

How to Apply for the Studentship

Applications should be submitted online (full instructions on the IDC website) and include a personal statement.

About TATA Steel

Tata Steel is one of the world’s most geographically diversified steel producers, with operations in 26 countries and commercial offices in over 35 countries. In Europe we are the second largest steel producer.

The company serves many demanding markets worldwide, including Aerospace, Automotive, Construction, Consumer Products, Defence & Security, Energy & Power, Lifting & Excavating, Packaging, Rail, and Shipbuilding. The Speciality Steels business, based in South Yorkshire, UK, manufactures carbon, alloy and stainless steel grades for some of the most demanding applications in the automotive, aerospace and energy & power markets.

About the IDC in Machining Science

The IDC in Machining Science is a unique collaboration between industry, the University of Sheffield's award winning Advanced Manufacturing Research Centre and the Faculty of Engineering.

We are an EPSRC Centre for Doctoral Training (CDT) offering 10 fully funded four-year PhD and EngD studentships per year.

Machining Science is the application of engineering theories to improve the machining of metals, alloys and composite materials. It covers a wide range of operations where material is removed as part of the production process (e.g. hole generation, turning and finishing), and crosses many engineering disciplines including dynamics, vibration, tribology, materials science, control systems, drive and actuation systems, and robotics.

Machining Science is a vital research area for companies in the High Value Manufacturing sector (e.g. automotive, aerospace, medical engineering) where at least 25% of the process time for components arises from machining.

Tax free stipend of £18,000 pa, plus tuition fees at UK/EU rates.

Taught elements will take place at the University of Sheffield. Research will mainly take place at the University of Sheffield’s state-of-the-art Advanced Manufacturing Research Centre, based on the Advanced Manufacturing Park at Catcliffe, near Sheffield. The EngD will also regularly visit the sponsor’s R&D laboratories and other relevant sites.