The AMRC process modelling team develops and tests techniques and computer-based models for machining processes.

We investigate metal cutting, composite machining, residual stress/machining distortion, and fatigue life prediction, and validate our models through machining trials and residual stress measurement.

We use computer-based models to investigate alternative machining processes, helping companies make more informed decisions. These models reduce the need for costly shopfloor trials, and shorten the lead time in bringing a new product to market.

We aim to cover all areas of modelling relevant to our industrial partners.

Core capabilities include:

• Prediction of residual stress, machining distortion and feedback loop for tool path optimisation.

We can integrate process models and in-process monitoring to investigate and validate the models to develop optimised machining strategies based on part distortions.

• Chip formation analysis in metal cutting and composite machining modelling, to better understand the relationship between the many process parameters and the machining responses. By modelling material removal, we can reduce the cost of experimental tests optimise cutting conditions, and redesign tool geometry.

• Work-holding modelling analysis, using numerical models to investigate the dynamic and static performance of a variety of aerospace components.

We have extensive software resources, including tools for finite element analysis, optimisation analysis, design of experiments and programming. Software providers and packages include Third Wave Systems, Deform, Abaqus, Ansys, Fluent, Nastran, Matlab, Isight, Umetrics and others.

We also have access to the Iceberg high-performance computing cluster at the University of Sheffield.

For more information, please contact: 

Dr. Sabino Ayvar-Soberanis
s.ayvar@amrc.co.uk