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

We investigate metal cutting, residual stress/machining distortion, and validation of simulations through machining trials and on line /off line measurement such as residual stress, cutting forces, temperature,
distortions.

We use computer-based models to investigate alternative machining processes, helping companies make more informed decisions. These models reduce the need for costly shop-floor 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 modelling to better understand the relationship between the many process parameters and the machining responses as well as surface integrity. By modelling material removal, we can reduce the cost of experimental tests optimise cutting conditions, andredesign tool geometry. We also have capability for simulation alongside experimental work for Ultrasonic assisted machining assisting for example in force reduction in difficult to cut materials.

• We have extensive software resources, including tools for finite element analysis, optimisation analysis, design of experiments and programming. Software providers and packages include, Deform, Abaqus, Ansys, Matlab, Simufact, 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