Simulation and experimental research of two different bending processes: free-form (3D) bending and roll stretch (2D) bending
Applications are invited for a full-time EPSRC Industrial CASE PhD studentship in research associated with the development of high strength Al-alloys in BCAST at Brunel University London and in collaboration with Constellium UK. The PhD studentship is for a period of four (4) years effective from 1 October 2024. The successful applicant will receive an elevated annual stipend (bursary) of approximately £23,000 to start, plus payment of their full-time Home/EU tuition fees.
Project Details
Simulation and experimental research of two different bending processes: free-form (3D) bending and roll stretch (2D) bending
Typically, steel has often been used as the primary material in structural automotive components. However, there is a need to reduce vehicle emissions which demands car manufacturers to focus on next-generation electric vehicle (EV) production. This can be achieved by designing and manufacturing lightweight vehicles by replacing steel components with extruded aluminum alloys due to their high mechanical properties and low density. Constellium UK, and its extrusion development of high-strength and high-crash alloys, play an important role in enclosure structure designs for EVs.
There are applications where the bending of extrusions is a necessary cold forming step included in the process route to produce automotive components such as enclosure structures. The free-form bending technology, often known as 3D bending is a novel bending process that opens new and unique opportunities concerning the complexity of geometrical shapes (extrusions) and innovative designs, reducing production process times, assembly efforts and consequently costs. This is a process that opens new and unique scenarios concerning the complexity of geometrical shapes (extrusions) and innovative designs, reducing production process times, assembly efforts and consequently costs.
Some of the major challenges with 3D bending of aluminum extrusions is dimensional stability due to variation in geometrical and material properties during the extrusion process. It is important to therefore conduct an in-depth investigation of the material's plastic anisotropic characteristics as it significantly influences strain distribution and the material's formability. Anisotropic properties evolve during cold working due to changes in the material's microstructure. It is also important to understand the common failure modes that arise from localized stretching strains leading to the formation of localized shear bands and necking or from the presence of compressive loading causing wrinkling. Formability is closely linked to the material's ability to either effectively manage or resist necking. To comprehend and forecast the material's formability, it is essential to ensure that the applied strains remain below a predefined formability threshold, as defined by the Forming Limit Curve (FLC).
BCAST is a specialist research centre focusing on light metallic material related research with an international reputation and hosts the national centre of excellence in liquid metal engineering (the EPSRC Future LiME Hub) and a UKRI Interdisciplinary Centre for circular metals. BCAST is well equipped with state-of-the-art facilities for solidification science, metal processing and materials characterization. We cover fundamental research, technological development and industrial applications in the field of solidification and processing of light metals. For more information see www.brunel.ac.uk/research/Centres/BCAST. The proposed research will use facilities for metal processing as well as the characterization facilities in the newly established future metallurgy centre to understand fundamental science behind an industrially relevant problem. The research conducted as part of this PhD programme will contribute to the activities of the Constellium University Technology Centre (UTC) established with BCAST and form part of the major strategic alliance between the two.
Applicants should submit the documents below to be considered for the research project on Simulation and experimental research of two different bending processes: free-form (3D) bending and roll stretch (2D) bending. Informal enquires may be addressed to Dr Rui Cardoso via email to rui.cardoso@brunel.ac.uk
Eligibility
Applicants will have or be expected to receive a minimum 2:1 or 1st class degree in materials engineering, mechanical engineering, manufacturing engineering or a related discipline. A master’s qualification is an advantage but not essential.
How to apply
Please e-mail your application comprising of all the documents listed below
to cedps-pgr-office@brunel.ac.uk in ONE PDF file by 12 noon on 28 June 2024.
- Your up-to-date CV;
- A one A4 page personal statement setting out why you are a suitable candidate (i.e.: your skills and experience);
- A copy of your degree certificate(s) and transcript (s);
- Names and contact details for two academic referees;
- Evidence of English language capability to IELTS 6.5 (minimum 6.0 in all sections), if applicable
Interviews will take place during July 2024.