PhD grants : Thermal and mechanical simulation of machining assistance and their effects on the surface integrity of the material (EMSTU)

Categories: News | PhD | Funding

DEADLINE: 1st May 2021


  • 36 months doctoral funding (October 2021 to September 2024)
  • Keywords

Surfacing, MQL, Numerical simulation, Microstructure, Thermomechanic, Surface Integrity

  • Profile and skills required

Having a completed training in

mechanic and / or materials, the person sought will have a pronounced

passion for shaping processes, in particular for machining. With strong

modeling skills, the requested person will have strong abilities on

structural analysis and numerical simulation (Abaqus and Python for

example). Managing computational or multiphysics fluid mechanics

software would be appreciated (StarCCM +).


The candidate must demonstrate the

ability to work on their own initiative, independently and strong

analytical and summurized skills, as well as have communication skills

in the English language.

  • Project description

Forming by removing material,

encountered in surfacing for example, occurs extreme thermal and

mechanical behavior. All the mechanical energy used to create the chip

is converted into thermal energy due to friction and plastic

deformation. The heat flow dissipates in the chip (65-75%), the tool

(5-10%) and the material (5-25%). Heat flow and plastic deformation have

a significant impact on tool life, but also on the surface integrity of

the material and its fatigue strength.


Recent studies have been carried out in order to develop tools with

inlet canalizations, offering optimal micro-spraying according to

different machining configurations. Machining assistance, in particular

Micro Quantity Lubrication (MQL), provides a real benefit in the tool

life compared to emulsion lubrication (approximately x3) and better

surface integrity. The residual stresses measured in the material

machined by MQL exhibit higher compressive stresses than in the material

machined by emulsion. The observation of these stresses gives a

positive perspective on the material characteristics and their fatigue

strength, when they are machined under MQL assistance.


The objective of this thesis is to study the impact of cutting

conditions and machining assistance on the surface integrity of the

machined material.


Previous experimental studies enable to be measured various

parameters resulting from cutting such as temperature, cutting forces

and parameters related to the surface integrity of the machined material

such as roughness, hardness and residual stresses.


A numerical part will complete the experimental expertise carried

out. Multiphysics modeling and numerical simulation would be highlighted

by the use of finite element and finite volume calculation software in

co-simulation in order to study the thermal and mechanical influence of

the material removal process on the state of stresses and more generally

the surface integrity which plays an important role in the durability

of the material. A macro mechanical model of the material taking into

account its microstructure can be developed, based on surface integrity

and thus be able to optimize cutting conditions and / or machining


  • References

[1] A. Ka, A. Duchosal, A. Morandeau, R. Leroy, Influence of the

both rake and flank faces metal working fluid (MWF) strategies on

machinability of Ti6Al4V alloy, Modern Machinery Science Journal,

Article de congrès HSM 2019, pp 3114-3121, 2019, DOI:



[2] S. Werda, A. Duchosal, G. Le Quilliec, A. Morandeau, R. Leroy,

Effect of minimum quantity lubrication strategies on tribological study

of simulated machining operation, Mechanics and Industry, Volume 20,

n°6, 2019, doi.org/10.1051/meca/2019057.


[3] S. Werda, A. Duchosal, G Le Quilliec, A Morandeau, R. Leroy,

Minimum Quantity Lubrication advantages when applied to flank face in

milling mold steel X100CrMoV5, International Journal of Advance

Manufacturing Technologies, Volume 92, Issue 5–8, pp 2391–2399, 2017 DOI



[4] A. Duchosal, S. Werda , R. Serra, C. Courbon, R. Leroy,

Experimental method to analyze the oil mist impingement over an insert

used in MQL milling process, Measurement, Vol. 86, pp 283-292, 2016,

DOI: 2016, 10.1016/j.measurement.2016.03.010.


[5] A. Duchosal, R. Serra, R. Leroy, Numerical steady state

prediction of spitting effect for different internal canalization

geometries used in MQL machining strategy, Journal of Manufacturing

Processes, Vol. 20, pp 149–161, 2015. DOI:10.1016/j.jmapro.2015.08.008.


    To apply, click here






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