Professor Kevin Kerrigan
Advanced Manufacturing Research Centre
Composite Machining Group Head
Senior Technical Fellow
Full contact details
Advanced Manufacturing Research Centre
Factory of the Future, Advanced Manufacturing Park
Wallis Way, Catcliffe
Rotherham
S60 5TZ
- Profile
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Kevin began his research career at Trinity College Dublin, Ireland after completing an undergraduate degree in Manufacturing Engineering with Management Science at the same university. In 2009, he completed an MSc in the Department of Mechanical and Manufacturing Engineering, where he developed novel heat exchanger designs.
He was subsequently awarded a scholarship by the Irish Research Council for Science, Engineering and Technology to undertake a PhD which he worked on in parallel to his role as a research engineer on the FP7 funded project ADACOM. In this work he developed a novel sensor for monitoring the in-process tool-side temperature during machining of thermally sensitive materials. Here, Kevin established his skills in polymer material characterisation, scientific instrumentation of CNC processes and data diagnostics of cutting process responses. He has been the AMRC’s Composite Machining Group Head and acted collaboratively across a wide number of communities of practice, including subtractive manufacturing, digital twins, artificial intelligence, additive manufacturing, automated composite manufacturing, accurate robotics and manufacturing process simulation.
He has spent the last 10 years producing world-leading research, utilising sensors to characterise process behaviours and responses of engineered composite materials during cutting and manufacturing operations. He works closely with industrial partners to introduce both new and enhanced machining and manufacturing processes for various applications. This has included aero engine / airframe parts, wind turbine structures, composite-metallic stack assemblies and large scale space components.
- Qualifications
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Fellow of Institute of Mechanical Engineers (CEng FIMechE)
PhD in Mechanical and Manufacturing Engineering
Chartered Engineer with Institute of Mechanical Engineers (CEng IMechE)
Research Affiliate with CIRP (RA-CIRP)
- Research interests
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Composites; Machining; Finite Element Analysis; Temperature Measurement Devices; Conduction inverse heat transfer; Adaptive Control; Aerospace structural design; Sensor Technology; Process Monitoring; Wireless communication and signal processing; Design for Manufacture and Assembly; Wireless Sensors; Wireless Sensors; CFRP Milling; Tool-integrated Sensors; Sensorial Perception; Mechanical Engineering; Aerospace Engineering; Manufacturing
- Publications
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Journal articles
- A Framework for Tool Condition Monitoring of Abrasive Waterjet Systems. Procedia CIRP, 126, 475-480.
- Effects of tool coating and tool wear on the surface quality and flexural strength of slotted CFRP. Wear, 498-499, 204340-204340.
- The effect of particle reinforcements on chip formation and machining induced damage of modified epoxy carbon fibre reinforced polymers (CFRPs). Composites Part A: Applied Science and Manufacturing, 154. View this article in WRRO
- Development of a novel friction model for machining simulations in unidirectional composite materials. Polymers, 14(5).
- Error motion trajectory-driven diagnostics of kinematic and non-kinematic machine tool faults. Mechanical Systems and Signal Processing, 164. View this article in WRRO
- Chip formation mechanism during orthogonal cutting of rubber microparticles and silica nanoparticles modified epoxy polymers. Procedia CIRP, 103, 176-181. View this article in WRRO
- A novel finite element method approach in the modelling of edge trimming of CFRP laminates. Applied Sciences, 11(11). View this article in WRRO
- A finite element assessment of chip formation mechanisms in the machining of CFRP laminates with different fibre orientations. Composite Structures. View this article in WRRO
- Towards intelligent CFRP composite machining: surface analysis methods and statistical data analysis of machined fibre laminate surfaces. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. View this article in WRRO
- Machining centre performance monitoring with calibrated artefact probing. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. View this article in WRRO
- Study of the machining induced damage in UD-CFRP laminates with various fibre orientations : FE assessment. Procedia CIRP, 87, 366-371. View this article in WRRO
- Review of recent developments and induced damage assessment in the modelling of the machining of long fibre reinforced polymer composites. Composite Structures, 240. View this article in WRRO
- Epifluorescent microscopy of edge-trimmed carbon fibre-reinforced polymers : an alternative to computed tomography scanning. Advanced Composites Letters, 29. View this article in WRRO
- A comparative study of the effects of milling and abrasive water jet cutting on flexural performance of CFRP. Procedia CIRP, 85, 277-283. View this article in WRRO
- The evolution of cutting forces during slot milling of unidirectional carbon fiber reinforced polymer (UD-CFRP) composites. Procedia CIRP, 85, 127-132. View this article in WRRO
- Wet vs dry CFRP drilling : comparison of cutting fluid delivery methods. Procedia CIRP, 85, 335-340. View this article in WRRO
- Chip formation in machining of unidirectional carbon fibre reinforced polymer laminates : FEM based assessment. Procedia CIRP, 85, 302-307. View this article in WRRO
- Varying CFRP workpiece temperature during slotting : effects on surface metrics, cutting forces and chip geometry. Procedia CIRP, 85, 37-42. View this article in WRRO
- Effects of machine stiffness and cutting tool design on the surface quality and flexural strength of edge trimmed carbon fibre reinforced polymers. Composites Part A: Applied Science and Manufacturing, 119, 88-100. View this article in WRRO
- Predicting geometric tolerance thresholds in a five-axis machining centre. Structural Health Monitoring, Photogrammetry & DIC, Volume 6, 93-100. View this article in WRRO
- FE modelling of CFRP machining- prediction of the effects of cutting edge rounding. Procedia CIRP, 82, 59-64. View this article in WRRO
- Wet vs dry CFRP drilling: Influence of cutting fluid on tool performance. Procedia CIRP, 77, 315-319. View this article in WRRO
- Abrasive Water Jet Machining of Multidirectional CFRP Laminates. Procedia CIRP, 68, 535-540. View this article in WRRO
- 2D and 3D Finite Element Models for the Edge Trimming of CFRP. Procedia CIRP, 58, 233-238. View this article in WRRO
- An optical method for measuring surface roughness of machined carbon fibre-reinforced plastic composites. Journal of Composite Materials, 51(3), 289-302. View this article in WRRO
- On the relationship between cutting temperature and workpiece polymer degradation during CFRP edge trimming. Procedia CIRP, 55, 170-175. View this article in WRRO
- Machining of Carbon Fibre: Optical Surface Damage Characterisation and Tool Wear Study. Procedia CIRP, 45, 71-74. View this article in WRRO
- A naturally aspirated convector for domestic heating application with low water temperature sources. Energy and Buildings, 67, 187-194.
- Temperature Measurement in CFRP Milling Using a Wireless Tool-Integrated Process Monitoring Sensor. International Journal of Automation Technology, 7(6), 742-750.
- An Integrated Telemetric Thermocouple Sensor for Process Monitoring of CFRP Milling Operations. Procedia CIRP, 1, 449-454.
- Heat pipe-based radiator for low grade geothermal energy conversion in domestic space heating. Simulation Modelling Practice and Theory, 19(4), 1154-1163.
Conference proceedings papers
- Understanding temperature effects on friction at tool – CFRP workpiece interface using open-loop friction testing. MM Science Journal, Vol. 2021(3) (pp 4605-4611). Prague, Czech Republic, 20 April 2021 - 20 April 2021. View this article in WRRO
- Editorial. Procedia CIRP, Vol. 85 (pp 1-1) View this article in WRRO
- Machining of carbon fibre: optical surface damage characterisation and tool wear study. 3rd CIRP Conference on Surface Integrity (CIRP CSI), Charlotte, NC, USA, 8 June 2016 - 10 June 2016.
- Automated Fault Diagnosis with Calibrated Artefact Probing. Structural Health Monitoring 2019, 24 October 2018 - 26 October 2018.
- A Framework for Tool Condition Monitoring of Abrasive Waterjet Systems. Procedia CIRP, 126, 475-480.
- Research group
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Composites
- Grants
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Kevin has been the acting PI or Co-I on 10 successful UK government funded research grants to the value of £3.2m. He has introduced capital equipment to further research in this area to the value of £3.6m and led in the delivery of over 80 research projects spanning TRL3-9, totalling £8.6m. Most recent projects include:
Role: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 19/20 OMI CFRP Drilled Holes Demonstrator
Application date: 25 June 2019
Award date: 25 June 2019
Start date: 1 April 2019
End date: 31 March 2020
Amount: GBP 29,990.00
Main project partners / collaborators: N/ARole: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 19/20 Doosan Mill-turn Capability Building
Application date: 8 July 2019
Award date: 8 July 2019
Start date: 1 April 2019
End date: 31 March 2020
Amount: GBP 100,000.00
Main project partners / collaborators: N/ARole: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 19/20 Cross Group OWA (Composites)
Application date: 31 January 2020
Award date: 31 January 2020
Start date: 1 April 2019
End date: 31 March 2020
Amount: GBP 25,007.00
Main project partners / collaborators:Role: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 19/20 Assess Abrasive Water Jet for CFRP Machining
Application date: 25 June 2019
Award date: 25 June 2019
Start date: 1 April 2019
End date: 31 March 2020
Amount: GBP 50,044.00
Main project partners / collaborators: CMSRole: Co-I
Funder reference: 2019-GT-054
Funder name: BOEING UNITED KINGDOM LIMITED
Title: AI3760 Boeing VSCI ATI Project - Future Nacelle - Very Short Composite Lipskin
Application date: 7 September 2018
Award date: 7 June 2019
Start date: 1 April 2019
End date: 31 March 2021
Amount: GBP 2,613,964.00
Main project partners / collaborators:Role: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 18/19 - (CODICES) Composite Digital Capability & Engagement Sidekick
Application date: 9 April 2019
Award date: 9 April 2019
Start date: 1 April 2018
End date: 31 March 2019
Amount: GBP 140,272.00
Main project partners / collaborators:Role: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 17/18 AI3421 Cross Laminate Timber Machining Investigations
Application date: 2 November 2017
Award date: 2 November 2017
Start date: 1 April 2017
End date: 31 March 2018Amount: GBP
Main project partners / collaborators:Role: PI
Funder name: INNOVATE UK (TSB)
Title: Catapult 17/18 AI3421 Cross Laminate Timber Machining Investigations
Application date: 1 March 2018
Award date: 1 March 2018
Start date: 1 April 2017
End date: 31 March 2018
Amount: GBP 62,946.00Amount: GBP 140,272.00
Main project partners / collaborators:Role: PI
Funder reference: AI2702
Funder name: High Value Manufacturing Catapult
Title: Composite Machining: Wet vs Dry part 2
Start date: 1 August 2016
End date: 31 March 2017
Amount: GBP 68,000.00
Main project partners / collaborators:Role: PI
Funder name: INNOVATE UK (TSB)
Title: Composites Catapult project: Wet versus dry: part 2
Application date: 18 November 2016
Award date: 18 November 2016
Start date: 1 April 2016
End date: 31 March 2017
Amount: GBP 67,000.00
Amount: GBP 140,272.00
Main project partners / collaborators: