George Riley

Integrated Simulation Approach to In-Process Machining Distortion Control

Supervised by: Dr Sabino Ayvar-Soberanis, Dr Josh Priest & Dr Christophe Pinna

Throughout my undergrad in aerospace engineering research was always the aspect that interested me the most. The opportunity to be at the forefront of technological advancements excites and motivates me to take on these new challenges.

The aim of my research is to develop a real-time simulation framework capable of predicting and preventing machining distortion in thin walled aerospace components. I'm hoping to investigate and discover how different factors, such as residual stresses, machining sequences and fixturing all interact to cause distortion. These insights will then be used to develop a real-time simulation approach using live data to enable in-process adjustments to prevent distortion occurring during the machining process

This research is exciting as it tackles one of the biggest challenges in precision manufacturing: machining distortion control. This problem is particularly critical in thin-walled aerospace components, where small deviations can lead to reworks, material waste and difficulties during assembly. These distortions are caused by a number of factors, which this research considers altogether rather than in isolation to one another. 

My research will make a difference by reducing the impact of machining distortion, which is a major source of cost and material waste in the manufacture of aerospace components. By developing a predictive model for real-time control, it will help lower rework and material waste, support the use of novel lightweight materials and enable more precise automated assembly. This will help leading aerospace companies to improve fuel efficiencies, reduce emissions and manufacturing costs, and maintain high quality for critical aerospace components. This ultimately contributes to more sustainable, efficient and environmentally responsible manufacturing practices.