School of Mechanical, Electrical and Manufacturing Engineering

Research

Manufacture with Pulsed-Electric Mechano-Vibratory Machining (UPSTREAM)

Manufacture with Pulsed-Electric Mechano-Vibratory Machining (UPSTREAM)

Improving productivity in the UK manufacturing context is important for viable and sustainable manufacturing of critical aerospace grade parts.

Our Aim

Aim:

  • Manufacture components quicker
  • Manufacture components with improved structural integrity
  • Improve machined surface topography
  • Reduce tool wear and damage
  • Eliminate the need for coolants - thereby making manufacturing sustainable.
  • Reduce overall machining/manufacturing costs

Manufacturing of high-end parts requires machining of difficult-to-cut materials which is rather challenging. Here, we explore a hybrid machining process where high-density DC current is delivered to the material being machined via a tool which is vibrating at very high frequencies. This electro-vibratory machining process will be effective in electrically conductive materials (which is essentially all metals and alloys which are used in the aerospace and energy industry). Such a unique machining process will allow for significantly reduced machining forces, improve part integrity in service and make the overall machining process much cheaper, by eliminating the need for environmentally harmful coolants. It is expected that the new manufacturing technique will significantly improve productivity in the UK manufacturing context, as the concept can be adapted to any machining process.

Our Research

The research utilises the state-of the art facilities available at the Hybrid Machining Lab and the Loughborough Materials Characterisation Centre (LMCC) at Loughborough University.

Our Outcomes

The project combines mechanical approaches with high-density electrical currents to deliver a new machining process that outperforms current machining techniques in terms of time, cost and structural integrity.

Professor Anish Roy - Professor of Mechanics of Materials and Processes

“UPSTREAM has the potential to disrupt the manufacturing industry by introducing a new machining paradigm.” 

Professor Anish Roy - Professor of Mechanics of Materials and Processes

Athena Swan Bronze award

Contact us

The Wolfson School of Mechanical, Electrical and Manufacturing Engineering
Loughborough University
Loughborough
Leicestershire
LE11 3TU