About the project
This project aims to develop a hybrid manufacturing technology, integrating metal additive manufacturing with ultrasonically assisted robotic machining to improve the quality and precision of lightweight alloys, including thin-walled structures and complex-shaped aerospace parts. The research will investigate machining mechanisms, process stability and surface integrity to optimise the manufacturing performance.
Lightweight alloy components, such as those commonly used in aerospace and automotive engineering systems, increasingly feature complex geometries and thin wall structures. Metal additive manufacturing enables the production of these components with reduced material waste and greater design freedom. However, as-built components often exhibit poor surface finish, geometric inaccuracies, internal defects, and residual stress, requiring secondary machining to achieve the required quality. Conventional machining can be challenging because of the complex geometries, while industrial robots offer flexibility but often suffer from limited structural stiffness and machining stability.
This PhD project aims to develop a hybrid additive–subtractive manufacturing approach, integrating metal additive manufacturing with ultrasonically assisted robotic machining technology. The research will focus on lightweight aluminium and magnesium alloy components, including thin-walled structures and complex geometry parts. The project will investigate the integration of ultrasonic vibration into robotic machining to improve material removal performance, machining stability, dimensional accuracy, and surface integrity.
The research involves the design and characterisation of an rotary ultrasonic machining tool, integration with a Kuka robotic platform, and systematic investigation of the interactions between ultrasonic excitation, robot dynamics, and material removal mechanism. Experimental studies will examine the cutting forces, temperature, vibration behaviour, surface roughness, and subsurface integrity under different machining and manufacturing conditions. Numerical modelling and advanced signal processing will support the understanding of machining mechanisms and identification of optimal process parameters.
The project will establish a scientific and technological foundation for flexible, high-performance hybrid manufacturing of lightweight alloy components, supporting the production of complex engineering structures with improved quality and manufacturing efficiency.
What’s in it for you:
- work in world-class laboratories at the University of Southampton, with access to advanced manufacturing, ultrasonic transducers design and characterisation, material sciences, and robotics facilities
- develop expertise in ultrasonic transducer design, robotic machining, metal additive manufacturing, and process optimisation
- gain hands-on experiences in experimental mechanics, vibration analysis, numerical modelling, and surface integrity assessment
- build transferable skills for careers in advanced manufacturing, aerospace engineering, robotics, and industrial research and development.
You will receive trainings on design, fabrication and characterisation of ultrasonic machining tools using engineering software. Technical training will include advanced material characterisation techniques such as micro-CT, SEM, and in-situ XRD.
You will benefit from professional development through the University of Southampton’s Doctoral College. This includes courses on academic writing, research ethics, presentation and communication skills, and public engagement. Opportunities will also be available to gain experience in teaching and supervision.
The School of Engineering is committed to promoting equality, diversity inclusivity as demonstrated by our Athena SWAN award. We welcome all applicants regardless of their gender, ethnicity, disability, sexual orientation or age, and will give full consideration to applicants seeking flexible working patterns and those who have taken a career break. The University has a generous maternity policy, onsite childcare facilities, and offers a range of benefits to help ensure employees’ well-being and work-life balance. The University of Southampton is committed to sustainability and has been awarded the Platinum EcoAward.
