Hybrid manufacturing of engineered lightweight metal components

Description of the project:

The Department of Mechanical Engineering and Materials of the School of Engineering of the University of Navarra (Tecnun) is seeking a candidate to carry out a doctoral thesis focused on the integration of hybrid manufacturing technologies (combining additive and subtractive manufacturing) of high performance in the manufacture of lightweight metal components, with special emphasis on the design and optimization of gears. The proposal seeks to establish a change in the manufacture of these components starting from a flexible and lightweight design oriented to hybrid manufacturing incorporating topological optimization and reticular structures. This approach aims to increase production flexibility and apply advanced hybrid manufacturing techniques to address the manufacture of this type of metal component. The project will focus on the development of methodologies and integrated analytical or numerical models for the design and hybrid manufacturing of lightweight components combining additive manufacturing by means of laser powder bed fusion (LPBF) and post-processing based on machining processes, in order to manufacture parts with zero defects and guaranteeing the required mechanical properties and the precision and surface finish of the part.

Requirements:

• Master Degree in Mechanical Engineering or similar.
• Language: Good level English.
• Basic knowledge of manufacturing technologies.
• Experience in experimental work in the manufacture of metal parts.
• Ability to work in a multidisciplinary team.
• To have initiative for research and to be autonomous.

Training:

During the completion of the thesis the candidate will receive and acquire training in:

• Modelling of parts using CAD software.
• Study on topological optimization and design of lightened structures in gears and static/dynamic analysis of their behavior through finite element modelling.
• Additive manufacturing of metal parts by means of laser powder bed fusion (LPBF).
• Design, modelling and CAM implementation of post-processing (milling) strategies for parts.
• Analysis of the precision and surface finish of metal components.
• Training activities for scientific, professional and personal development.

Offered:

Tecnun, the Engineering School of the University of Navarra offers a 4-year predoctoral contract at the Technological Campus in San Sebastian (Spain).

Schedule:

• Winter: 7.75 hours per day. Half working day in July and August: 5.5 hours a day.
• Flexible hours: check-in between 8:00 and 9:30, check-out from 4:15 p.m.

Holidays: 23 days of summer holidays + Christmas holidays (10 days) + Easter holidays (1 week).

Documentation:

Send the following documentation by email to jcramos@unav.es:

• Cover letter describing your motivation as a thesis candidate.
• Updated CV.
• Undergraduate and Master’s degree transcripts.