This vacancy refers to a KU Leuven – TU Eindhoven joint PhD position in the framework of the Flemish ICON project Tesco (Temperature and geometrical Shape simulation and validation for FFF and FGF printed Components) on the topic of 3D printing (also known as additive manufacturing) using Fused Filament/Pellet Fabrication (FFF/FPF). The project is a close collaboration between the industrial partners Deceuninck, Colossus, and HDM Engineering and the academic partners KU Leuven, TU Eindhoven, and Centexbel. This specific PhD topic concerns the development and integration of a multi-scale modelling environment, where expertise from both KU Leuven and TU Eindhoven needs to be combined. The selected PhD candidate will therefore have promotors from the two universities, giving an international dimension to the research. The main location of work will be KU Leuven, campus de Nayer, but secondments at TU Eindhoven in the Netherlands of long/short period spread during the work are expected.
Description of the organizational unit.
Due to the joint PhD status, the candidate will be active at two universities: KU Leuven and TU Eindhoven. The promotors of the PhD will be Prof. dr. ir. Eleonora Ferraris (eleonora.ferraris@kuleuven.be, +3215316944) from the AML group of the Mechanical Engineering department, campus De Nayer, KU Leuven, Belgium (https://iiw.kuleuven.be/onderzoek/aml) and Dr. Ir. Joris Remmers, (j.j.c.remmers@tue.nl) from the section Mechanics of Materials of the Mechanical Engineering Department, TU Eindhoven, the Netherlands (https://www.tue.nl/en/research/research-groups/mechanics-of-materials/group-remmers). Upon successful completion of the PhD trajectory, the candidate will obtain a joint PhD in Mechanical Engineering at the Faculty of Engineering Technology of KU Leuven (http://www.kuleuven.be/kuleuven/) and at Eindhoven University of Technology (www.tue.nl).
Project
Outline:
Fused Filament/Pellet Fabrication (FFF/FPF) is one of the best-known 3D printing techniques for the production of thermoplastic components. It is based on thermal energy driven material extrusion and is used to manufacture parts with complex, unique geometries in small series, as well as in large volumes. In the Advanced Manufacturing Lab (AML) of KU Leuven, campus de Nayer, a model to predict and simulate the build temperature of FFF/FPF printed parts has been developed [doi:10.1007/s40964-022-00271-0]. This code, named T4F3: Temperature for Fused Filament Fabrication, has been successfully applied to simulate thermal evolution in products during the print process under various conditions. The model can be used to predict critical reheating temperatures for high-quality and optimise the print process of PLA (polylactic acid) and other polymers, parts. [https://iiw.kuleuven.be/onderzoek/aml/technologyoffer/FFFthermalsimulation/T4F3_original]
Content:
The objective of this PhD is to develop a multiscale model for part and process simulation including coding and modelling of the mechanical bond quality. The key component is the coupling of the micro-scale polymer bond kinetics to the mesoscale bond strength and performance. To reach this objective, the KU Leuven T4F3 model will be integrated into the currently available Finite Element-based simulation environment of TU Eindhoven, which allows the mechanical analysis of print processes of larger parts, including thermal boundary conditions. The result will then be further extended and validated for free-form geometries and relevant shapes for the industry partners in the project (such as cylindrical and long bar-shaped designs). The bond development (kinetics, morphology, strength) will be studied under various thermal processes, including isothermal and non-isothermal processes above the glass transition temperature of an amorphous and/or semicrystalline thermoplastic material. Eventually, a theory of local bond quality will be achieved for an arbitrary temperature history typical in FFF/FPF printed parts. Experimental work (to be done by a colleague) will provide input to the model and will be used for model validation.
Profile
● A Master's degree in Science or Engineering with a background in Mechanical Engineering or Material Engineering or Chemical Engineering or Computer Science, or Applied Physics or Aerospace Engineering… or an equivalent Master’s degree.
● The candidate preferably has a background modelling with interest in manufacturing and/or polymer processing, but eagerness to learn is certainly just as important. Understanding thermal transfer mechanisms is considered an added value.
● Graduation with distinction is a requirement to start the PhD
● Proficiency in the programming languages for scientific computing such as Python, Matlab and/or C++.
● Expertise in additive manufacturing with focus on fused filament fabrication (FFF) is a plus.
● Being fluent in English (both speaking and writing) is a must
● You are creative and a team worker
● You are curious, and application driven with an interest in science and technology
Offer
● a joint Ph.D. fellowship with the university of KU Leuven and TU Eindhoven for the duration of a maximum of 4 years at a competitive salary.
● A challenging project with a very large industrial exploitation potential
●A multidisciplinary training and international working environment
● A highly valued academic environment and multi-cultural working group
Interested?
For more information please contact Prof. dr. ir. Eleonora Ferraris (eleonora.ferraris@kuleuven.be, +3215316944) or Dr. Ir. Joris Remmers (j.j.c.remmers@tue.nl, +31402473175).
You can apply for this job no later than April 30, 2024 via the online application tool: https://www.kuleuven.be/personeel/jobsite/jobs/60319504
Please, provide your CV, motivation letter, and transcripts. Highlight in your CV the relevant expertise matching the demanded background as described above. Hence, indicate your knowledge in FFF and/or filament extrusion and/or numerical modelling. Also, indicate how you have distinguished yourself during your academic career until now. Clearly list your GPA (and GPA ranking if available), your (journal) publications as first author, talks or research grants/scholarships, if any.
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