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2 PhD scholarships in Sheet Metal Forming Tribology (Denmark)

Applications are invited for two 3-year PhD scholarships starting October 2014 or later within the field of metal forming tribology at the Department of Mechanical Engineering (DTU Mekanik), Technical University of Denmark (DTU).

Interest and experience within metal forming and metal forming tribology is required for the successful performance in these posts. The projects are conducted in the research group on Metal Forming and Joining, headed by Professor Niels Bay, at the Division of Manufacturing Engineering (MPP), Department of Mechanical Engineering. The two PhD positions are part of a larger project: “New environmentally benign sheet metal forming tribology systems”funded by the Danish Council for Independent Research. Manning of the project includes all in all one postdoc and three PhD students of which one is already found.

Responsibilities and tasks
The project aims at finding environmentally benign tribo-systems for sheet metal stamping of difficult materials such as advanced high strength steels, stainless steels, Al- and Ti-alloys, in order to replace present, environmentally hazardous lubricants. An off-line procedure for evaluation of new tribo-systems is to be developed based on a new, custom built PC/PLC controlled sheet-tribo-tester and a procedure including numerical analysis of the production process to select appropriate laboratory test parameters, which emulates the production conditions. Fundamental analysis of liquid lubrication in sheet stamping including influence of tailored tool surface topographies facilitating micro-hydrodynamic lubrication will form basis for improving limits of lubrication of environmentally acceptable lubricants developed and tested together with leading manufacturers. New tool coatings e.g. pure diamond, which impedes galling, will be tested.

Stamping of sheet metal by deep drawing, ironing and punching in tribologically difficult materials such as advanced high strength steel (AHSS), stainless steel, aluminium alloys and titanium alloys requires very efficient tribo-systems. It is often necessary to apply environmentally hazardous lubricants such as chlorinated paraffin oils to avoid lubricant film breakdown and galling, which lead to poor surface quality of formed components and eventually production stop. During the last decade legislation in Europe and Japan has been increasingly restrictive with respect to the industrial application of such lubricants and many sheet stamping industries are struggling to find alternative, environmentally benign lubricants. Testing of possible alternatives in the production line is, however, costly and problematic, due to the necessary production stops, cleaning of tools before introducing the new test lubricant, as well as production stops caused by possible lubricant film breakdown and pick-up of workpiece material on polished tool surfaces, which requires dismounting and repolishing of tools. The present project addresses the above mentioned problems via three lines of approach:

  • Fundamental research on analysis and modelling of liquid lubrication mechanisms
  • Development of methodology for off-line evaluation of performance of new tribo-systems
  • Development and testing of new tribo-systems

To be qualified candidates must have a master degree in mechanical engineering or a similar degree with an academic level equivalent to the master’s degree in engineering. The candidates MUST furthermore have experience in at least two of the following topics:

  • Metal forming
  • Numerical modelling of large plastic deformations
  • Tribology
  • Numerical modelling of fluid flow
  • Experimental analysis

The candidates should possess self-motivation in scientific research, ability to work independently and to plan and carry out complicated tasks. They should have good communication skills in English, both written and spoken.

Approval and Enrolment
The scholarships for the PhD degree are subject to academic approval, and the candidates will be enrolled in one of the general degree programmes of DTU. For information about the general requirements for enrolment and the general planning of the scholarship studies, please see theDTU PhD Guide.

The assessment of the applicants will be made by Professor Niels Bay.

We offer
We offer an interesting and challenging job in an international environment focusing on education, research, public-sector consultancy and innovation, which contribute to enhancing the economy and improving social welfare. We strive for academic excellence, collegial respect and freedom tempered by responsibility. The Technical University of Denmark (DTU) is a leading technical university in northern Europe and benchmarks with the best universities in the world.

Salary and appointment terms
The salary and appointmentterms are consistent with the current rules for PhD degree students. The period of employment is 3 years starting in October 2014 or later.

Further information
Further information may be obtained from Professor Niels Bay, DTU Mechanical Engineering,, tel.: + 45 4525 4764.

You can read more about Department of Mechanical Engineering on

Please do not send applications to this e-mail address, instead apply online as described below.

Please submit your online application no later than August 15th 2014. Applications must be submitted as one PDF file containing all materials to be given consideration. To apply, please open the link « Apply online, » fill in the online application form, and attach all your materials in English in one PDF file. The file must include:

  • A letter motivating the application (cover letter)
  • Curriculum vitae
  • Grade transcripts and BSc/MSc diploma
  • Excel sheet with translation of grades to the Danish grading system (see guidelines and excel spreadsheet here)

Candidates may apply prior to obtaining their master’s degree, but cannot begin before having received it.

All interested candidates irrespective of age, gender, disability, race, religion or ethnic background are encouraged to apply.

Source: , july 2014

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