PRR Project

Summary

The metallurgical and metalworking sector is one of the most representative transformation sectors at national level, including near 22000 companies, approximately 90% being SME’s and employing about 250000 workers. It has been setting consecutive records in terms of increasing exports and competitiveness, marked a record-breaking 24 billion euros in exports in 2023, with a growing of 4%. However the industry faces substantial challenges from global decarbonization and digital transition trends, demanding both optimization of production efficiency and innovation in the use of new technologies and materials. The transition from internal combustion engines to electric vehicles and the growth of autonomous mobility concepts, significantly impact metallic component production. This extends beyond automotive to the two-wheel mobility sector (Portugal is EU leader in bicycle production), where both face the challenge of producing lightweight components without compromising performance. The researcher should focus on key tasks related to Advanced Manufacturing in Forming Technologies , positioning DEMEc/FEUP at the vanguard of future technological developments. In this challenging scenario, the following tasks are foreseen for this position: T1. Research and Development in Sustainable ManufacturingConduct extensive research on last trends and advancements in lightweight material (e.g. high-strength steels, aluminum, titanium, magnesium alloys) forming technologies, providing more sustainable solutions for industry . Assess materials for their mechanical properties, cost-effectiveness, sustainability and compatibility with existing manufacturing processes. Provide support for Advanced Mechanical Characterization (FLD, fatigue) to optimize manufacturing tools design and to improve parts structural performance. T2. Advancing Forming TechnologiesExplore and refine forming technologies like stamping, forging (e.g. technology hybridization), aiming to improve efficiency, reducing waste and enhancing product quality. Develop and implement advanced simulation tools to model forming processes, predict outcomes and optimize parameters for best results. T3. Application of Digital Twins and AI to Manufacturing (Forming)Leverage digital twins, AI and machine learning in manufacturing, using sensors for precise control and real-time adjustments. Design and showcase demonstrators within FEUP labs to highlight the practical application of advanced manufacturing techniques, specifically through the use of instrumentation in laboratory-scale models of forming operations (e.g. bending). Create highly reliable tools using a hybrid approach of numerical and data-driven methods for deep process understanding and optimizing complex stamping processes. T4. Collaboration and Knowledge TransferLead FEUP-industry collaborations in R&I , promoting research joint projects and disseminating findings through publications and events organization that bridge scientific and industrial communities. Also, internationalization of a FEUP group on metal forming is also required, through the participation in EU research consortiums and events organization. T5. Inter-Institutional SynergiesFoster synergies between FEUP´s R&I units, other educational institutions and research centers, aiming on novel technologies and solutions in forming technologies. T6. Educational Role EnhancementAddress FEUP teaching staff gaps, particularly in forming technologies, guide students in research projects and develop courses to prepare students with industry-relevant skills in Mechanical Engineering. Develop and streamline lessons on technological processes, integrating them into the core curriculum to provide students with crucial knowledge and skills in Mechanical Engineering, including advanced modeling, simulation, manufacturing techniques and new materials aligned with industry standards. Scientific Profile Required: PhD in Mechanical Engineering educational background, with a focus on manufacturing technologies. Research Experience : Metal forming techniques. A robust history of publications in reputable journals is expected, providing evidence of contributions to theoretical understanding and practical applications in manufacturing processes domain. Technical Skills: Proficiency in Advanced Mechanical Characterization for metal forming , CAD/CAM/CAE software, finite element analysis (FEA) of metal forming and other technologies, and data analysis tools. Rationale for Hiring: The metalworking industry undergoes a major transformation towards sustainability, efficiency and innovation driven by green and digital transition. To maintain its leadership in cutting-edge research and development within advanced manufacturing, FEUP recognizes the vital importance of expertise in manufacturing technologies, particularly in areas such as forming. This is essential to ensure that FEUP continues to make a significant contribution in sustainable advances and efficient manufacturing practices.