RUB Research School

Feng Pan

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Numerical and experimental investigation of the microstructure evolution during precision machining

The Research Project

Precision machining is a vital technology for manufacturing high-performance components in industries such as aerospace, microelectronics, and medical devices, where surface quality directly impacts the performance of them. A critical challenge lies in achieving ultra-smooth surfaces with roughness at the nanometer scale, as microscopic material behavior-such as grain deformation, chip formation, and shear band development - directly impacts surface quality. These phenomena are complex and not yet fully understood, limiting the ability to optimize machining processes.

My doctoral research addresses this gap by focusing on technically pure copper and other related alloys, the model material widely used in industrial applications. The project aims to uncover how microscopic structures evolve during precision machining and how these changes correlate with surface integrity. By integrating advanced computational methods (finite element simulations, crystal plasticity finite element simulations, finite element coupled cellular automata simulations, multiscale simulations) with orthogonal cutting experimental validation, the study will provide a theoretical foundation to guide the design of more efficient and reliable machining strategies.

What I need the IRB for

The IRB grant is essential to support the international dimension of my doctoral research, which involves collaborations across at least three countries (Germany, the United States, and China). Its flexibility and continuity will enable me to efficiently organize participation in international conferences, arrange short-term research visits, and conduct collaborative research abroad. These international activities are crucial for expanding my academic network, gaining valuable expert feedback, and enhancing the visibility of my research within the global scientific community. In short, the IRB will provide the funds I need to expand my network and establish myself as a visible contributor to the field, ensuring the long-term success and international impact of my doctoral studies.

IRB funded activities

Summer School: CASMaT International Summer School 2025, 24-29 August 2025, Technical University of Denmark, Copenhagen, Denmark

My first IRB-funded activity was attending the CASMaT International Summer School 2025, held from August 24th to 29th at the Technical University of Denmark in Copenhagen. During the program, we visited the Structural Lab at Lyngby Campus and the Materials Lab at RISØ Campus, where we gained in-depth insights into the theories and concepts behind advanced multiscale testing of structures and materials, using wind turbine composite blades as an example. The advanced and comprehensive experimental facilities left a strong impression on me and provided valuable understanding of the entire process from blade design to manufacturing, testing, and validation, which will significantly benefit the experimental part of my PhD research.

Furthermore, the summer school offered a valuable networking opportunity, allowing me to connect with researchers from over ten different countries. I also engaged in a productive discussion with Professor Henrik Stang, which led to a mutual interest in maintaining communication and exploring potential future collaborations. We are both optimistic about these prospects.