AI-based Vision-Guided Robotic Machining: Intelligent Perception and Learning for Adaptive Manufacturing

Summary

CNC machining delivers high precision but is costly, rigid, and limited in adaptability.

Robotic machining offers a flexible alternative where industrial robots hold the cutting tools. However, these systems lack the real-time perception and intelligence needed to detect stresses, predict tool wear, and prevent failures.

This project proposes developing a novel vision-guided robotic machining platform capable of adaptive manufacturing by integrating advanced sensors and AI.

The work will involve collaboration with the Advanced Manufacturing Innovation Centre (AMIC), which provides a critical capability for this research.

Specifically, the project will have access to AMIC's existing machining centres to conduct essential comparative trials, allowing the demonstrator's performance to be rigorously benchmarked against traditional CNC machines on industrial test parts like aerospace ribs.

Key challenges this research will overcome include:

• Lack of Real-Time Monitoring: Current systems cannot accurately detect machining stress or predict tool wear/breakage in real time.
• Static Cutting Strategies: Few systems have the adaptive learning capability to optimise cutting parameters dynamically.

The research will focus on three core contributions:

• Multi-modal Vision Systems: Integrating advanced cameras (RGB, IR, high-speed) to provide real-time stress and tool monitoring.
• Adaptive Learning Framework: Employing Reinforcement Learning and adaptive control to predict tool failure and dynamically optimise toolpaths and cutting conditions.
• Explainable AI (XAI): Developing an operator interface with XAI to ensure trust and usability in the manufacturing cell.

This project offers an exciting opportunity to produce a demonstrator platform and benchmark its performance against traditional CNC machining centres, with work conducted in collaboration with Advanced Manufacturing Innovation Centre (AMIC).

Essential criteria

Applicants should hold, or expect to obtain, a First or Upper Second Class Honours Degree in a subject relevant to the proposed area of study.

We may also consider applications from those who hold equivalent qualifications, for example, a Lower Second Class Honours Degree plus a Master’s Degree with Distinction.

In exceptional circumstances, the University may consider a portfolio of evidence from applicants who have appropriate professional experience which is equivalent to the learning outcomes of an Honours degree in lieu of academic qualifications.

• Experience using research methods or other approaches relevant to the subject domain
• A demonstrable interest in the research area associated with the studentship

Desirable Criteria

If the University receives a large number of applicants for the project, the following desirable criteria may be applied to shortlist applicants for interview.

• First Class Honours (1st) Degree
• Masters at 70%
• For VCRS Awards, Masters at 75%
• Experience using research methods or other approaches relevant to the subject domain
• Work experience relevant to the proposed project
• Publications - peer-reviewed
• Experience of presentation of research findings
• Use of personal initiative as evidenced by record of work above that normally expected at career stage.

Equal Opportunities

The University is an equal opportunities employer and welcomes applicants from all sections of the community, particularly from those with disabilities.

Appointment will be made on merit.

Funding and eligibility

This project is funded by:

• Department for the Economy (DfE)

This scholarship will cover tuition fees and provide a maintenance allowance of £21,000* (tbc) per annum for three years (subject to satisfactory academic performance).  A Research Training Support Grant (RTSG) of approximately £900 per annum is also available.

To be eligible for these scholarships, applicants must meet the following criteria:

• Be a UK National, or

• Have settled status, or

• Have pre-settled status, or

• Have indefinite leave to remain or enter, or

• be an Irish National

Applicants should also meet the residency criteria which requires that they have lived in the EEA, Switzerland, the UK or Gibraltar for at least the three years preceding the start date of the research degree programme.

Applicants who already hold a doctoral degree or who have been registered on a programme of research leading to the award of a doctoral degree on a full-time basis for more than one year (or part-time equivalent) are NOT eligible to apply for an award.

Due consideration should be given to financing your studies.

*Part time PhD scholarships may be available, based on 0.5 of the full time rate, and will require a six year registration period