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Master Thesis: Virtual Tool Breakage Prediction for Milling Tools

Milling tools are exposed to mechanical and dynamical loadings during cutting. Under stable cutting conditions harmonically varying cutting forces and corresponding vibrations which are acting towards cutting edge may break away some parts and the nominal cutting geometry and angles change which in turn deteriorate the surface quality. Similarly high cutting forces at the tool tip during roughing operations may even result shaft breakage. Thus the cutting parameters must be selected properly to avoid tool/edge breakage by modeling the forces and maximum stress level for various aerospace tool materials.


  • Develop numerical simulations to predict the local stress at the cutting edge and tool shaft for given set of cutting parameters and workpiece material properties
  • Understanding the effect of different cutting parameters on the tool breakage phenomena and optimization of process parameters to avoid tool/edge breakage.
  • Experimental validation of the developed virtual model
  • Validation of predicted stress levels with laboratory tests


  • Student in the field of mechanical or aerospace engineering or any related field
  • Basic knowledge of machining mechanics and dynamics
  • Experience with Finite Element Analysis (FEA) Software and Structural Mechanics Simulation
  • Hands on experimental skills (force measurement, data analysis, signal processing)
  • Programming or scripting experience, preferably in Python
  • Good knowledge of English is must, German is a plus
  • High level of personal initiative and structured way of working


  • Insights into practical work in aviation as an innovative, high-tech industry
  • Exciting jobs that carry responsibility and are performed in an atmosphere of team spirit
  • A personally assigned contact and individual support services
  • Flexible working hours and compensatory time off
  • Networking opportunities


Give your career a boost and send us your complete application (Letter of Motivation, CV, Transcript of Records, High School Diploma).

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