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ADVANCED FORMING RESEARCH CENTRE Inchinnan, Renfrewshire Bill Ion Operations Director © AFRC, University of Strathclyde 2010 Advanced Forming Research Centre Visualisation of the AFRC © AFRC, University of Strathclyde 2010 The AFRC • A research centre supporting fundamental and applied research in forming and forging – Setting new standards for the design and forming of high integrity, high value added products – Dedicated building, staff and equipment – A key member of a global network of advanced manufacturing research institutes • Established August 2009 • Target growth within 5 years to; – Over 45 staff members – Over 20 industry members – Sustainable Research/KT portfolio of over £2.2M per annum © AFRC, University of Strathclyde 2010 High Value Manufacturing Characteristics “Manufacturing matters, it creates wealth, sustains jobs and is central to economic success” • • • • High research and technology content Profound understanding of the customer Exploitation of intellectual property Well developed systems integration capability • Data informed responses to complex events • Rapid development from concept to exploitation © AFRC, University of Strathclyde 2010 Forged/Formed Components Fan Blade 737 APU Exhaust Finish Machined Parts Aircraft Wheel 787 Nose Cone Compressor Rotor © AFRC, University of Strathclyde 2010 Forging Challenges • Higher quality material – More uniform – Understand the distribution of properties – Location specific properties • Improved tooling – Higher precision – Longer tool life/better lubricants • Improved process control – Press instrumentation – Equipment layout and process flow – Automation • New techniques – Novel forming processes, net shape forming – Novel heating methods, e.g. microwave Main landing gear legs © AFRC, University of Strathclyde 2010 AFRC - the Challenges • To conduct research into key forming and forging ‘challenges’ and to provide industry with ‘useable’ knowledge. – Materials utilisation for economic and environmental benefit – New materials with improved metallurgical properties – New product designs demanding ever more accurate and repeatable formed components – Mass customisation requiring adaptable and flexible processes • To take low maturity technology from a university environment and deploy it in a manufacturing facility © AFRC, University of Strathclyde 2010 AFRC Capability Pipeline 9 INDUSTRY 8 6 AFRC MCRL/ TRL 7 5 4 3 2 1 0 KTP TSB 2 EPSRC 1 0 1 2 3 4 5 YEARS © AFRC, University of Strathclyde 2010 The AFRC Model ‘Traditionally there has been no effective route to transform early research into industry ready applications – a new model was required’ Rolls-Royce • Industry scale technology ‘Sand Pit’ • Mutually beneficial public/private partnership • OEM, supplier and academic collaboration • Strong industry pull from partners • Industry scale equipment and real parts • Dedicated high calibre team focused on solution delivery • Focus on technology transfer and exploitation © AFRC, University of Strathclyde 2010 Partnership Model • Cross-sectoral collaborative partnership between leading academic institutions, government, equipment suppliers, OEM’s and other major industrial companies. • Rapid “technology pipeline” from concept – demonstration – exploitation. © AFRC, University of Strathclyde 2010 AFRC Capability Pipeline 9 INDUSTRY 8 6 AFRC MCRL/ TRL 7 5 4 3 2 1 0 KTP TSB 2 EPSRC 1 0 1 2 3 4 5 YEARS © AFRC, University of Strathclyde 2010 Current Membership Tier 1 Aubert &Duval Boeing Mettis Aerospace Rolls-Royce Timet Tier 2 Bodycote EKES Fanuc GKN Houghton Microsoft Mitutoyo Renishaw © AFRC, University of Strathclyde 2010 AFRC Key Activities • Core Research programme • Funded through membership fees – two membership levels (Tier 1 and Tier 2) • Informed by members • Members share access to IP • Research support • Direct company research support • Research council funding – gearing member fees • Technology Fore-sighting • Roadmapping the next generation of processes, materials etc • Informs the AFRC research agenda • Information Management • Databases • State of the art reviews • Knowledge Exchange • Seminars and short courses • KTPs • Events © AFRC, University of Strathclyde 2010 Developing Mutual Understanding • Interaction with industry partners develops; – Good understanding of each company’s ‘vision’ and the research and KE roadmaps that can help them get there – Leads to targeted collaborative activity • Robust funding applications • Higher funding ‘success rate’. © AFRC, University of Strathclyde 2010 Enhanced University/Industry Staff Interaction Industry partners • Facilitators/Coordinators based in the AFRC • Member companies represented on AFRC Board and Technical Board • Other industry staff based in AFRC for short periods • Regular throughput of company personnel – provides a mechanism for inter company communication AFRC • AFRC staff secondments to companies • Regular interaction with staff in partner companies both in the AFRC and on company premises © AFRC, University of Strathclyde 2010 AFRC Membership Tier 1 • £200k per annum – cash • Contribution funds core research programme • Minimum 3 year commitment • Seat on AFRC Board and Technical Board • Key role in steering the research agenda • All members have access to IP generated though core research Tier 2 • £25k per annum – cash or donation (equipment/services) • Minimum 3 year commitment • Single Tier 2 representative on Board and Technical Board • All members have access to IP generated though core research Non members • Projects undertaken on an individual basis • No direct access to core research programme IP © AFRC, University of Strathclyde 2010 The AFRC - Current Status • Operations commenced August 2009 • 26 dedicated AFRC staff in place (end June 2010) • University staff team engaged in support of AFRC • Industry membership recruitment ongoing • Core research programme, industry funded projects, KTP and PhD studentships underway • Funding; – Research/KE (EPSRC, TSB, KTP, company) - £4.3M – Member fees – Start up funds (Scottish Enterprise) • New Building occupancy - June 2010 © AFRC, University of Strathclyde 2010 AFRC Building and Equipment • Building – Workshops, laboratories, staff accommodation, seminar/exhibition space • Equipment being procured – Industry and laboratory scale – Partnership with key technology providers and OEM partner supply chain Building November 2009 © AFRC, University of Strathclyde 2010 2500m2 © AFRC, University of Strathclyde 2010 The Rolls-Royce AxRC Network The AFRC as a part of a global manufacturing research and KE network © AFRC, University of Strathclyde 2010