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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”
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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
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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