advanced forming research centre inchinnan, renfrewshire bill ion operations director
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© AFRC, University of Strathclyde 2010
ADVANCED FORMING RESEARCH CENTRE
Inchinnan, RenfrewshireBill Ion
Operations Director
© AFRC, University of Strathclyde 2010
Advanced Forming Research Centre
Visualisation of the AFRC
© AFRC, University of Strathclyde 2010
• 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
The AFRC
© 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
Aircraft WheelCompressor Rotor787 Nose Cone
737 APU ExhaustFinish Machined Parts
© 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
8
7
6
5
4
3
2
1
0
EPSRC
TSB
0 1 2 3 4 5
YEARS
MC
RL/
TR
L
1
2
KTP
INDUSTRYA
FRC
© 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
8
7
6
5
4
3
2
1
0
EPSRC
TSB
0 1 2 3 4 5
YEARS
MC
RL/
TR
L
1
2
KTP
INDUSTRYA
FRC
© AFRC, University of Strathclyde 2010
Current Membership
Tier 1Aubert &Duval BoeingMettis Aerospace Rolls-RoyceTimet
Tier 2BodycoteEKESFanucGKNHoughtonMicrosoftMitutoyoRenishaw
© 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 InteractionIndustry 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
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