© 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

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• 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

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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

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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

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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

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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