Collaborative Project Involvement

Transcription

1 Collaborative Project Involvement The Forum+ collaboration project portfolio is made up of 10 technical projects. Each of which involve at least 2 of the HVM Catapult centres in the work. Figure 1 below shows the geographical location of the each of the 7 centres which make up the HVM Catapult. Figure 1: The geographical location of the each of the 7 centres which make up the HVM Catapult Figure 2 below lists the 10 technical projects which make up the Forum+ portfolio for financial year and details the HVM Catapult centres involved in each project. Green squares indicating involvement in a project. Intelligent Composite Structures Dynamic Flow Visualisation Additive Manufacturing with Graphene Welding Dissimilar Metals SLM with Recycled Powder Metrology from Computed Tomography Immersive Construction Visualisation ALM Metals Web Based Costing Tool Low Cost Composite Forming Tool Die Remanufacture AFRC AMRC CPI MTC NAMRC NCC WMG Figure 2: Ten technical projects which make up the Forum+ portfolio for financial year and details the HVM Catapult centres involved in each project. Green squares indicating involvement in a project. Each of these projects is outlined in the following document

2 Intelligent Composite Structures Video Messages Introduction Intelligent structures form the foundation of the Internet of things and the industrial application of the cyber revolution (industry 4.0). This project will demonstrate the use of printed electronics to create suitable, cost effective, bespoke sensors that can be embedded to create intelligent composite structures. The productions of this intelligent structure will be used to demonstrate in-process monitoring of the composite manufacturing process, through life embedded health monitoring and cyber connectivity. Engineers Involved: - Dr Marcus Walls-Bruck (NCC, Engineering Capability Lead) Project Lead - Madhu Herath (NCC, Research Engineer) - Dr Simon Johnson (CPI, Electronics Engineering Manager Printable Electronics - Eddie Iredia (CPI, Research Engineer) Project Output - Demonstrated capability to embedded printed electronic into composite structures - Demonstrator part with embedded electronics which can communicate wirelessly using your mobile phone - Technology Roadmap has been developed and is now task based with critical work identified for the future

3 Primary Messages What if an Aeroplane could talk? Would it tell you it lost weight? Would it tell you it knew it was is full working order? Would it tweet that is could reduce your ticket price by operating more efficiently? Would it your car and tell it that all of the required technology was now low cost enough for the automotive industry? Secondary Messages Technology Printed electronics, Bespoke sensing, Rapid Sensor development, Near field communications, Process monitoring, Structural health monitoring, Embedded sensing - Printed electronics are highly customisable with infinite possibility to incorporate electronic capability into products - Wireless communications can be embedding into structural parts - Composite components are ideal for embedding additional capability as the manufacturing process is additive - Electronics do survive the composite manufacturing process - Embedded electronics enable the connectivity of things to the IoT - Embedded sensing can monitor production of each and every component reducing scrap and waste and providing confidence in critical parts - Sensors remain in place through life and can be used for in service and health monitoring Industry - Future interest in technology from Williams, RR, Airbus and others already, meetings about potential follow on projects have been held - Wireless communications enable seamless assembly of parts without connectors - Embedded electronics remove expensive and heavy wiring systems and also remove the cost of in-line assembly steps - Embedding capability increases the value of components in the supply chain and reduced the cost at final assembly - Self-aware products can be designed lighter and more optimised as the safety factors for in-service uncertainty can be reduced HVMC & Government - NCC and CPI working together - New capability is available to UK manufacturing - Leading Industry 4.0 by providing inherently smart and connected components - The future of manufacturing is digital and we are developing the underpinning process and solutions today

4 Dynamic Flow Visualisation Video Messages Introduction This project addresses the challenges of bringing CFD simulation data into virtual environments to create dynamic, immersive visual experiences. Communicating fluid characteristics in relation to the relevant equipment or process. The project will deliver a case study around an existing collaboration between CPI and an industrial partner, which can be used to demonstrate HVMC capability, and will develop new workflows which can be used in future projects and disseminated to other centres, industry partners and applications. Engineers Involved: - Alex Attridge a.attridge@warwick.ac.uk; - Chris Freeman c.freeman@amrc.co.uk - Alex Smith alex.smith@uk-cpi.com; - Rab Scott r.w.scott@amrc.co.uk Project Output - Workflow(s) for bringing CFD data into VR software - Workflow(s) for running dynamic simulation data within a VR environment - Navigable VR environment augmented with dynamic CFD data

5 Primary Messages How would you create the most efficient Bio-Refinery in the world? Would you go Cyber? Would you let engineers explore the possibilities in Virtual Reality? Would you discover the manufacturing/construction/operational challenges before ground was broken on foundations? Would you visualise complex fluid data in 3D and go swimming? Secondary Messages Technology Immersive visualisation, computational fluid dynamics, dynamic virtual modelling, simulation data formats compatibility, virtual environments, virtual reality (VR) or augmented reality (AR), demonstrator immersive experience. - Horizontal Innovation, bringing VR to the process industry - Application of CFD to optimise process engineering and increase efficiency and productivity - Cross compatibility of data formats between different software applications can be achieved using common work flows Industry - Optimisation of large projects by enabling engineers to walk through systems and get behind the walls - Immersive experience used to demonstrate and understand large scale projects where the systems cannot be easily viewed HVMC & Government - Design and development of UK Bio-technology and the development of a new Bio- Refinery can be world leading with application of CFD through VR - UK is leading the way in the industrial application of VR technology in high value manufacturing - Transfer of HVM Catapult capability to new sectors can support UK manufacturing with confidence to deliver

6 Additive Battery with Graphene Video Messages Introduction This project is going to demonstrate the innovative manufacture of micro-lithium ion batteries (mlib) with graphene-enhanced electrodes through Additive Manufacturing. It will deliver a mlib with graphene-modified cathode and measured electrochemical performance. Engineers Involved: - Dave.Barwick@uk-cpi.com - G.J.Gibbons@warwick.ac.uk Project Output - Printed working graphene Lithium Ion Battery made with graphene enhanced ink - Formulation recipes for graphene-modified cathode, and carbon anode materials compatible with ink jet printing (IJP). Including plasma functionalisation of graphene. - Deposition of graphene-modified cathode. IJP LiFePO4 graphene cathode and carbon anode demonstrators. - Deposition of LiFePO4 graphene-modified cathode and carbon anode. Complex interdigitated and interpenetrating co-printed electrode structures - Electrochemical performance of IJP batteries assessment.

7 Primary Messages What if you could print a battery? How powerful could you make it? Where would it fit? How fast could it be manufactured? Why would you need shipping? Could you think outside the cyclinder? Secondary Messages Technology Formulation, Power and Energy Storage, Additive Manufacturing - Printed batteries enable complex forms which increase capacity and re-charge rates - Complex shapes can be packaged more efficiently making smaller batteries which fit the space envelope more effectively. - Bespoke batteries could be manufactured rapidly - The power density of a battery can be improved through application of graphene Industry - Proven capability for EIC to allow prototyping of complex battery architectures and enhanced electrode performance. - Exposure of Versarien - Increased opportunity for SMEs to utilise the battery technology through HVMC Reach Programme, supporting the Systems group for e.g Smarter products. HVMC & Government - NCC and CPI working together - New capability is available to UK manufacturing - Leading Industry 4.0 by providing inherently smart and connected components - The future of manufacturing is digital and we are developing the underpinning process and solutions today

8 Welding Dissimilar Metals Video Messages Introduction Joining dissimilar metals using fusion welding processes produces metallurgical incompatibility in the weld structure e.g. the formation of brittle phases, segregation of high and low melting phases due to chemical mismatch and significant amount of residual stresses due to melting involved. Such challenges of the fusion welding can be mitigated by solid state welding which produces sound welds and does not suffer from development of detrimental microstructures in the weld zone. Linear and rotary friction welding processes have been widely used to join bulk and tubular, similar and dissimilar, metals. Forge welding has also been used for dissimilar metal joining, however reported literature on this is scarce. The present project aims to compare the three processes to carry out qualitative and quantitative investigation of properties of the welds produced by the three different processes. This project is going to develop an APP for the numerical simulation of the process of fusion welding. The APP will be designed in a way to allow the easy application by a nonmodelling-expert, from industry for example. The outcome of the simulation will be temperature profiles, residual stresses and distortion. The APP will model a tube or pipe with a similar or dissimilar welding consumable. It is a pioneering project that can pave the way to a set of APPs that can be generated to cover a wide range of industrial processes and conditions. The APPs would readily and easily be used by non-experts, hence allowing simulation to become embedded in design and manufacturing procedures, leading to a change in the culture of using simulation in industry. Engineers Involved: - himanshu.lalvani@strath.ac.uk - Anas.Yaghi@the-mtc.org - Pedro.Santos@the-mtc.org - b.baufeld@sheffield.ac.uk Project Output - Produce fusion welds of dissimilar metal rings - Produce preforms of dissimilar metal rings through EBW and TIG for further forge welding at AFRC - Produce fusion welds of dissimilar metal rings - Produce preforms of dissimilar metal rings through EBW and TIG for further forge welding at AFRC

9 - Produce solid state welds through rotary friction welding of dissimilar metal rings. - Forging of dissimilar metal ring preforms received from AMRC - Microstructure characterisation and mechanical testing of welds (on all samples produced at AMRC, MTC and AFRC) - A fusion weld model with all the necessary simulation input data as well as output data for the purpose of validation - An FE model, simulating the process of fusion welding & heat treatment, depicting the entire evolution of temperatures, residual stresses and distortion (animations) - An APP that can easily be used by the non-expert to model fusion welding & heat treatment of a range of geometries, materials and conditions, with clearly defined limitations - A validated APP for the modelling of fusion welding and heat treatment Tested and validated APP; capability announced by NAFEMS - for the benefit of industry

10 Primary Messages What if you could weld anything together? How much lighter would it be if I could use the right metal in every location? What if I could get rid of nuts and bolts and rivets and glue? How much could you save if you put the right material in the right place? Secondary Messages Technology Fusion welding, EB Welding, Friction welding, Screw press forging, weld characterisation, Numerical Simulation Industry - The project is a feasibility study on producing metal connectors/couplings for oil and gas, nuclear and chemical industry sectors using two different solid state joining methods. - The outcomes of the project can lead to development of a new manufacturing route for such components. - Faster, cost effective and robust processing route and supply chain development. - Capability of easily simulating fusion welding is facilitated for the first time by the creation of an APP - APP will be available for use by non-experts to simulate a range of welded tubes and pipes under similar and dissimilar fusion welding conditions - The benefits of having such an APP will be demonstrated so that it can be replicated for other conditions and processes including additive manufacture - This will pave the way for a larger project in which other APPs would be generated and made available to industry for easy and effective simulation HVMC & Government - This project will promote cross HVMC centre engagement, enable capability demonstration for each of the centres involved, will demonstrate commercial value through evaluating feasibility of solid state welding processes in producing representative industry scale components. - The creation of the APP will comprise part of a potentially large collaborative project, including industrial partners, to find an effective solution for the omnipresent and serious problem of residual stresses - The news about the acquired capability will be disseminated by NAFEMS as a step towards changing the culture of using simulation within industry

11 Selective Laser Melting with Recycled Powder Video Messages Introduction To investigate the effect of the recycling powder in the SLM process has on the powder characteristics in terms of particle size and distribution, morphology and possible contamination that may be picked up during the powder handling/recycling process i.e. oxygen, metallic and non-metallic inclusions. Also aims to identify the source of these contaminants through site to site variation analysis compared with previous work. In addition the project aim to identify any possible correlation between the main findings of the powder analysis and the AM built parts. Engineers Involved: - Jason Dawes Jason.Dawes@the-mtc.org - James Hughes J.Hughes@amrc.co.uk - Kristina L Parry k.parry@namtec.co.uk - Noemi Cooper Noemi.Cooper@the-mtc.org Project Output - A complete history of 10 SLM subsequent builds with no virgin powder top to capture any change in the powder and mechanical properties of part density. - In-depth analysis of the 10 powder samples to identify any significant change in terms of particle size, morphology, chemistry, interstitials (oxygen) and inclusion of foreign contaminants (metallic and non-metallic) - Analysis of the 10 tensile test results and its correlation with the powder testing - Analysis of the 10 CT scan results and its correlation with the powder testing results. - Understanding of powder recycling in additive manufacturing

12 Primary Messages What if you could use all the Powder? How much would you save? When would your additive process become commercially viable for production? Secondary Messages Technology Additive manufacturing, materials characterisation, powder technology Additive manufacturing is the future, making it commercially viable sooner requires lean production development to create production without waste. Industry - Maximum process efficiency requires all powder to be used - Understanding the properties of processed powder - Achieving lean production in additive required process and waste reduction - Supply chain education is critical to high performance additive manufacturing - By creating a database of through process materials, the capability of recycled powders can be understand. This enables them to be used and not disguarded. HVMC & Government - HVMC is focused on raising MCRL levels in parallel to TRLs - Resource efficient manufacturing is critical to UK competitiveness - UK can lead the world in understanding Powder property databases - There is more to additive manufacturing than a printer

13 Metrology from Computed Tomography Video Messages Introduction XCT is used for non-destructive testing across a range of industries, but is rarely used for dimensional measurement as there are no establish metrology standards for the technology. With growing complexity of components being produced in HVM industry sectors, in particular, internal geometries in ALM components, and the strong capability in XCT across a number of centres, this project will establish best practices and potential sources of error in the use of XCT for dimensional metrology, building on work already done in this field by both MTC and WMG, utilising the centres ALM capabilities to generate relevant case studies and dissemination material. Engineers Involved: - daniel.mcmahon@strath.ac.uk - r.james@amrc.co.uk - Evangelos.Chatzivagiannis@the-mtc.org - Richard.VanGelder@nccuk.com - a.attridge@warwick.ac.uk Project Output - Report on existing processes, best practices and uncertainty in the application of XCT for metrology, based on MTC study - Selection of a limited number of ALM sample geometries and materials to be used in the study source/make samples - Detailed measurement reports for ALM samples - XCT measurement reports for the ALM samples and report on minimising errors and uncertainty - XCT measurement reports for the ALM samples and report on minimising errors and uncertainty - Case study for HVMC website and concise report and/or presentation for industry

14 Primary Messages What if your manufacturing documentation was in 3D? We Design in 3D, we manufacturing in 3D, why is production controlled in 2D? Can 3D metrology enable manufacturing documentation to be entirely digital and remove demand for paper work? How much faster could information flow and processes feedback if everything was 3D? What if 3D manufacturing data enabled commercial rapid bespoke production? Secondary Messages Technology Metrology, AM & 3D Printing, Computed Tomography - Capabilities of the XCT systems within the HVM Catapult for use in dimensional metrology, - Optimising the processes and protocols for achieving the maximum possible confidence in dimensional data from XCT. - Best practices and protocols for the use of XCT for dimensional measurement Industry - End to end 3D digital manufacturing is possible - One major hurdle is 2D paperwork and current metrology documentation practice - CAD to Product via cyber metrology - Paperwork is dead, long live digital manufacturing HVMC & Government - Manufacturing certification standard will need to be brought into the 21 st century - We live in a 3D world where 3D data - Products can be defined and measured in 3D without paperwork - Industry 4.0 includes all areas of manufacturing including measurement and verification - UK is at the forefront of developing manufacturing capabilities for Industry 4.0

15 Immersive Construction Visualisation Video Story Board Introduction State of the art review of VR applications in the construction sector and the creation of a technology road map. This will support the creation of with 3 demonstrators investigating the art of the possible. Engineers Involved: - Alex Attridge a.attridge@warwick.ac.uk; - Chris Freeman c.freeman@amrc.co.uk & m.magill@sheffield.ac.uk - Rab Scott r.w.scott@amrc.co.uk - David grant david.grant@strath.ac.uk Project Output - Construction life cycle mapped and aligned with AR/VR/MR opportunities. - Outlines the system and the various architectures at play, ie which systems need to communicate and how they could all be managed. - A minimum of 3 demonstrators which will allow the consortium to engage with their partners to disseminate the benefits of using VR and visualisation technology in a construction environment and fuel interest. - Future project planning Construction LSP and Innovate submission.

16 Primary Messages What is the Virtual enabled the Construction of Reality? What if you could virtually see construction data? What if you understand BIM data visually? How much faster could we improve new buildings and projects? What if I could accurately analyse building performance before it is built? Secondary Messages Technology - Many of the consumer grade VR headsets can be purchased off the shelf and can be combined with a relatively high powered computer. The CAD files which are used to create the virtual world can be created on a multitude of software platforms, and the technology is readily available to convert these files to be readable on any of the mass market VR technologies. Existing case studies are available to accelerate the development of any demonstrators. - Background research on existing + emerging technologies including; mapping out possible practical applications of advancing technologies, resulting in the identification of 6 key platforms to improve MES. Industry - The need to improve productivity and profitability within the construction industry through informed processes enhanced by technology. - Diversification of skills to address the pending skills shortage, tackling the skills deficit through new ways of developing apprentice skills utilising technology. - Improved communication of disciplines / sharing knowledge within the construction industry. - Extending the life of future buildings through an improved design process, which will be achieved through an informed, visual design and manufacturing process. (It is more likely that the building will fully meet the needs of the client as they can better visualise the building before it is built). - The durability of future buildings can be improved through resolving potential maintenance issues through a visual development process. - Define the opportunities and develop strategies around it, helping to identify the quick wins and the more difficult challenges. HVMC & Government - In 2011, the UK government set up a Building Information Modelling (BIM) task force with Construction Industry partners. The outcome was the creation of a phased approach to introducing BIM through levels. Level 1 was essentially the use of computer aided design (CAD). Level 2 was described as A managed 3D environment held in separate discipline BIM tools with attached data. The approach may utilise 4D Programme Data, 5D cost elements and 6D Carbon Footprint to feed operational

17 systems. A target for all government (public) construction projects to achieve BIM level 2 by 2016 was set. Primary capabilities of BIM are aimed at the planning and construction of assets, however the outputs of BIM have impacts in areas such as knowledge management, construction, building management and asset maintenance, supply chain management, resource planning, risk management, security management, carbon management, health and safety, performance, reporting and analysis. - Advanced visualisation is already widely adopted within the design and construction industry but further opportunities are available which the industry has yet to realise. The HVM Catapult Visualisation and VR Forum would like to run a project which investigates the wider capabilities and potential applications of immersive visualisation within BIM. - SMAS (Scottish Manufacturing Advisory Service) external assessment of current productivity levels at CarbonDynamic. - CarbonDynamic process mapping (showing current process + identification of needs/improvements to be made). - Co-design day utilising VR technology / mixed reality, to engage with stakeholders (NHS) and future assisted living housing occupants.

18 ALM Metals Web Based Costing Tool Video Messages Introduction A simple cost model is required by industry to enable them to make informed decisions on the application of metal ALM in their business. It was proposed by the ALM&3DP Forum that this is a necessity and we propose to develop a high level cost model for the major metals ALM technology groups, which will be accessible to industry through the HVMC web site. Engineers Involved: - david.brackett@the-mtc.org - u.woy@sheffield.ac.uk - G.J.Gibbons@warwick.ac.uk Project Output - Map of metal / alloy vs sector. - ALM cost models built in an appropriate, web compatible environment (spreadsheet / database). - Web enabled ALM cost model, providing indicative cost for metals AM (PBF, DED and EBM). - Report communicating the relevant results - Determine the material requirements by sector (to enable the cost model to be relevant to industry s needs). - Develop process chain cost models (to include feedstock, build, post-process) for i) metal Laser Powder Bed Fusion, ii) Electron Beam Powder Bed Fusion, iii) Directed Energy Deposition (with variants for Laser and Arc, and for wire and powder feed). - Develop a web front end to provide industry with access to the cost models, providing a simple utilisation parameter (such as /kg processed).

19 Primary Messages When should I go additive? How much would it cost? What value could my parts hold? What would a business case look like? When will this additive thing become commercial? Secondary Messages Technology - A tangible accessible web-based interactive cost tool to make process selection choices for use of metals ALM. - The project is focused on the metal component manufacturing industry but is sector agnostic. - The output could be integrated within existing CAD software systems as part of the ALM capability. Industry The project provides a tangible accessible web-based interactive cost tool to enable production engineers (especially within SMEs) to make process selection choices e.g. whether to further investigate the use of metals ALM for their application or to look for an alternative process. This will be fully accessible to industry through the HVMC website and signposted from other Centre websites (and potentially the IET etc). It will also highlight opportunities for alloy developments based on identification of the most useful alloys required by the different sectors. The project is focused on the metal component manufacturing industry but is sector agnostic. The identification of key alloys of interest for each sector will influence future material / process development which will broaden the uptake of ALM in the future. The output could be integrated within existing CAD software systems as part of the ALM capability. e.g. it could be employed by Autodesk as a plugin tool, which would enable quick assessment of design choices HVMC & Government - Additive manufacturing is the future - We need to accelerate the industrial take up by educating new users in the cost benefit - A cost model is now publically available for UK plc to understand the cost of manufacturing parts using AM processes and create compelling business cases

20 Die Remanufacture Video Messages Introduction Demonstrate if AM is a suitable technology for die and mould repair, as well as the repair of large structures, e.g. civil nuclear, this project will demonstrate on a small scale, the deposition and removal of repair material and re-machining back to original geometry of Carbon Fibre Reinforced Plastic (CFRP) mould tool and hot forge die alloys. Engineers Involved: - s.fitzpatrick@strath.ac.uk - w.redpath@sheffield.ac.uk - Faraz.Shahid@the-mtc.org - jack.greaves@namrc.co.uk - Shaw.Beattie@nccuk.com Project Output - Demonstrate if AM is a suitable technology for die and mould repair, as well as the repair of large structures, e.g. civil nuclear, this project will demonstrate on a small scale, the deposition and removal of repair material and re-machining back to original geometry of Carbon Fibre Reinforced Plastic (CFRP) mould tool and hot forge die alloys.

21 Primary Messages How can I keep production tooling in service? Manufacturing cost of a product can be reduced by making the tooling last longer. - Cost effective repair makes tools last longer - Automated repair keeps tooling in service and being productive longer Secondary Messages Technology High temperature processing, Joining, Machining, Metal forming and forging, Metrology, Netshape and Additive, Surface Engineering Industry - Currently in the UK there are die repair specialists, however this is a manual process carried out by highly skilled individuals using craft techniques. The output of this project would potentially improve the repair integrity of the work currently undertaken. In the longer term, the output of this project will enable the creation of automated or semi-automated repair systems that could be manufactured in the UK and exported and or the creation of a UK based repair and remanufacturing service industry. - The creation of an automated or semi-automated process should be of great interest to OEMs such as Airbus, BAE Systems and JLR as this will reduce tool and die downtime and improve repair integrity thus facilitating greater output and reduce disruption to production. At a Tier 1 supplier level the project will be of interest in terms of maintenance and repair of tools and dies, and reworking errors during manufacture. At a Tier 2 supplier level the output of this project will inform and enable repair and maintenance of extrusion and forming tools. HVMC & Government - This proposal aligns with the UK strategies for High Value Manufacturing, Circular Economy, Sustainable Manufacturing, Aerospace and re-shoring of Automotive manufacturing capability. - Developing more flexible or efficient manufacturing processes to increase the productivity and competitiveness of the UK s manufacturing industry. - Significant improvements in productivity and efficiency, - Bring volume manufacturing back into the UK, which can only be achieved by increasing the efficiencies and productivity of UK manufacturers. - The development of approaches for remanufacturing and repair of dies also aligns with the current focus of Innovate UK and the target for resource efficient manufacturing processes.