Confidential. © 2016 AMRC with Boeing. Template - AMRC.PPT Revision 1 (February 2015)

The University of Sheffield AMRC

AMRC Technologies for Automotive Applications

The AMRC & Advanced Manufacturing Park

1. Design Prototyping & Testing centre 2. Factory of the Future 3. Knowledge Transfer Centre 4. Nuclear AMRC 5. AMRC Castings 6. Composites Centre 7. AMRC Training Centre 8. Factory 2050

1

2

6

4

5

8

7 3

Innovation District

4

Part of the High Value Manufacturing Catapult

The High Value Manufacturing (HVM) Catapult is the catalyst for the future growth and success of manufacturing in the UK. Established and overseen by the Technology Strategy Board, with over £200 million of government investment. The AMRC with Boeing & Nuclear AMRC are 2 of the 7 centres within the HVM Catapult.

AMRC Partners

5

Industry trends – Parallels to Aerospace

6

Automotive Aerospace

Lightweighting Use of aluminium, HSS and composite bodies. Optimisation of power- and drivetrain systems for mass.

Lightweighting Use of composites, MMCs and titanium alloys. Reduction in components (unitization), optimisation of sub-systems.

Powertrain revolution Downsizing of IC engines and increased hybridisation. Increasing temperatures and BMEP

Propulsion evolution Increasing specific output, increasing combustion temperature and increasing technical complexity (GTF for example)

Manufacturing Increased volume, increased flexibility, faster ramp up, increased complexity, reduced failure rate

Manufacturing Increased volume, reduced batch size, faster ramp up, increased complexity, reduced failure rate

Market High net growth, broadening demographic, long term growth prospects

Market High net growth, broadening demographic, long term growth prospects

AMRC technologies & groups

©AMRC 2012 ©AMRC 2014

Core cross group technology themes

• Digital manufacturing

• Through life near net processing

• Gear manufacturing

• Design for manufacture

9

Factory 2050

Need Manufacturing foresight “Factory of the Future” Government Office for Science • Reconfigurable • Digital • High value product

10

IMG Themes and Capability Summary

Integrated Large Volume Metrology

Laser trackers White Light Scanner

K600 optical CMM (K-cam) ROMER arm

Measurement, Metrology and Vision Systems Factory Scanning

Robot NDT iGPS

Robotics and Automation

(Chris Greaves)

Industrial robots Kinematics

Robot accuracy Robotic Machining, CMM

Robotic adhesive application Reconfigurable Fixturing Self-adapting machines

Human-robot collaboration AGVs and part movement

Digitally Assisted Assembly (DAA) (Chris Freeman)

Manual Assembly

Intelligent Tools (DC) Virtual Reality

Digital Twin Augmented Reality

Digital Work Instructions Optical Projection Laser Projection

Wearable technologies

Manufacturing Informatics

(Aiden Lockwood)

Ubisense part tracking SCADA / WinCC Control Systems

Programming Integrated Sensors

Low-power wireless Sensors Networks

Analytics

11

SENSORS / EQUIPMENT / CELLS / BUILDING

STATE LOCATION

ACCELERATION ORIENTATION

TEMPERATURE HUMIDITY PRESSURE

VIBRATION IMPACT

ACOUSTICS + … ??

DELIVERY OF INFORMATION RIGHT INFORMATION RIGHT TIME RIGHT PLACE RIGHT PERSON RIGHT DEVICE RIGHT FORMAT

F2050 Interconnected Manufacturing Environment

Factory Information BUS

no

REPORTING ANALYSIS STRUCTURED DATA STORE / WAREHOUSE

CLOUD / LOCAL CLOUD

FACTORY PLANNING MES / ERP

TABLET WEARABLE PHONE LAPTOP / PC

ALERTS / JUST IN TIME INFORMATION / WORK INSTRUCTIONS / PROCESS / PROGRESS INFO

CUSTOMERS / ORDER INTAKE

LOW POWER BLUETOOTH / WI-FI / RFID / FACTORY LAN

EMPLOYEES

INTELLIGENT DECISIONS / ANALYTICS FEEDBACK

DASHBOARD INTERNET / WEB PORTAL

SUPPLY CHAIN

LIVE DATA

USER FEEDBACK / VALIDATION

HISTORIC DATA

Machining Technologies

The AMRC Machining Group is a world leading centre of machining innovation and technology. - Process and cycle time optimisation - Operation roll up - Process monitoring and control - Gear machining

13

Machining Technologies – Gear Machining

- Machining of complex forms using flexible tooling & multi functional machines

- Integrated single-hit manufacture of complex gear and shaft components

- High performance rough and finish grinding of hardened gears

- Enable new designs and materials

Composite technologies

• Automated Production

– body panels, drive train, interior

• Machining

• Advanced Curing Microwave Heating, Hot Pressing Directly Heated Tooling

• Novel processes

3D weaving- affordable preforms

Castings Technology Typical Materials and Project Process

15

22 47.90

Titanium Ti

47.90 22

Ni Nickel

12 24.31

Mg Magnesium

26 55.85

Fe Iron

13 26.98

Al Aluminium

27 58.93

Co Cobalt

+ Steel

Scope • Value for

money analysis

• Materials selection

• Supply-chain evaluation

•Gate-review

Product Development • Design for

casting man-ufacture

•Design and simulate techniques

Process Development • Devise new

process •Produce

prototypes • Initial rate

production • FAST-MAKE

Process Optimisation • Improve

yields • Small batch

production • Create

knowledge pack

Technology Transfer • Activity

within the supply-chain

• Prove and validate

• Continuous improve- ment

CastFast- High-Integrity Fast-Make Facility

16

3D printer - large-scale sand moulds and cores Aluminium heat treatment Steel heat treatment Close-coupled pouring air melt Close-coupled pouring vacuum melt Ultra high-integrity, volume production, counter gravity aluminium

Business Model 1 – Fast-Make of Cast Aerospace Components

Compared to conventional manufacturing techniques, the resulting casting gives:

89% reduction in lead-time Compliant to full-rate production standards

Business Model 2 – Light-weight cast Invar Aerospace Wing Tooling

16

Compared to conventional manufacturing techniques, the resulting casting is:

23% lighter + 38% cheaper

Cross sector opportunities

Product and Process Development

Turbo-chargers Material selection for higher temperature operation Conversion of Aluminum to Steel compressors Investment casting compressor and turbine

17

Ways to fund engagement

1. Become a member of the AMRC. The AMRC partnership offers access to a

world leading research portfolio and partnership group. All membership contributions are spent on research projects.

2. Direct purchase order cover. This is the most flexible and fastest way in

which to progress development work.

3. Build a project funded by a grant body. Projects funded by grant bodies such as Innovate UK, BIS, EPSRC, APC and Horizon 2020 can be applied for and carried out by the AMRC. AMRC has strong links with such bodies and excels in putting together project consortiums. This takes more time since funding must be put in place before the project begins.

4. Join existing consortiums. The AMRC also carries out projects funded by ATI and APC; joining calls already in progress is a rare opportunity but may present good value to both Red Bull Technology and the existing consortium if a suitable opportunity is found.

Confidential. © 2016 AMRC with Boeing.

Email:

Tel:

web: amrc.co.uk

Twitter: @theAMRC

Thank you. For further information please contact or visit:

b.kitcher@amrc.co.uk

07846 084 621

Further information

Further information relating to AMRC technology groups can be found on the AMRC website. Please click the links below to download capability brochures for each division. IMG (robotics and automation) Machining Group Structural testing Composites Centre Design and Prototyping AMRC Castings Research Support