advanced forming research centre services directory · pdf filethe country’s only high...

Advanced Forming Research CentreServices Directory

AFRC facts

• Formed in 2009

• Centre is 5,600m2 in size

• Workshops total 2,376m2

• 8 laboratories

• Robotics cell commissioned in 2015

• Employing over 130 talented individuals: researchers, chartered and non-chartered engineers, technicians, EngD and PhD students all supported by commercially astute business development and programme management teams

AFRC SERVICESOverview

The Advanced Forming Research Centre (AFRC) is a globally recognised centre of excellence in metal forming research, manufacturing technologies and innovation. It is the heart of Scotland’s manufacturing research and development sector and is the country’s only High Value Manufacturing Catapult centre; one of just seven in the UK.

The AFRC addresses the important challenge of taking low maturity technologies developed within research environments and deploying them within industrial manufacturing facilities.

It fills the gap between traditional university research and the industrial need to demonstrate new technology on real products, in real factories. This is often expressed in terms of manufacturing readiness levels which were derived from the NASA TRL scale and are used to articulate the journey to industrial application of new technologies.

How we work with businesses

The centre’s work supports businesses of all shapes and sizes by helping them to increase their competitiveness by taking a structured approach to innovation. It de-risks and accelerates the introduction of new technologies, materials and processes and assists companies by converting the art of innovation into a science that can be applied to their businesses.

The AFRC’s work covers the entire product development cycle – from material testing and characterisation through to industry standard manufacturing trials and product assessments. The way we work is based on our customers’ needs; all of our standard services can be tailored accordingly and if there is a need we can create bespoke services depending on customer requirements.

University of Strathclyde Advanced Forming Research CentreServices Directory

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Contents

Overview 2

Manufacturing innovation 6

Our approach 7

Process evaluation 8

Process design & redesign 8

Modelling & simulation 9

Manufacturing trials 9

Process validation 10

Automation & control 11

Standard services 12

Industrial tools 14

Forging cost reduction toolkit 14

Tool life improvement 15

Design for manufacture 15

Materials characterisation 16

Mechanical testing 17

Residual stress measurement 17

Sheet metal (BUP) testing 18

Microstructural evaluation 18

Metrology & inspection 20

3D contact measurement 21

3D non-contact measurement 21

Surface form & roughness measurement 22

Thermal imaging & temperature measurement 23

Other services 24

Precision machining 24

Thermal processes 25

Reliability modelling 25

Technology roadmapping 26

Project management 27


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The AFRC supports manufacturing innovation in business and industry by helping companies to de-risk and accelerate the introduction of new technologies, new materials and new processes.

At our purpose-built facility adjacent to Glasgow International Airport we have the capability to address an entire development cycle, from testing and characterisation of material, through full-scale manufacturing trials, to material and product assessment. This provides a complete toolkit for developing predictive techniques, and most uniquely for validating these at full scale.

We also help our customers identify all of the barriers to implementation, along with potential solutions, as early as possible in the development cycle. These barriers can relate to supply chain, commercial, business case, funding, intellectual property, operational handover, systems, and product maturity, as well as the maturity of the technology itself and our underlying understanding of the material which has been processed.

Manufacturing innovation


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Physicalprocessing

Process evaluation

Modelling & simulation Manufacturing trials

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Automation & control

Process validation

Our approach

Our ‘full-cycle’ approach to manufacturing innovation is illustrated in the following diagram:-

Entry can take place at any stage in the cycle, depending on the customer’s needs. Further details on each of these stages, and how your company can benefit from them, is given in the following pages.


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Process evaluation

Manufacturing innovation often begins with process evaluation. AFRC experts can visit your premises and conduct an evaluation of your current manufacturing process. This may involve taking real- time measurements using a range of portable instrumentation and test equipment. Where a manufacturing process is heavily reliant on a specific employee, our experts can also document the process to ensure future reproducibility.

Using their in-depth knowledge of the latest manufacturing methodologies, such as Lean Six Sigma, Continuous Improvement and Design for Manufacture (DfM), our experts will then advise you on how best to optimise your process in order to improve operational efficiency and increase competitiveness. They can also help identify innovative technologies to create a step change in the competitiveness of your business.


Process design & redesign

Using our skills in systematic experimental design, process improvement and our expert knowledge of processing technology, we can design your new manufacturing process. Existing processes can be redesigned to improve manufacturability or reduce manufacturing costs, using methodologies such as DfM and Manufacturing Process Selection. Materials selection and process flow are also taken into consideration in order to maintain or enhance operational efficiency.


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Modelling & simulation

The AFRC offers a Total Modelling Solution, from material and boundary condition characterisation through model development to full validation on industrial scale equipment. Modelling improves process capability and component performance through the development of an enhanced understanding of the material characteristics that impact on formability and the subsequent mechanical properties.

Benefits include:-• Process optimisation• Prediction of component geometry• Reduction in material usage• Avoidance/mitigation of manufacturing defects• Prediction of microstructure and material properties

Manufacturing trials

We can heat, shape, finish, measure, test and analyse a variety of parts and components in-house. Running trials on AFRC equipment allows you to undertake research and development, pre-production, or just test new ideas without disrupting your manufacturing facility. By doing so, you can:-

• Mirror your existing manufacturing capability for problem solving, development, assessing suitability for automation, process changes, etc

• Gain materials/process knowledge by observing effects of changes

• Undertake component testing and metrology• Take advantage of our expertise



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Process validation

All except the simplest of manufacturing innovations need to be validated. Validation of manufacturing innovation involves confirming that the manufactured product is fit for purpose, can be produced consistently at cost, and can meet these standards at the volume needed to support the market.

Our extensive suite of physical processing equipment allows us to undertake parallel physical and virtual trials. Our metrology and materials characterisation capabilities are used to assess the product of the physical process for comparison with the virtual trial. This allows validation of predictive capability.



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Automation & control

Our automation and control services are focused on developing integrated manufacturing systems to enable quality and productivity improvements in manufacturing operations. These build upon our in-house expertise in state-of-the-art monitoring systems, especially for hot processes.

With our flexible automation cell, we can configure advanced robotic systems to suit your manufacturing process, allowing automation and control technology to be assessed and Return on Investment (ROI) calculated before capital expenditure is committed.


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In addition to manufacturing innovation support,we also offer a range of standard services.

Standard services

Industrialtools

Materialscharacterisation

Metrology& inspection Other services

Microstructural evaluation

Forging costreduction toolkit

Tool lifeimprovement

Design forManufacture

Mechanicaltesting

Residual stress measurement

Sheet metal (BUP) testing

3D contact measurement

3D non-contact measurement

Surface form & roughness

measurement

Thermal imaging & temperaturemeasurement

Precisionmachining

Thermalprocesses

Reliabilitymodelling

Technology roadmapping

Projectmanagement

Further information on each of these is given in the following sections.


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University of Strathclyde

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Industrial Tools is a set of AFRC services which are specifically aimed at reducing the cost of products, particularly those manufactured using a hot forming or forging process. Cost reduction can occur as part of the design process, using standard methodologies such as Design for Manufacture (DfM) and Manufacturing Process Selection, or at the manufacturing stage through new methodologies developed by the AFRC for supporting forging process improvement and investigating and improving tool life.

Forging cost reduction toolkit

AFRC experts have developed a toolkit which brings together a series of individual research and consultancy activities to support forging process improvement by focusing on reducing variability, increasing energy efficiency and effective process simulation. The toolkit comprises eight modules:-

Industrial tools

• Forging system review• Forging parameter optimisation• Oxygen level and dew point measurement• Thermal camera surveys• Dynamic press scan• Process modelling for predictive manufacturing• Energy survey• Transfer time optimisation

Benefits include process optimisation, reduced energy costs and minimisation of rework.

Modules are offered at a fixed price regardless of your geographical location or business size and can be combined to suit your company’s priorities. If you would like to work with the AFRC using the toolkit, we can help you identify the combination of modules most appropriate to your business needs.


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Tool life improvement

The tools and dies used in most hot forming and forging processes experience high cyclical mechanical and thermal loads. These conditions result in the degradation of the tool, thereby reducing the quality of the parts formed. The costs associated with replacing a die can be significant, as they include reduced productivity due to press down time, the cost of manufacturing the new die and the time taken to set up the press with the new tooling.

At the AFRC, we have developed a new methodology for investigating and improving tool life which draws together expertise in areas such as tool mortality forensics, process monitoring and process simulation. This methodology allows the tool material, tool construction and lubrication to be matched with process conditions for maximum cost benefit. With our full-scale forming and forging equipment, we can conduct manufacturing trials in order to generate die wear under controlled conditions and our advanced metrology and materials characterisation capabilities allow this wear to be accurately assessed.

Design for Manufacture

Design for Manufacture (DfM) is a methodology which can be applied to the design of a new product to ensure that the product is easy to manufacture at an economic cost, is manufactured to the required quality and can achieve the necessary reliability. DfM seeks to optimise manufacturability by selecting the most cost-effective material and process to be used in the production of the product.

At the AFRC, we can provide DfM solutions through definition technical vetting and process selection. Using their in-depth knowledge of engineering materials and manufacturing processes, our experts will work with you to optimise the manufacturability of your product in order to minimise costs and reduce time to market.

Industrial tools


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The testing and characterisation of materials is fundamental to the understanding of manufacturing processes and underpins the majority of the work carried out at the AFRC. Our experts are at the forefront of materials characterisation research and employ the latest equipment and techniques to develop an in-depth understanding of the structure and behaviour of engineering materials.

We offer a full range of materials characterisation services, from mechanical testing and residual stress measurement to microstructural evaluation. Our fully equipped metallographic preparation laboratory plus Wire EDM machinery allows material samples to be prepared in-house, thus reducing the lead time required to undertake the work. Further information on each of these services is given in the following pages.

Materials characterisation


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Mechanical testing

Mechanical testing indicates whether a material or part is suitable for its intended application by measuring properties such as elasticity, tensile strength, elongation, hardness, stress rupture and the fatigue limit. In forming and forging, the ability to establish accurate flow stress data of a specific material under conditions as close as possible to those at the press is essential to accurate process simulation. Other manufacturing processes also benefit from an understanding of the mechanical properties of the material for purposes such as process optimisation and quality control.

At the AFRC, we have a full suite of mechanical testing equipment configured to obtain stress-strain data at a range of temperatures up to 1,200°C and a range of strain rates spanning seven orders of magnitude of strain rate. This includes two screw-driven machines suitable for lower strain rate tests (10–4 per second to 0.7 per second) and two hydraulic machines suitable for a strain rate range of 1 to 200 per second.

Residual stress measurement

Residual stress is the stress present in a material after all external loading forces have been removed. The presence of residual stress means that energy is locked into the material which can then influence the structural integrity and performance of components in service or cause distortion during downstream processes such as machining. Therefore, it is vitally important to quantify residual stress in applications where high dimensional accuracy or high structural integrity of components is required. The AFRC’s James Watt Laboratory is a state of the art facility for residual stress measurement and strain mapping. It supports both destructive and non-destructive measurement of residual stress, from micro scale to macro scale. Techniques employed include Electronic Speckle Pattern Interferometry (ESPI), X-Ray Diffraction (XRD) and Contour Method. Our experts combine experience in measurement techniques with an in-depth knowledge of materials science and mechanical engineering, all of which is necessary in order to fully understand the origin and evolution of residual stresses during manufacturing processes.



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Sheet metal (BUP) testing

In sheet metal forming, it is necessary to establish certain mechanical properties of the material in order to determine formability. Sheet metal (BUP) testing can be used to test the formability of sheet metal under complex stress states (simple tension, plane strain, stretch forming, biaxial tension). This supports the generation of forming limit diagrams which are widely used in modelling and simulation to provide failure limits for cold sheet metal forming processes. Sheet metal testing can also be employed to investigate the influence of surface treatments, coatings and lubricants.

Our hydraulically operated sheet metal (BUP) testing machine can be used to determine the room temperature formability of sheet materials of thicknesses between 0.3 and 4.0 mm and sample sizes up to 260 mm in diameter. Tests available include Nakajima, Marciniak, Erichsen, earing and cupping. The machine also incorporates a GOM ARAMIS 5M optical 3D deformation system for non-contact measurement of deformation under both static and dynamic loading conditions. This provides accurate measurement of 3D displacements and velocities, surface strain values and strain rates.

Microstructural evaluation

Characterisation of material microstructure before and after manufacture is essential to understanding the effect of the manufacturing process on product integrity. At the AFRC, we operate a fully equipped facility for microstructural evaluation of parts and materials. Techniques employed include energy-dispersive X-ray spectroscopy (EDS) and wavelength-dispersive X-ray spectroscopy (WDS) for chemical composition analysis, and electron backscatter diffraction (EBSD) to determine the structure, crystal orientation and phase of the material. We can also carry out optical microscopy and scanning electron microscopy to identify and evaluate grain structure, precipitates, carbides and various phases present in the microstructure.

A typical project might involve the detailed micro-structure characterisation of a high-performance alloy for specific applications where the main objective of the work is to study the effect of various process parameters on the microstructure evolution of the formed component. In this case, grain size analysis, precipitate and carbide volume fraction analysis would be carried out on samples obtained from components formed through different process parameters in order to obtain a comparative analysis.



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The AFRC’s purpose-built, temperature controlled, metrology laboratory with live temperature recording houses an array of general-purpose and specialist measuring equipment. Our experienced metrology engineers will work with you to understand every aspect of your measurement need, including interpretation of design requirements, design intent and the effects of geometric tolerancing on manufacturability. As a research centre, we take a pragmatic view and this gives us additional flexibility in terms of our approach and how we use the measuring equipment. We can also provide an impartial opinion in situations where there may be disagreement within a supply chain over the acceptance of components.

Close links with measuring equipment manufacturers GOM (Gesellschaft für Optische Messtechnik) and Land Instruments, both of whom are AFRC tier 2 members, ensure that we always have the most up to date knowledge of equipment and techniques.

Metrology & inspection

Our in-house capability is further enhanced through a strategic partnership with NPL, the UK’s National Measurement Institute, and we are able to call upon NPL’s world-leading measurement expertise to help address the most demanding of metrology and inspection requirements. We also have access to the extensive knowledge and expertise available within the other six centres of the High Value Manufacturing Catapult.

Our metrology and inspection capability covers the following areas:-

• 3D Contact Measurement• 3D Non-Contact Measurement• Surface Form & Roughness Measurement• Thermal Imaging & Temperature Measurement

Further information on each of these services is given in the following pages.


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3D contact measurement

Where precision geometric measurement on objects up to approximately one cubic metre in size is required, our high performance Mitutoyo Crysta-Apex C Coordinate Measuring Machine is the ideal solution. The machine can be fitted with a variety of Renishaw touch-trigger and scanning probes to address a wide range of general and specialised measurement tasks.

These include:-• Inspection of components for dimensional accuracy• High accuracy surface mapping for residual stress

quantification, wear analysis, etc• Aerofoil inspection and analysis

Using Mitutoyo’s MCOSMOS version 3.5 metrology suite, our advanced CMM programming capability facilitates the cost- effective measurement of multiple parts and permits offline programming to a nominal CAD model in order to reduce lead times. Statistical analysis may also be carried out using Mitutoyo’s MeasurLink quality management suite.

3D non-contact measurement

For 3D measurement applications involving complex surfaces or where a higher density of points is required, we have a range of optical non-contact measuring systems that can be deployed. Our state-of-the-art GOM ATOS III Triple Scan 3D scanner may be used to capture high resolution point cloud data over measuring areas ranging from approximately 30 mm to several metres in size. For discrete measurements on objects up to 20 metres in size, our GOM TRITOP Optical CMM can be used and for full 3D point deflection measurement at up to 500 frames per second we have our GOM PONTOS HS Dynamic 3D Analysis system. We also possess the specialist knowledge to apply this flexible, powerful equipment to a wide range of measurement tasks, from full-field scanning of large objects to real-time 3D tracking of position for assembly monitoring. Typical applications include:-

• Acquisition of surface mesh data for reverse engineering, rapid prototyping, CNC programming or Finite Element model validation

• Before and after analysis for the investigation of wear or deformation, and deviation from a nominal CAD model or previously scanned part

• Dynamic 3D measurement of deformation/displacement



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Surface form & roughness measurement

Our Alicona InfiniteFocus G4 optical 3D micro coordinate system employs an optical measurement technique to perform non-contact surface form and roughness measurement on areas up to approximately 50 by 50 mm in size with a vertical resolution of up to 10 nm. Larger parts may also be accommodated by taking moulds of areas of interest.

When combined with our in-house surface analysis expertise, this versatile system can handle a very wide range of surface measurement tasks. It is particularly useful for the investigation of wear or erosion. It is also capable of automatic operation. Available outputs include all common surface roughness and profile parameters plus various types of 3D data for area-based surface characterisation.

For surface roughness measurements on objects in situ or where access may be more difficult, we also have a Mitutoyo contact profilometer.



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Thermal imaging & temperature measurement

We have a wide selection of high resolution thermal imaging and temperature measurement cameras covering temperature ranges from 0°C to 1,250°C and at a range of wavelengths. When combined with our expertise in thermal processes, this versatile equipment can be used for various applications, such as:-

• Thermal process monitoring• Emissivity calibration: determining the true emissivity

of materials under different thermal and environmental conditions – this is important when modelling radiative heat transfer in furnaces

• Greater accuracy of radiation thermometers, pyrometers and thermal imagers

• Work on bespoke contact measurement (true surface thermocouples) and non-contact measurement techniques

• Advanced capability for heat treatments, quenching and residual stress – development of bespoke instrumentation and measurement techniques


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In addition to the services described in the preceding sections, we also have knowledge, expertise and facilities in the following areas:-

• Precision machining• Thermal processes• Reliability modelling• Technology roadmapping• Project management

Precision machining

Complex product geometries and advanced materials can present engineering, economic and environmental challenges. At the AFRC, our approach utilises four key Innovation Strands to provide a knowledge-based understanding of the machining process:-

• Machining process design• Machining simulation• Machine tool instrumentation• Residual stress and integrity

This can be employed to develop, optimise and advance new solutions and technologies for precision machining. Our precision machining capability includes:-

• Simultaneous 5-Axis machining• Multi-tasking technology: mill turn• High speed machining• Twin spindles• Real-time data feedback• Large component size: up to 1,250 mm diameter and 2,000

mm length

Other services


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Thermal processes

At the AFRC, we have the capability to address a range of thermal processes. Our collection of electrically and gas powered furnaces cover a wide range of temperatures and capacities, allowing a variety of heat treatments, such as stress relieving, tempering, normalising and annealing, to be carried out. We also have a vacuum heat treatment furnace which is suitable for treating a wide variety of alloys in Argon and Nitrogen gas environments.

Our fully instrumented gas furnace permits investigation of the key parameters affecting heating efficiency and part quality, and allows characterisation of combustion, gas flow and burner parameters. Using our polymer quench tank, we can also replicate production quenching environments and undertake testing of various polymer quench parameters in order to understand quenchant performance and optimise the process accordingly.

AFRC experts can also conduct a thermal/energy audit of your manufacturing process to determine efficiency and show where improvements can be made.

Reliability modelling

The failure of products to function can be costly and lead to unsafe operating conditions, making reliability a key attribute of any product. It is therefore critical to ensure that the evaluation and management of reliability is taken into consideration during product development.

Working in collaboration with industry partners such as Rolls-Royce, BAE Systems and Scottish Power, our colleagues in the Department of Management Science have developed methodologies to allow engineers to evaluate the reliability of designs even in cases of limited data. Department of Management Science reliability experts have experience in developing and applying a variety of techniques and have worked closely with industry partners in sectors such as manufacturing, defence, energy and utilities. Their expertise has been recognised internationally through serving on the editorial board of international journals. A reliability growth modelling framework developed from research at the Department of Management Science is also included in the international reliability growth standard (IEC 61164) which has been adopted globally by manufacturing firms and procurement agencies.

Areas of reliability management covered include:-

• Reliability and availability growth modelling• Common cause failure modelling• Reliability data analysis• Structured engineering judgement• Prognostics modelling

Other services


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Technology roadmapping

Technology roadmapping is a powerful technique which allows organisations to develop a strategy based on market needs and technology availability over time. It is particularly beneficial for long-term or strategic planning, providing a roadmap that allows technology developments to be integrated with business planning, and the impact of new technologies and market developments to be assessed. It can also be employed in situations where more than one organisation is involved, such as collaborative projects, or across an entire industry.

At the AFRC, we routinely use technology roadmapping for forward planning of our own research programmes. We can also apply this capability to your business through our technology roadmapping service. Our experts will conduct a technology roadmapping workshop at your own premises, or hosted at the AFRC if you prefer. The workshop should ideally involve a broad range of participants in order to ensure that the resulting roadmap constitutes a shared vision of your organisation’s future and provides an understanding of the key steps needed to realise that vision. The output from the workshop will be a document containing the roadmap and implementation plan.

Other services


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Project management

Projects are separate to business-as-usual activities, requiring people to come together temporarily to focus on specific project objectives. Given the transient nature of such activities, many companies may be unable to justify having permanent project managers on the payroll or may have insufficient staff resources to deal with multiple projects simultaneously. In these situations, AFRC project managers can be deployed to meet demand and help ensure business critical projects are managed in an efficient and professional manner.

Our project managers are highly experienced, with certifications in industry standard methodologies such as PRINCE2 and PMP. They will work with you to establish the project brief, business case, governance requirements and project team. They will then assume responsibility for running the project, working to ensure that the project is delivered according to the agreed schedule and budget. The level of involvement can also be tailored to individual requirements, thereby providing the most cost-effective solution for your project management needs.


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Contact usAdvanced Forming Research CentreUniversity of StrathclydeEmail: [email protected]: +44 (0)141 534 5200

www.afrc.org.uk

http://www.afrc.org.uk

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