How to Successfully Adopt New Technologies - University of Leicester

mammettiredMechanics

Nov 18, 2013 (3 years and 8 months ago)

74 views

CEEAM

Components for Energy Efficiency in Transport by
Additive Manufacturing

Piyal Samara
-
Ratna

Mechanical Engineer & Project Lead

Space Research Centre

Dept. of Physics and Astronomy


Project Overview


Funding by the Transport
iNet


18 month project


Started September 2010


Collaboration:


Space Research Centre


Mechanics of Materials Group at Leicester University


Additive Manufacturing group at DMU


MTT (industrial collaborator)


Project objectives:


Bring additive manufacturing into Space and other commercial
markets for regional benefit


4 businesses engaged with collaborations with HEIs


4 businesses assisted to improve performance


1 job safeguarded


6 graduates employed and 1 assisted in STEM training

What is Additive Manufacturing?

Conventional Machining

Additive Manufacturing

Additive manufacturing now available to manufacture components in metal

Benefits of Additive Manufacturing


No limit to complexity of parts


No time/cost penalty for complexity


No additional tooling costs


Minimal wastage:


All excess material can be recycled and
reused immediately


Potential to be extremely
environmentally friendly


It’s a process that encourages the engineer to
make the component as efficient as possible


It enables engineers to manufacture products
that were simply never possible


High performance lattice structures




Space Research Centre (SRC)


The Space Research Centre
needs

to adopt
innovative manufacturing techniques to remain
competitive in building space instrumentation:


Technology improvements are driving tougher
design requirements


The SRC needs to produce real hardware that
works


We also need to prove to our customers that it
works


Facilities to be a customer and technology
developer for additive manufacturing


Current SRC portfolio highlights:


3 instruments on the future ESA Mars Rover


1 Instrument on the replacement to Hubble
Space Telescope


1 instrument on a mission to Mercury


Development of nuclear power systems for
future spacecraft

The Problem?


High Production costs


Appropriate for the low volume manufacture


Technology still needs development before it is suitable for
mass volume production


Lack of process control


Uncertainty in ensuring that parts have no defects


Risk of high financial losses if parts do not meet the build
standard


Lack of material properties for parts produced using additive
manufacturing:


The process dictates the material properties


Each machine will need to be certified


The Solution!


Development of an in
-
process monitoring
system:


Ensures the quality of the parts


Ability to stop/alter the process


Developed primarily between DMU and
MTT (additive manufacturing machine
supplier)


Development of materials qualification
process:


Developed primarily between Space
Research Centre and the Mechanics of
Materials Group


Developed to international space
standards


Mechanical and thermal testing


Qualification initially for titanium (Ti64AV)
and then expanded to other materials (e.g.
Stainless steel)

Process Chain Evaluation

Raw material
handling

Machine
Setup

Part
Production

Part Design

Part post
-
processing

Integration to
end
application

Concept to Production Process Chain

Designing
parts to fit the
manufacturing
process



Specification



Grade



Purity



Approved suppliers



Handling



Storage



Machine qualification



Setup procedure



Calibration



Process settings



Environmental settings



Build orientation



Process monitoring



Quality assurance




Removal of
support structure


Heat treatment



Surface finish



Drilling/tapping



Interfacing



Bonding



Part monitoring



Maintenance

Industry Collaboration


Currently working with 11 industrial collaborators in
Motorsport, automotive, aerospace, manufacturing, rail
and dental


Promote technology by development of sample parts for
each industrial sector


Free training & Free sample parts enables:


Promotional technology demonstrators


Tools to generate interest amongst industrial
partner customer base


SRC to provide engineering effort:


CAD design facilities


Analysis data to support:


Mechanical


Thermal


CFD


Technology development covered by NDA




Summary


By making real working hardware the
SRC bridges
the gap between
research and commercial industry



The SRC is paving the way for innovative manufacturing like Additive
Manufacturing to be used in commercial sectors:


Proving it to work in harsh test environments


Tackling issues preventing uptake of technology


Benefits for the SRC:


Development of knowledge and experience


Fulfils obligation of the University to support the region


Opens the door to possible future research collaborations


Benefits for industry:


Low investment in new technology


Publicity of using innovative technology used on space instrumentation


Long
-
term establishment of regional research expertise