COMBATING 21ST CENTURY CHALLENGES IN MANUFACTURING: REDUCING FRICTION, VIBRATION AND WEAR
4 November The AMRC with Boeing, Rotherham, South Yorkshire Tribology Group www.imeche.org/events/S6169 Seminar COMBATING 21ST CENTURY CHALLENGES IN MANUFACTURING 4 November 2014, The Advanced Manufacturing Research Centre with Boeing, Rotherham, South Yorkshire
BENEFITS OF ATTENDANCE: • Discover the latest developments for COMBATING 21ST CENTURY integrating condition monitoring into CHALLENGES IN MANUFACTURING standard products with Siemens ADDRESSES THE DIFFERENT • Explore the application of tribological APPLICATIONS AVAILABLE FOR testing and analysis with Cummins MANUFACTURERS THAT AVOID Turbo Technologies MACHINE DOWNTIME, POOR • Gain insight into how lubricants improve PRODUCT DESIGN AND INCORRECT energy efficiency with a presentation MATERIAL SELECTION. from Shell • Hear BAE Systems compare the Manufacturing contributes £6.7 trillion to the global latest innovations versus conventional economy, 11% of the UK’s GVA (gross added value,) 54% of techniques, alongside the Advanced UK exports and directly employs 2.6 million people. This is an exceptionally valuable industry and it is therefore Manufacturing Research Centre essential that potential improvements are explored and • Develop diagnostic manufacturing additional costs and delays are avoided. capabilities with insight from the Across multiple industries, manufacturing is united University of Sheffield in improving productivity, asset management and maintenance, responding to energy efficiency pressures. This seminar will provide you with the opportunity to learn from large scale manufacturers and will provide you with further opportunities to evaluate conventional techniques compared to new innovations, all in order to improve ROI. Build your understanding of: The ability to manufacture and maintain complex shapes with precision and control is essential for manufacturers. • Innovations for energy efficiency to improve Attend this event to hear lessons learnt and best practices power and meet environmental targets from across the manufacturing industry to increase process optimisation. • Applications to improve techniques for life tension of tools, components and ensure cost efficiency SUPPORTING PARTNERS: • Technology that is able to test and identify malfunctioning machinery to determine whether major repairs are needed • Methods to prevent surface fatigue and bearing failure to avoid replacing materials
SPONSORSHIP & EXHIBITION OPPORTUNITIES GET INVOLVED Attending this event as either an exhibitor or sponsor will give you the opportunity to display your solutions, services and products to the right people at the right time. This is an excellent way to enhance your company profile and communicate effectively to your target audience. BENEFITS OF SPONSORING • Showcase new products • Raise awareness of your operation • Improve perception of your brand • Influence other organisations’ spending plans For more information please call +44 (0)20 7973 1309 or email [email protected] PROGRAMME
TUESDAY 4 NOVEMBER 2014
08:30 REGISTRATION AND REFRESHMENTS
09:00 CHAIR’S OPENING REMARKS Dr Mandar Thakare, Member of the Tribology Group, Institution of Mechanical Engineers
PERFORMANCE OPTIMISATION
09:15 DELIVERING REAL TIME CONDITION MONITORING Paul Hingley, Safety Condition Monitoring and Industrial IT Security, Siemens • Integration of condition monitoring into standard products • Cloud based access: what this means for users • Industry 4.0: what it means for future condition based monitoring
09:45 HIGH SPEED RAIL GRINDING: TAKING A LEAD FROM THE AEROSPACE INDUSTRY Matt Marshall, Senior Lecturer, The University of Sheffield • Explore the application of super-abrasive grinding concepts to rail steels • Understand the tribological challenges associated with grinding soft steels at high speed • Gain insight into the use of novel solid lubricants in high speed grinding
10:15 EXPLORING THE LATEST COMPOSITE BEARING Tim Biswell, Head of Engineering, Wärtsilä • Explore the thermoset resin systems (Phenolic, Polyester and Epoxies) and the advantages of filament winding • Discover the oil lubrication, Environmentally Acceptable Lubricants (EAL) and where there still might be problems to be resolved • Understand a lower cost lubricant with water lubrication and discover the true price for your business
10:45 NETWORKING REFRESHMENT BREAK
MAINTENANCE AND ASSET LIFE EXTENSION
11:15 THE DESIGN OF CURRENT AND FUTURE SURFACE ENGINEERING COATINGS TO RESIST EROSION AND WEAR IN AERO TURBINES Richard Wellman, Specialist Surface Engineering, Rolls-Royce plc • Explore the environmental pressures, performance, efficiency and reliability that all need to be considered in the design of modern gas turbines • Understand the role that advanced tribological solutions play in this design process by illustrating how materials and coating systems are being adapted for a wide range of operating conditions • Analyse the need to give tribological systems adequate consideration at the design stage, rather than view them as remedies when problems arise
11:45 THE APPLICATION OF TRIBOLOGICAL TESTING AND ANALYSIS PRINCIPLES TO MANUFACTURING RESEARCH Michael Burkinshaw, Senior Tribologist, Cummins Turbo Technologies • Gain an overview of tribological testing and analysis of turbomachinery components • Explore how such an approach to testing and analysis can be applied to manufacturing research • Explore the benefits to industry of conducting fundamental tribological testing
12:15 INTERACTIVE PANEL DISCUSSION: MANUFACTURING TECHNIQUES FOR LIFE EXTENSION OF TOOLS, COMPONENTS AND ENSURE COST EFFICIENCY Panellists: Tim Biswell, Head of Engineering, Wärtsilä, John Williams, Professor of Engineering Tribology, University of Cambridge and Paul Hingley, Safety Condition Monitoring and Industrial IT Security, Siemens • Discuss the latest developments from heat relaxation trials to reduce overheating • Discover the different techniques to avoid surface fatigue and bearing failure to avoid replacing materials • Evaluate the different condition monitoring techniques to maximise equipment performance
13:00 NETWORKING LUNCH AND TOUR OF THE AMRC WITH BOEING FACILITIES REDUCING FRICTION AND ENSURING COST EFFICIENCY
14:15 TRIBOLOGY AND MECHANICAL TESTING PRINCIPLES Allan Matthews, Professor of Surface Engineering, The University of Sheffield • Evaluate the application required from the product to ensure your business is using the most efficient tool • Use tribological techniques as a vehicle for monitoring and development • Develop diagnostic manufacturing capabilities to ensure quality control throughout the production line
14:45 THE ROLE OF LUBRICANTS IN IMPROVING ENERGY EFFICIENCY Ian Taylor, Technology Manager, Shell • Explore the role of lubricant viscosity and surface active additives in affecting friction • Gain insight from automotive case studies including cars and heavy duty trucks • Hear the latest case studies from industrial hydraulics and industrial gearboxes
15:15 NETWORKING REFRESHMENT BREAK
TRIBOLOGICAL INNOVATIONS FOR MANUFACTURING
15:45 INNOVATION IN PRODUCTS AND PROCESSES Chris Dance, Specialist Development Engineer, BAE Systems • Explore advances in manufacturing from Tornado to Typhoon and beyond • Gain insight into manufacturing the next generation of aircraft • Innovation case studies: F35 Lightning Nozzle Bay Door and the Taranis Demonstrator
16:15 INTERACTIVE PANEL DISCUSSION: MANUFACTURING TRIBOLOGY FOR ENERGY EFFICIENCY Panellists: Richard Wellman, Specialist Surface Engineering, Rolls-Royce plc, Michael Burkinshaw, Senior Tribologist, Cummins Turbo Technologies, and Allan Matthews, Professor of Surface Engineering, The University of Sheffield • Evaluate fuel efficiency and energy management, ensuring your business is forward thinking • Reduce friction to improve the power of existing machinery • Explore the different lubricants that are available to meet environmental targets
16:50 CHAIR’S CLOSING REMARKS
17:00 CLOSE
Find out more about our speakers at www.imeche.org/events/S6169 • This programme is subject to change. • The Institution is not responsible for the views or opinions expressed by individual speakers.
Organising committee: With thanks to the Tribology Group
ENGINEERED IN BRITAIN THE RESULTS OF THE MANUFACTURING A 2014 ENGINEERED SUCCESSFUL ECONOMY? IN BRITAIN SURVEY REFLECT MUCH OF THE CONFIDENCE BEING REPORTED IN THE MEDIA IN RECENT MONTHS.
For more information: http://goo.gl/A1qiut
+44 (0)20 7973 1258 FOLLOW OUR WEEKLY UPDATES [email protected] ON WWW.IMECHE.ORG SPEAKERS AND CONTRIBUTORS
MANDAR THAKARE CHAIR MEMBER OF THE TRIBOLOGY GROUP, INSTITUTION OF MECHANICAL ENGINEERS Mandar Thakare is a Senior Applications Engineer with Element Six A SUCCESSFUL Ltd developing structure-performance relationships for polycrystalline TRIBOLOGICAL diamond based drill-bit cutters. Dr Thakare has ten years of R&D APPROACH IS experience in developing an understanding of tribological performance CRITICAL TO THE of coatings, ceramics and alloy-steels in a wide range of engineering applications. He has published several journal papers, two book chapters ECONOMICS AND and has been invited to present at international conferences. Since OPERATIONAL completing his PhD, Dr Thakare has worked for Schlumberger plc and RELIABILITY the University of Oxford. Dr Thakare also holds a college lectureship at St OF INDUSTRIAL Catherine’s College, University of Oxford and is a reviewer for Tribology MANUFACTURE AND International, ASME Journal of Tribology and Wear. PROCESSING. - The Tribology Group PAUL HINGLEY SAFETY CONDITION MONITORING AND INDUSTRIAL IT SECURITY, SIEMENS Paul Hingley began his engineering career in the automotive industry as a Project Manager. After working overseas for some years he returned to the UK and worked on developing industrial control solutions, utilising industrial control networks, before joining Siemens in 1997 as a Network Applications Engineer. Paul’s role for Siemens includes responsibility for condition monitoring, industrial cyber security and safety services and products.
MATT MARSHAL SENIOR LECTURER, DEPARTMENT OF MECHANICAL ENGINEERING, THE UNIVERSITY OF SHEFFIELD Matt Marshal completed a PhD in Tribology in 2005, and then worked for Sheffield’s Advanced Manufacturing Research Centre (AMRC) for three and a half years before starting as a lecturer in the Department of Mechanical Engineering. He was promoted to Senior Lecturer in 2012, and specialises in cross-disciplinary applications of tribology, particularly in manufacturing and power generation. His research is sponsored by EPSRC, The Royal Society, TSB, and UK industry. He has published 35 papers including 18 in journals, of which two have won international prizes. Dr Marshall is also a Co-Director of the EPSRC Industrial Doctoral Centre in Machining Science, a flagship collaboration between the Department of Mechanical Engineering, AMRC, and industry.
TIM BISWELL HEAD OF ENGINEERING, WÄRTSILÄ Tim Biswell has over 25 years of experience in the design, application and development of composite materials of seals and bearings. This experience has been attained in many different industrial sectors including automotive, rail, marine, energy and general engineering. Since 2007, Tim has been the Head of Engineering at Wärtsilä’s UK-based Face Seal & Composite business, responsible for R&D, application design and field service. Prior to this, he held a variety of technical and operational positions within Railko Ltd, the UK-based composite bearing specialists, spending over 10 years as Technical Director. SPEAKERS AND CONTRIBUTORS
ALLAN MATTHEWS PROFESSOR OF SURFACE ENGINEERING, THE UNIVERSITY OF SHEFFIELD Allan Matthews joined the Department of Surface Engineering in 2003. SCIENCE AND Allan originally worked in the aerospace sector in a hi-tech manufacturing TECHNOLOGY OF project management role. He then returned to academia and joined a INTERACTING research team at Salford University, investigating tribological coatings for SURFACES IN A STATE industrial tooling. In 1982, he established one of the earliest laboratories in the world designated with the Surface Engineering title. He also OF RELATIVE MOTION worked with others on the creation of the first international journal with AND THE PRACTICES that title and has been instrumental in establishing and growing several THERETO. international conferences in the coatings field. - Dr. Peter Jost OBE and Prof. Duncan Dowson, The Jost Report, 1966. IAN TAYLOR TECHNOLOGY MANAGER – LUBRICANTS FUTURE PROJECTS, SHELL Ian Taylor received a First Class Honours Degree in Natural Sciences (Physics & Theoretical Physics) from Cambridge University in 1984 and a PhD in Applied Physics and Electronics from Durham University in 1987. He spent four years working for Plessey Research, before joining Shell Research Limited at the Thornton laboratory in 1991. Ian has spent the majority of his Shell career working on lubricant energy efficiency, involved in both fundamental modelling studies, product development, and experimental validation of energy efficiency benefits. He has published more than 50 papers in the areas of tribology and lubrication and has five patents.
MICHAEL BURKINSHAW SENIOR TRIBOLOGIST, CUMMINS TURBO TECHNOLOGIES Michael Burkinshaw is Senior Tribologist at Cummins Turbo Technologies, where he is responsible for research and development conducted in the topic areas of tribology and surface engineering. Michael and his team’s current research is focused on developing innovative solutions to meet future engineering challenges within the turbo-machinery industry, specifically materials and surface treatments to improve product durability, optimise frictional response and minimise product cost.
CHRIS DANCE AERONAUTICAL ENGINEER, BAE SYSTEMS Chris Dance is a Specialist Development Engineer within the Manufacturing Development and Technology department of BAE Systems Military Air & Information. He has represented BAE Systems in collaborative research projects across composites, machining and additive manufacturing technologies. Most recently, this has included the build of titanium structures through the development of a large-scale additive manufacturing process and the design and manufacture of a highly- loaded composite-metallic structural demonstrator.
RICHARD WELLMAN SPECIALIST SURFACE ENGINEERING, ROLLS-ROYCE PLC Richard Wellman has spent the last two years working at Rolls-Royce as a Specialist in Surface Engineering and is currently running the Tribology strategy, aimed at reducing wear and increasing component life and efficiency. Prior to this he was a Lecturer in Tribology at Cranfield University working on erosion and wear resistant coatings for extreme environments. COMBATING 21ST CENTURY BOOKING FORM CHALLENGES IN MANUFACTURING EVENT CODE: S6169AB 4 November 2014 FIVE WAYS TO BOOK The AMRC with Boeing, Wallis Way, 1 Online: Catcliffe, Rotherham, S60 5TZ www.imeche.org/events/S6169 REGISTRATION Please complete in capitals. 2 Email: [email protected] Family Name Title (Mr, Mrs, Miss) 3 Phone: First Name Job Title +44 (0)20 7973 1258 Membership No Institution 4 Post completed booking form to: Name of Organisation (for name badge) Event Registrations Address for correspondence Institution of Mechanical Engineers 1 Birdcage Walk Town/City London SW1H 9JJ Postcode 5 Fax: Contact Telephone +44 (0)20 7222 9881
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