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,