Pioneering research at the University of Ulster’s School of Engineering could revolutionise the global aerospace industry by helping make the next generation of aircraft quieter, more streamlined and more fuel-efficient.
Mechanical engineers at Ulster’s Advanced Metal Forming Research Group (AMFOR) have perfected a sheet metal manufacturing method that reduces the drag on aircraft nacelles, which house the engines, by increasing the depth of the lip-skin.
The lip-skin is the highly polished leading edge on the nacelles. The proposed system is capable of forming both the current and next generation of lip-skins, found on the 787dreamlinerand C-series aircraft.
The research will be presented by Dr Alan Leacockin a keynote address to SheMet 2013, the 15th international biannual conference on sheet metal forming hosted by the AMFOR group at the Ramada Plaza Hotel, Shaw’s Bridge, Belfast from March 25– March 29.
Dr Leacock, co-chair of SheMet 2013and AMFOR Group leader, said the event, which has attracted delegates from 23 different countries, is an important forum for both industry and academia alike to present their latest findings in the area of sheet metal forming.
"Harsh economic times necessitate innovation at all levels in the supply chain. The products from sheet metal forming industries feed in to all sectors, from consumer electronics through medical devices to transport."
He continued: "An essential underpinning of these future developments is the close collaboration of academia and industry at all levels in the international supply chains.”
Rising fuel costs mean that aircraft manufacturers are constantly seeking new solutions to reduce drag and improve fuel efficiency. Focused applied research activities in the area of aerospace sheet metal forming by the AMFOR group, has led to the development of a new forming technology.
Dr Leacock explained: "Although composites are now prevalent in aerospace production, the demanding operational requirements of elevated temperature and
damage tolerance necessitate the use of metallic materials in lip-skin manufacture.
"Present production methods are limited in the depth of the lip-skin or precluded by a convoluted and lengthy production cycle.
"This internationally patented process we have developed at the University of Ulster, enables the manufacture of next generation extended lip-skins in a single stage process with a cycle time of less than 5 minutes per skin.
"The development of this new forming technology, which was only possible through our focused applied research activities in the area of aerospace sheet metal forming, will enable the production of quieter, more efficient aircraft and presents significant market opportunity.
The conference was opened by Gavin Campbell, Director of Design Engineering & Technology Development Aerospace for Bombardier Aerospace.
His presentation highlighted the challenges faced by the aerospace industry and showcased some of the solutions derived from joint research work conducted between the AMFOR Group and Bombardier working together in NIACE (Northern Ireland Advanced Composites and Engineering Centre).
Earlier this month, the UK Government pledged to invest 2 billion to create a UK Aerospace Technology Institute that will develop lighter, quieter, faster and more fuel-efficient aircraft.
The Government will pump £1 billion into the centre, while eight aerospace companies including Bombardier, Rolls-Royce, GKN and Airbus have pledged the other half.
By 2030, there will be a global demand for an estimated 27,000 new passenger aircraft worth £2.5trillion.
Britain has the second-biggest aerospace industry after the US and a 17 per cent share of the global market.
