Periodic Reporting for period 2 - SHARK (Laser surface engineering for new and enhanced functional performance with digitally enabled knowledge base)
Okres sprawozdawczy: 2019-04-01 do 2021-03-31
A form of surface engineering, laser functional texturing is a key enabling technology that is relevant to almost every industrial sector, with applications ranging from anti-icing/self-cleaning surfaces to wear reduction and biocompatibility enhancement. It can offer significant benefits to manufacturers, such as cost savings, improved product performance and faster product development. However, the process is viewed by many as complex and costly, and there can be a lot of trial and error involved in getting the desired surface texture.
The SHARK project has addressed these challenges by industrialising laser functional texturing through a holistic approach, to boost the productivity, cost effectiveness and flexibility of the process, and ultimately build confidence in the process as a viable option for enhancing product performance, quality and reliability.
A group of 11 research organisations and market leading companies from across Europe teamed up to increase the industrial uptake of laser functional texturing and unlock the benefits of the technology for European manufacturers.
Supported by funding through the European Union’s Horizon 2020 Framework Programme for research and innovation, the project consortium has developed a fully integrated system that reduces production time with a ‘right first time’ approach through modelling of the process and in-situ inspection. The platform allows end-users to test run the functionality obtained through laser surface texturing on their components, which significantly reduces risk and cost.
The amount of component testing has been reduced through the establishment of a knowledge data management system and modelling software, and provides a cost model analysis for implementing laser surface texturing in specific application areas.
Laser texturing has a wide range of applications in sectors as diverse as aerospace, medical, food and drink, power generation and tooling. The SHARK project is focused on such end-use applications including anti-icing for ice cream production lines and controlled friction for high-friction discs resulting in significant benefits to the functionality of the chosen case-study components.
The consortium consisted of world class research organisations: Fraunhofer IWS (Germany), Heriot-Watt University (UK) and the Manufacturing Technology Centre (UK). Companies bringing their technology expertise were: ATS (UK), GF Machining Solutions (Switzerland), Sensofar (Spain), SIMTEC (France). End users provided application case studies in the power generation, medical, tooling and food and drink sectors, namely MAN Diesel & Turbo (Denmark), Johnson & Johnson (Ireland), Sandvik Coromant (Sweden) and Unilever (UK).
The SHARK project has addressed these challenges by industrialising laser functional texturing through a holistic approach, to boost the productivity, cost effectiveness and flexibility of the process, and ultimately build confidence in the process as a viable option for enhancing product performance, quality and reliability.
A group of 11 research organisations and market leading companies from across Europe teamed up to increase the industrial uptake of laser functional texturing and unlock the benefits of the technology for European manufacturers.
Supported by funding through the European Union’s Horizon 2020 Framework Programme for research and innovation, the project consortium has developed a fully integrated system that reduces production time with a ‘right first time’ approach through modelling of the process and in-situ inspection. The platform allows end-users to test run the functionality obtained through laser surface texturing on their components, which significantly reduces risk and cost.
The amount of component testing has been reduced through the establishment of a knowledge data management system and modelling software, and provides a cost model analysis for implementing laser surface texturing in specific application areas.
Laser texturing has a wide range of applications in sectors as diverse as aerospace, medical, food and drink, power generation and tooling. The SHARK project is focused on such end-use applications including anti-icing for ice cream production lines and controlled friction for high-friction discs resulting in significant benefits to the functionality of the chosen case-study components.
The consortium consisted of world class research organisations: Fraunhofer IWS (Germany), Heriot-Watt University (UK) and the Manufacturing Technology Centre (UK). Companies bringing their technology expertise were: ATS (UK), GF Machining Solutions (Switzerland), Sensofar (Spain), SIMTEC (France). End users provided application case studies in the power generation, medical, tooling and food and drink sectors, namely MAN Diesel & Turbo (Denmark), Johnson & Johnson (Ireland), Sandvik Coromant (Sweden) and Unilever (UK).
SHARK has advanced laser surface texturing from the current ‘trial and error’, lab-scale concept into a highly predictable, data driven industrial approach by developing a digitally enabled knowledge management platform with a comprehensive database of process parameters and functionalities. This has enabled the end-users to successfully implement the technology on their selected case-study components. The SHARK system is configured as an Open platform independent of the laser source manufacturers, which previously has been one of the main limitations for the process. The main results achieved for the case-study parts are:
* Significant cutting force reductions on cutting inserts.
* Reduced operating temperature on round cutting tools with subsequent reduction in flank wear.
* Improved heat transfer rates of food moulds.
* Significant reduction in bacterial adhesion of medical implant components.
* Reduced material on surfaces of product mixers after cleaning.
* Significant reduction of the friction coefficient of surgical equipment.
* Improved friction coefficient and consistency of power generator component.
End-users plan to include the surface texturing of their case-study parts in their manufacturing process with one end-user having already integrated the technology.
Work in Period 2 (Month 19 to Month 42) focussed on:
- In-Situ surface characterisation.
- Predictive modelling.
- System integration & knowledge management.
- Demonstration & validation.
- Dissemination & exploitation.
* Significant cutting force reductions on cutting inserts.
* Reduced operating temperature on round cutting tools with subsequent reduction in flank wear.
* Improved heat transfer rates of food moulds.
* Significant reduction in bacterial adhesion of medical implant components.
* Reduced material on surfaces of product mixers after cleaning.
* Significant reduction of the friction coefficient of surgical equipment.
* Improved friction coefficient and consistency of power generator component.
End-users plan to include the surface texturing of their case-study parts in their manufacturing process with one end-user having already integrated the technology.
Work in Period 2 (Month 19 to Month 42) focussed on:
- In-Situ surface characterisation.
- Predictive modelling.
- System integration & knowledge management.
- Demonstration & validation.
- Dissemination & exploitation.
SHARK’s system is underpinned by a number of technological advances. Two laser surface texturing technologies have been developed, both based upon nanosecond fibre lasers. Pseudo Random laser texturing and Direct Laser Interference Patterning (DLIP) has been employed, offering complementary techniques to yield a highly flexible tool capable of delivering a wide range of functional surfaces with exceptional productivity and excellent process efficiency. The project has developed surface texture predictive modelling to rapidly define key process variables required for specific surface functionalities. This has been combined with inline surface characterisation to enable rapid feedback and inbuilt quality assurance.
The project has delivered:
• Cost savings: The capability to deliver surface functionalities into real products for less than 10% of the cost of the conventional part.
• Improved product performance based on the surface functionalities deployed
• Faster product development.
• A strengthened global position for European manufacturing.
The project has delivered:
• Cost savings: The capability to deliver surface functionalities into real products for less than 10% of the cost of the conventional part.
• Improved product performance based on the surface functionalities deployed
• Faster product development.
• A strengthened global position for European manufacturing.