The Evolution of Hot Forming and Superplastic Forming Presses in the Aerospace Industry
Thierry Favre, Product Engineer, ACB
Mechanical Engineering Degree (Ecole Centrale de Nantes, France) 1991
DEA genie mécanique (Ecole Centrale de Nantes, France) 1991
Master of Science in Computer Aided Engineering (Cranfield, UK) 1992
FTV (France): Plastic Injection mold manufacturer. 6 years
Design Engineer 4 years
Head of Design Office 2 years
Aviatube (France) : Aluminium extrusion for Aerospace. 2 years
Continuous improvement Engineer
ACB (France): Hydraulic presses for Aerospace 13 years
Design engineer 3 years
Product engineer for Superplastic/Hot Forming presses 10 years.
ACB (France) and its sister company Cyril Bath (USA) have a long experience in the fields of hydraulic presses and metal forming for the aerospace industry. This experience is particularly focused on the manufacturing of structural and engine titanium parts. The purpose of this presentation is to show how the combination of both activities in the fields of Hot Forming/Sizing and Superplastic Forming results in continual progress and how recent evolutions open new opportunities. An example is the potential use of Hot Forming and Superplastic Forming on new material like Nickel-based alloys.
Both processes will be shortly introduced and a short focus will be done on process simulation. Then the influence of forming conditions on material microstructure, mechanical properties and post-process operation (machining, cutting, etc) will be discussed. To illustrate the interest of both technologies, some examples based on real titanium parts will be presented.
The advantages of Hot Forming, Superplastic Forming and Diffusion Bonding technologies will be demonstrated regarding current customer’s requirements like process reliability, part quality, repeatability, raw material saving, etc.
To conclude an overview of on-going research programs will be made to present strong advantages of dual presses combining Hot Forming and Superplastic processes.
- Development of Hot Forming process and corresponding machines to keep it competitive in the aerospace industry.
- Strength of hot forming processes applied to titanium parts for the aerospace industry and evolution toward new alloys.
- Near-net shape part manufacturing
The Smart Factory
Dr. Mohamed Abuali, Chief Operating Office, FORCAM
Dr. Mohamed Abuali is responsible for leading and managing the full life cycle of FORCAM’s shop floor technology at discrete manufacturing companies in Automotive, Aerospace, Medical Devices, and Oil & Gas. Mohamed brings 15 years of manufacturing experience specializing in program and project management as well as research and development of advanced shop floor technologies.
Industry 4.0 is a European initiative led by the German government to computerize traditional industries, such as manufacturing, with the goal of achieving the Smart Factory. This presentation will detail the elements of a Smart Factory and how advanced Shop Floor Management technology can be combined with Lean Manufacturing philosophy to pave the path for a Smart Factory. Companies that have adopted shop floor management technology have been able to monitor and increase productivity (measured by Overall Equipment Effectiveness – OEE) of their shop floors by 10 to 50% within the first year. Their return on investment (ROI) was less than 1 Year. With the right tool and proper usage, manufacturers can maximize their ROI and reduce their total cost of ownership (TCO). Through several case studies focusing on Aero&Def, the presentation will cover the necessary technical functions required to build a shop floor management system for a Smart Factory, including integration with the shop floor (machines) through live data collection; bidirectional integration with the Enterprise Resource Planning (ERP) system; and other advanced functions for web-based reporting, visualization and maintenance alerting. It will detail how the resulting performance data can be used to drive a continuous improvement process and a Plan-Do-Check-Act cycle with actions and measures. Several case studies with videos will be presented from global companies in Automotive (Daimler, AUDI Powertrain and Stamping), Automotive Tier Suppliers (BorgWarner), and Aerospace (MTU Aero-Engines, GKN Aerospace).
- What is Industry 4.0 initiative and how does it define a Smart Factory?
- How can manufacturing productivity be optimized in order to meet the requirements of “Smart Factory”?
- How have global discrete manufacturers in Automotive, Aerospace, Machinery, and other industries increased productivity by at least 20% with an ROI < 1 Year?
California Competes Tax Credit Overview and Application Process Workshop
Will Koch, Deputy Director, California Competes Tax Credit Program, California Governor’s Office of Business and Economic Development (GO-Biz)
The California Competes Tax Credit is an income tax credit available to businesses that want to come to California or stay and grow in California. Tax credit agreements are negotiated by GO-Biz and approved by a statutorily created “California Competes Tax Credit Committee,” consisting of the State Treasurer, the Director of the Department of Finance, the Director of GO-Biz, one appointee each by the Speaker of the Assembly and Senate Committee on Rules.
Small, medium, and large businesses are encouraged to attend and receive instructions on how to apply for this tax credit program. The California Competes Program has approximately $200 million in tax credits available during the 2015-16 fiscal year for businesses that want to expand in or relocate to California.
Proper Implementation of Industrial CT Scanning to Reduce Iinspection Costs and get to Production Faster
Jesse Garant, President, JG&A Metrology Center
Jesse Garant is a mechanical engineer with 18 years of management and practical manufacturing experience. In 2009 he founded JG&A Metrology Center and currently serves as president. The company is the only lab in North America solely focused on providing 3D internal part inspection services using Industrial Computed Tomography Equipment.
Manufacturers understand how important it is to acquire an accurate and precise scale of measurement to check their parts to specification and establish conformity with the data. Much of today’s industry and technology relies on accurate measurement. Turning to industrial CT Scanning is a cost effective solution compared to other traditional methods. With Industrial CT you are obtaining a complete and accurate 3D model of the part’s internal and external geometries after scanning. Parts are scanned in a free-state environment, allowing for both external and internal measurements to be made and validated quickly and accurately.
Our presentation will outline an introduction to Industrial CT Scanning, types of analysis available and how you can reduce pre-production inspection costs, we will show examples and outline the benefits of industrial ct scanning.
- What Industrial CT Scanning is and how properly implement it for quality control
- The types of analysis available using Industrial CT Scanning
- How to reduce pre-production inspection costs using Industrial CT Scanning
Maximizing Savings With R&D (Research & Development) Tax Credits
Sean Yearout, R&D Tax Credits Manager, Black Line Group
Sean Yearout is the Director of R&D Tax Incentives for The R&D Credit Company. As a veteran of the Big 4 accounting firms, Sean brings more than fourteen years experience as an R&D tax credit specialist. He has consulted with numerous clients of various sizes (ranging from manufacturing to financial institutions), assisting them in quantifying, documenting, and defending hundreds of millions of dollars in R&D tax credits.
The purpose of our seminar is to educate the manufacturing community on the value of the Research and Development Tax Credits. According to a report from the Office of Tax Policy, approximately $8.3 billion R&D tax credits were claimed in 2008 -corporations such as Apple, Microsoft, Lockheed Martin, and Intel filed 90% of those claims. Unfortunately, due to the various misconceptions of what qualifies, millions of dollars in R&D credits go unclaimed annually. Our seminar will provide valuable education that will help businesses of all sizes have a better understanding of these lucrative tax credits, and help address many misconceptions that exist with these tax credits.
- The value of R&D Tax Credits for U.S. manufacturers
- Identifying manufacturing activities that are eligible for R&D Tax
- New developments with both the Federal and State R&D programs
- Making these tax credits more accessible to businesses
- The process of claiming R&D Tax Credits, and the documentation
- Requirements to substantiate the credits