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Dr Richard Brooks and his team at the University of Nottingham have been investigating the high strain rate behaviour of composite materials since 2003. This has led to the development of two products that are being installed in streets in the UK and Ireland by East Midlands SME Frangible Safety Posts Ltd. The direct benefits to the company have been: the installation of 900 products in the UK and Ireland; saving of £17k capital cost and 2 months in terms of time to market per product developed and; raising of £1.8M investment to bring the products to market At least one life has already been saved in the Shetland Islands as a direct consequence of the product behaving in the way it was designed to.
This case study describes the international impact of research in the computer modelling and simulation of automotive and aerospace crashes, undertaken by Professor Blundell. The main impacts arising from the research can be summarised as:
Economic impact and impact on passenger safety: i) our research has led to improvements in the MADYMO software suite, the `industry standard' software for safety design and virtual crash testing, which is produced by TNO Automotive Safety Solutions (TASS) and sold to all the main equipment manufacturers in the automotive and aerospace sectors ii) our research has reduced the costs of these equipment manufacturers, who can simulate a crash rather than undertake expensive, physical, crash tests iii) by improving MADYMO, our research has had an impact on passengers who are now travelling in cars and aircraft which safer as a result of MADYNO's enhanced capabilities.
Impact on practitioners and professional services: through working with Blundell and his group, Autoflug GmbH has learned how to incorporate advanced simulation into its product development process. The work has also transferred practices from the automotive sector into aviation. Blundell's research has helped to introduce manufacturers and European regulators to new methods to design safety systems to helicopters, an area previously underdeveloped as an area in aviation occupant crash protection.
Beneficiaries include Autoflug GmbH, TASS and its customers, and European aviation regulators.
Research at the University of Bradford has enabled many major vehicle and brake manufacturers to improve the design of their brakes and braking systems to increase customer satisfaction and sales, and reduce costs. Methods have been developed to predict the thermo-mechanical and dynamic performance of brakes and provide design improvements. Durable solutions have been developed for noisy brakes, which have reduced warranty costs for approximately ten international collaborating companies including Bentley, where a squeal noise from the front brakes of a new vehicle had prevented it from being released for production. Our research has been embedded into short courses, which have trained over 250 engineers since 2008 and is incorporated into Jaguar Land Rover's (JLR) professional training.
Impact on industry, academia and government institutions from engineering materials research in the Mechanical Engineering department has been delivered through it directly leading to UK, USA and International Standards and Codes relating to three themes:
The results of the research of staff in this unit have led directly to UK, US and International Standards and Codes: ASTM Standards E1457-07 (2012) and E2760-10 (2012); R5 EDF Energy Code of Practice (2012); BS 7910 (2013); ISO 25217 (2009); ISO CD 15114 (2011) and ISO 13477 (2008). These documents all cite peer-reviewed publications by staff from this unit. These Standards and Codes are now the basis of fracture-mechanics methodologies used by leading engineering companies like Airbus, EDF, E.ON, GKN, Rolls-Royce and Vestas, whose commercial success depends upon technological leadership. In this way our research has led to savings by UK industry of many millions of pounds, as detailed in Section 4.
For aerospace vehicles, the development of new materials and structural configurations are key tools in the relentless drive to reduce weight and increase performance (in terms of, for example, speed and flight characteristics). The economic drivers are clear — it is widely recognised that it is worth approximately $10k to save one pound of weight in a spacecraft per launch and $500 per pound for an aircraft over its lifetime. The environmental drivers (ACARE 2050) are also clear — reduced aircraft weight leads to lower fuel burn and, in turn, to lower CO2 and NOx emissions. With such high cost-to-weight ratios, there is intense industrial interest in the development of new structural configurations/concepts and enhanced structural models that allow better use of existing or new materials. Analytical structural mechanics models of novel anisotropic structures, developed at the University's Advanced Composites Centre for Innovation and Science (ACCIS), are now used in the industrial design of aircraft and spacecraft. Based on this research, a new, unique anisotropic composite blade, designed to meet an Urgent Operational Requirement for the MoD, is now flying on AgustaWestland EH101 helicopters that are deployed in Theatre. In addition, the new modelling tools and techniques have been adopted by Airbus, AgustaWestland, Cassidian and NASA and incorporated into LUSAS's finite element analysis software. These tools have, for example, been used to inform Airbus's decision to use a largely aluminium wing design rather than a hybrid CFRP/aluminium wing for the A380.
As a direct result of University of Glasgow research, there have been no deaths in a gyroplane accident in the UK since 2009. Previously, gyroplanes (also known as autogyros) had a questionable safety record. Following fifteen years of comprehensive studies, researchers recommended innovative new design standards to the Civil Aviation Authority. These recommendations led to the introduction of new civil airworthiness requirements in the UK, subsequently adopted by Australia and Canada. The implementation of these revised regulations has forced gyroplane manufacturers to change their designs. Close to 2000 machines have been produced since this design change, revolutionising gyroplane safety worldwide.
HDM-4 is the most widely used system for road investment appraisal and decision making, generating improvements in public policies and services. Economic development and road agencies in developing countries are major users of the tool. HDM-4 has become the de facto standard used by the World Bank for its road investment appraisals and has been used to assess more than 200 projects since 2008, with some $29.5bn of World Bank loans, credits or grants drawn-down to fund these. Uptake of the tool has led to the commercial success of HDMGlobal, a consortium which manages the distribution and development of the software under exclusive licence from the World Road Association-PIARC, with revenues of £1.6m generated since 2008. HDM-4 has also been utilised for economic assessment and road systems investment management in the UK.
The research produced accurate simulation models of piezoelectric actuators for investigating sensitivities to parameter variations that led to maximum power for minimum electric field. This was the basis of design rules for determining new products at the industrial partner NXT, now named Hi-Wave Technology, headquartered in Cambourne, UK. Old design rules had led to two failed products whereas these new design rules have guided successful products with a major Japanese television manufacturer, a Japanese printer company and a Russian mobile phone company. Without this research Hi-Wave would have stopped activities in this technology. To date, licences for more than 24 million units per annum have been sold and more than 280,000 units manufactured.
The A350-XWB is the first Airbus airliner to have composite wings, thereby reducing structural weight compared with the current generation of metallic wings. With over 700 orders for the aircraft, the company has placed great emphasis on the need to maximise performance benefits whilst mitigating risk associated with manufacture of the all-new wing. The Bath Composites Research Unit has supplied underpinning research to:
(1) Develop an algorithm that has been used to design the composite wing skins for optimised performance;
(2) Analyse the laminate consolidation process for the wing spars.
The impact of (1) is a direct saving of 1.0 tonne of fuel per typical flight compared with current metallic skins. This represents a total fuel saving of around 40,000 tonnes, over the design life of each aircraft. The impact of (2) is the achievement of satisfactory part quality for current production rates of spars valued at £1M each when equipped.
Using powertrain system models arising from QUB research Wrightbus Ltd developed an advanced eco-friendly hybrid diesel-electric bus which won the New Bus for London contract worth £230M supplying 600 buses to Transport for London (commencing August 2012).
Demonstrating highly significant economic and environmental impacts the bus has twice the fuel economy of a standard diesel and emits less than half the CO2 and NOx. The full fleet reduces annual CO2 emissions in London by 230,000 tonnes, improving air quality and reducing greenhouse gases.
The company continues to develop the technology in new hybrid vehicles reaching worldwide, including USA, Hong Kong, Singapore and China.