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Research from the Sheffield Department of Mechanical Engineering has led to major improvements in engineering analysis and design software for aerospace companies such as Rolls-Royce and Airbus. As a result of introducing new practices based on our research, the organisations have reported significantly reduced time input to design components as well as related economic benefits. For example: Rolls-Royce has reported an order of magnitude improvement in the time needed to mesh components. Similarly, by adopting our highly efficient computational aerodynamics solvers, Defence Science & Technology Laboratory has reduced the time its engineers spent evaluating concepts from many days to a few hours.
Cost savings in the order of £130M over the REF period have been achieved by Rolls-Royce through the improvement of engine reliability of civil and military aero-engines, industrial machines used for electricity generation and gas/oil pumping applications through the use of techniques and processes developed by the Vibration University Technology Centre (UTC) at Imperial College London.
University of Huddersfield research into the optimal design of flow-handling systems has been credited with "transforming" the development strategies and global market sales of an industrial partner. Weir Valves and Control Ltd has enjoyed a 75% saving in design lead time and a 1,800% increase in annual sales - from several thousand before its collaboration to millions in 2013 - through the structured integration of researchers' computational fluid dynamics expertise in its design process. The success of this collaboration, which has been described as an exemplar of a Knowledge Transfer Partnership, has also led to further research contracts.
Research at GCU led to a novel method for backfilling pipeline tunnels providing the ability to fill tunnels three times more quickly than the traditional method resulting in a cost saving of £1.5M on a single project. This approach is now best practice at Murphy Pipelines Ltd (MPL) and features in current tenders to a value of £30M. The change in fill material lowered the carbon footprint by 5000 tonnes in a CEEQUAL award winning project, in addition, the removable fill material allows the recycling and re-use of tunnels, adding to the assets of the company and reducing costs.
The largest investment banks in London each have thousands of servers largely devoted to Monte Carlo simulations, and to quantify their risks and satisfy regulatory demands they need to be able to calculate huge numbers of sensitivities (defined below) known collectively as "Greeks". An adjoint technique developed by Professor Mike Giles in 2006 greatly reduced the computational complexity of these calculations. The technique is used extensively by Credit Suisse and other major banks, reducing their computing costs and energy consumption. It has also led to the Numerical Algorithms Group developing new software to support the banks in exploiting this new adjoint approach to computing sensitivities.
Research in the University of Cambridge Department of Engineering (DoEng), which made it possible for the first time to design a 3D compressor blade as a single component, underpinned the design of compressors in Rolls-Royce civil aero engines. Blades designed using the research results yielded fuel efficiency improvements of 0.8% when deployed in Rolls-Royce Trent engines. The efficiency improvements in engines in service are estimated to have delivered savings of 460k tonnes in CO2 emissions and USD 145 million in fuel costs during the assessment period. Rolls- Royce's outstanding order book for engines in which the technology made a significant contribution to efficiency is estimated to be worth GBP 27 billion at list prices as at 31 July 2013; orders received during the assessment period are estimated to be worth GBP 18 billion at list prices.
Graph-theoretic and mathematically rigorous algorithmic methods developed at the University of Hertfordshire have improved the applicability of compiler technology and parallel processing. A compiler developed in the course of a ten-year research programme at the university has been successfully applied to a number of commercial problems by re-purposing the research tool. NAG Ltd has adapted the tool into a commercial product [text removed for publication]. Numerous applications of the mathematical methods (such as type-flow graphs used conjointly for correctness and optimisation) have been deployed by industry (including SAP, SCCH, German Waterways Board) working closely with the university.
Our flow modelling and process optimisation research has improved significantly the scientific understanding of key industrial coating, printing and droplet flow systems. We have implemented our research findings in software tools for staff training and process optimisation which have enabled: (i) the worldwide coating industry to improve the productivity and sustainability of their manufacturing processes; (ii) [text removed for publication]; (iii) a major automotive supply company to develop an award-winning droplet filtration system for diesel engines. [text removed for publication].
Many of the top supercomputers use Graphical Processing Units (GPUs) to accelerate scientific computing applications with less energy consumption and lower overall cost. GPUs achieve this by having comparatively large numbers of simple processing elements when compared against CPUs, which have fewer, more sophisticated, elements. However, to take full advantage of GPUs requires quite different algorithms and implementation techniques for mathematical software libraries. Researchers at the University of Oxford have developed a number of such algorithms and implementation techniques over the period 2008-2013, which have been incorporated into software libraries distributed by NAG, NVIDIA and the Apache Foundation and have enhanced the performance up to 150x compared with single thread CPU calculations and 20x relative to multithreaded CPU calculations. These libraries are used by large numbers of application developers worldwide.
This impact is the improvement of aircraft engine efficiency by the application of profiled endwalls to turbine blades. The technology was researched by Durham University and exploited by Rolls-Royce by deploying the technology on airframes. Engines with profiled endwalls include the Trent 900 (A380 airframe), Trent 1000 (787 Airframe) and Trent XWB (A350 airframe). This (as of April 2013) totals around 2000 aircraft engine orders with profiled endwall technology applied. A saving of 1750 litres of fuel per flight from Zurich to Singapore was estimated when profiled endwalls are applied. This gives a 4400 kg reduction in carbon dioxide emissions for such a journey with a fuel cost saving of over $1100. In addition to the environmental benefit and the obvious cash savings for airlines an economic benefit for UK industry has arisen as Rolls-Royce is able to sell engines with a reduced fuel burn as well.