Recent projects undertaken by CRDM/ALMC

KnowEDM

KnowEDM was launched in 2006 to improve the competitiveness of the European tool making and precision engineering sector. The project was an EU funded Collective Research programme under Framework 6. Its objectives were to automate EDM technology in both improving the accuracy of EDM time estimation and to generate all the necessary EDM electrodes quickly and with no human intervention. Finally, the data generated had to be integrated into the rest of the toolmaking process.

CRDM had a pivotal role in this project. Its work programme was to simulate the milling process in 3 dimensions; any remaining material had to be removed by EDM so knowing what could be machined was paramount. There had been many attempts to simulate the milling process in 3D but these took hours to run and would only work for relatively simple geometries. CRDM developed an algorithm that could accurately simulate the milling process in a few minutes irrespective of geometry, as well as generate the shape of the necessary EDM electrodes. With this knowledge, the project partners were able to generate EDM time estimates and prepare toolpaths for the automatic machining of the generated electrodes. Finally, the whole output was integrated into the toolmaking cycle, which included an important tool revue package.

The KnowEDM partnership comprised five trade associations, four research establishments and 39 SME's from six European countries.

CRDM was able to successfully complete its objectives within the timescale of the project and within budget.

Additive layer manufacture of critical performance components in light-weight aluminium alloys (ALMA)

A consortium of five industrial partners and the Department of Materials - Oxford University, led by CRDM Ltd. has been awarded the ALMA project by the Technology Strategy Board under its High Value Manufacturing Supplementary Competition The aim of this one year project is to create a high value manufacturing technology that will eliminate technical and cost constraints on the development and commercialisation of innovative heat dissipators, heat exchangers and heat engines. Target applications embrace the electronics, avionics and carbon-saving energy sectors.  

The ALMA Project aimed to develop the application of additive layer manufacturing (ALM) to aluminium-high silicon alloys that are light and cheap, with high thermal conduction coefficients, and coefficients of thermal expansion that can be adjusted by altering the proportion of silicon in the alloy. 

The programme was completed in January 2011. After many development trials, some sucessful small components were built by ALM, demonstrating the capability of the process. However, larger objects were subject to distortion as a result of the thermal strains induced. Much of the programme comprised of attempts to control these stresses. The ALMA programme gave some important insights into the issues in processing by ALM, high thermal conductivity and eutectic materials.