Innovation, research and technology development from the point of view of engine manufacturer Rolls-Royce

This paper describes the application of advanced manufacturing technologies in producing aero engine components. The key focus of this research lies on the design and the manufacturing process of functionally integrated low cost and lightweight aero engine components. Advanced manufacturing technologies reduce the number of processing steps to achieve higher material utilisation compared to alternative methods of manufacturing. The research conducted under the collaborative framework of Fraunhofer Institute for Machine Tools and Forming Technology IWU and Rolls-Royce resulted innovative forming process chains as opposed to traditional manufacturing routes in producing a bevel gear shaft. The alternative forming process chains clearly simplified the method of manufacturing and reduced the cost of the bevel gear shaft component. Further, these forming process chains were investigated and validated using process modelling techniques for future manufacturability of pre-production components.