INTELLIGENT TOOLING

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INTELLIGENT TOOLING

• Team 99.08
• Joseph Staley Jeffrey Roushey
• Glenn Gardner Andrew Graybill

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Design Concept Review

• Background - Mission - Approach
• Customers - Wants - Constraints
• Benchmarking
• Quality Metrics - Target Values
• Concept Generation
• Concept Selection
• Schedule - Budget

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Background

• What is Metal Foam?
• How is it Produced?
• Why Use Metal Foam?

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Project Summary

• Mission
• To develop a sensor system that will signal the
  completion of the metal foaming process inside a
  mold.
• Approach
• By working together as a team, making use of the
  customers resources, and performing extensive
  research we will provide the best possible sensor
  system design for our problem.

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Customers - Wants - Constraints
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Customers - Wants - Constraints
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System Benchmarking

• Die Casting / Injection Molding
• general process, sensors
• High Temperature Monitoring
• high temperature materials (Macor)
• data acquisition
• Materials Level Monitoring
• sensors

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Functional Benchmarking

• Electrical Properties Sensors
• Piezo-electric Transducer
• Thermocouple
• Optical Fiber
• Eddy Current Detector

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Target Values
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Critical Functions

• Sense metal foaming process completion
• Attenuate/Amplify the sensor output signal
• Channel signal(s) into data acquisition card
• Use LabVIEW software to interpret signals and
  alert user that the process is complete

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Concept Generation

• Electrical Circuit Completion
• Piezo-Electric Force Sensor
• Thermocouple Array
• Optical Fiber
• Eddy Current Position Sensor

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Concept Selection Method
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Concept Selection
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Conductivity Testing at Room Temperature
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Conductivity Testing at 700 C
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Schedule - Fall 98
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Schedule - Spring 99
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Estimated Budget
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Future Direction

• Winter Break - Build Concept
• February - Testing and Design Iterations
• March - Cushion Period
• April - Final Report Preparation