1. INTELLIGENT TOOLING

2. Progress Review Introduction Updated Customers/Wants/Constraints Metrics Benchmarking Concept Evaluation Schedule

3. Project Summary

4. Background Powder Metallurgy Semi-finished product Metal working Foaming Material Properties

5. Problem Description Over-aging Technicians rely upon experience Material waste Molding defects

6. Customers Fraunhofer Resource Center, DE Automotive Industry Aerospace Industry Building Industry

7. Prioritized Wants 1) High Percentage of Successful Foams 2) System Reliability 3) Simplicity of System 4) Low Cost

8. Constraints Operating Temperature - 1400 C Oven Size Cost - $8000 LabVIEW Interface

9. Metrics

10. System Benchmarking High Speed Temperature and Process Signal Measurement System Bricesco Pyrotrace Material Level Monitoring System Die Casting Injection Molding

11. Temperature & Process Signal Measurement System System Includes: - Sensors - “Black Box” - Voltage Input - Digital Output - Software and user interface

12. Temperature & Process Signal Measurement System Advantages: - Only one signal altering device - Low setup time - Cost ($2000) Disadvantages: - Interface is not LabVIEW

13. Bricesco Pyrotrace Designed for kilns Monitors temperature Presents data in graphs Uses a software package called Pyrographics

14. Bricesco Pyrotrace Advantages according to Metrics –Small # of signal alterations - 0 –Max operating temperature - 1350 C –Programming time Disadvantages according to Metrics –Set up time - thermocouple attachment –Cost - High ($6000) –Doesn’t use LabVIEW

15. Functional Benchmarking Sensors Circuit Completion Piezo-electric Transducer Thermocouple Optical Fiber Linear Position

16. Concept Evaluation 1) Electrical Circuit Completion 2) Piezo-electric Transducer

17. Electrical Circuit Completion

18. Electrodes are isolated by ceramic material on side and top of mold. Metal foam rises to touch top electrode Foam acts as a medium to conduct current. Advantages – Simple program to interpret signal –Small size –Low cost - $1000 –Low set-up time Disadvantages –Mold alterations

19. Piezo-electric Transducer

20. One-component quartz force sensor Deformation of sensor disrupts dipole orientation Temporary excess of surface charge seen as a voltage drop across crystal

21. Piezo-electric Transducer Advantages –Small size –Minimum mold alterations Disadvantages –Requires large charge amplifier –Complex programming to interpret signal –High cost - $5000 –Calibration time required

22. Proposal Presentation

23. Preliminary Design and Progress Review

24. November 98 - Spring 99

25. Conclusion Continue research on concept components Work more closely with resources at Fraunhofer Purchase system components before winter break