Shaped Plate Verification March 12-14, 2019 Charleston, SC DCN# 43-5040-19 This material is based upon work supported by the Center of Naval Metalworking under Contract No. 2017-508-002. DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

Agenda Problem/Issue Project Goals/Objectives Project Team Current Practice for Line Heating Project Schedule at a Glance Process Flow Requirements Development Accomplishments Path Forward Q&A

Problem/Issue Verifying plate geometries is a manual process requiring highly skilled labor to effectively execute. There are currently no readily available COTS solutions to: Automate or semi-automate plate shaping and verifying plate geometry. Automate or semi-automate the alignment and verification process for setting shell plates and maintaining the required geometry while stiffeners are attached. Large heavy plates with complex 2-D and 3-D shapes that require tooling, and/or fixtures and processes to quickly and accurately locate and monitor these plates.

Project Goals/Objectives Reduce the manual labor in shaping shell plates. Provide a robust method enabling rapid positioning and alignment of shell plates on fixtures. Provide the capability for in-process verification of each shaped plate in both the Fabrication Shop and Shell Shop. Supporting Information This will be enabled through the development of an automated or semi- automated system and processes to form shell plates in the Fabrication Shop and verify the geometry of the as-built plates as compared to design data. In addition, tooling and/or fixtures will be developed to set, align and fabricate shell plates and shell plate assemblies in the Shell Shop. These fixtures will have the ability to check and monitor the as-built shape geometry and quickly and accurately determine any out of tolerance conditions.

Project Team

Current Shipyard Practice Modern Shipbuilding employs traditional forming technologies (e.g. press bending and line heating) that are labor intensive and heavily dependent on the experience of only several craft workers. There is no model-based guidance given on how to accurately achieve the final design shape in a timely fashion. Current state: Plate shaping with flame heating

Shaped Plate in Shipbuilding

Project Schedule at a Glance Phase I Process Baseline Oct 2018 – April 2019 Concept Development Oct 2018 – Oct 2019 Go-No Go Decision Oct 2019 Phase II Prototype Development Oct 2019 – Aug 2020 Automated Line Heating/ Aug 2020 – Sep 2020 Plate Shaping Pilot Final Report Nov 2020

Phase I – Shaped Plate Process Flow Engineering Design Planning Develops Plan Material Is Delivered Fabrication Shape Validation Joining Engineering ensures geometry and develops drawing necessary for fabrication Planning ensures all materials are identified and plans the work accordingly Production Control obtains and delivers required materials Craft fabricates shape per design and direction Accuracy Control verifies as built matches as designed This craft is an art…… Shapes are joined to larger structures

Phase I – Requirements Development Currently In Process Preliminary Data Mining Additional Development Required

Accomplishments Activities Deliverables Current Process Maps 1/18/2019 Complete Deliverables Kickoff Meeting/Report 11/25/2018 Complete Quarterly Status Report #1 1/15/2019 Complete Baseline Process Report 3/4/2019 Complete

Accomplishments – Hardware Market Survey The First Automatic Thermal Forming System (IHI-α) In 1997, IHI developed the first automatic thermal forming system with induction heating. “IHI-α” was applied to the forming of curved shell plates on Very Large Crude Carriers (VLCC), and container ships. Tango, Ishiyama, and Suzuki, IHI Engineering Review, 2011

Iterative Thermal Plate Forming (Software) Accomplishments – Software Market Survey Iterative Thermal Plate Forming (Software) Automatic thermal forming system formed a plate iteratively, which is similar to the manual practice in current Ingalls shipyard. Similarity change with respect to the iteration number Iterative forming process Park et al. International journal of computed integrated manufacturing, 2016

Automated Forming Path Forward Next Steps Current Activities Concept Development Prototype Development Automated Line Heating/Plate Shaping Pilot Shaped Plate Verification Current Activities Plate Shaping Requirements Market Survey Deliverables Requirements Report 3/25/2019 Quarterly Status Report #2 4/15/2019 Market Survey Report 6/20/2019

Questions??