1. INTELLIGENT TOOLING Team 99.08 Joseph StaleyJeffrey Roushey Glenn GardnerAndrew Graybill

2. Design Concept Review Background - Mission - Approach Customers - Wants - Constraints Benchmarking Quality Metrics - Target Values Concept Generation Concept Selection Schedule - Budget

3. Background What is Metal Foam? How is it Produced? Why Use Metal Foam?

4. 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 customer’s resources, and performing extensive research we will provide the best possible sensor system design for our problem.

5. Customers - Wants - Constraints

7. System Benchmarking Die Casting / Injection Molding –general process, sensors High Temperature Monitoring –high temperature materials (Macor) –data acquisition Materials Level Monitoring –sensors

8. Functional Benchmarking Electrical Properties Sensors Piezo-electric Transducer Thermocouple Optical Fiber Eddy Current Detector

9. Target Values

10. 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

11. Concept Generation Electrical Circuit Completion Piezo-Electric Force Sensor Thermocouple Array Optical Fiber Eddy Current Position Sensor

12. Concept Selection Method

13. Concept Selection

14. Conductivity Testing at Room Temperature

15. Conductivity Testing at 700 °C

16. Schedule - Fall ‘98

17. Schedule - Spring ‘99

18. Estimated Budget

19. Future Direction Winter Break - Build Concept February - Testing and Design Iterations March - Cushion Period April - Final Report Preparation