title: glsv exhaust systems overview · • (1) welder certified in mig sst (horizontal) • (1)...

906.482.7535 www.glsv.com This entire document and its attachments are subject to the restrictions stated in the proprietary notice.

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Title: GLSV Exhaust Systems Overview

Great Lakes Sound and Vibration (GLSV) Inc.Greg Kangas

12/21/2015

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Proprietary Notice

• PROPRIETARY WARNINGAll data, illustrations, photos, and information contained in this presentation and communication is considered proprietary to Great Lakes Sound & Vibration Inc (Hereafter GLSV). Information contained herein shall be held in strict confidence. Furthermore, it shall not be distributed or disseminated to any third parties without written consent from GLSV.


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Exhaust Background

• GLSV specializes in the design and fabrication of prototype and low volume metal custom engineered exhaust systems for both Military and Commercial applications for 20+ yrs.

• Utilizing its extensive background in NVH and customized fabrication, GLSV has become a leader in producing robust, cost-effective solutions for its partners

• GLSV exhaust systems are analyzed and engineered to excel in the most demanding environmental conditions known


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Exhaust System Development

• GLSV supports vehicle prime contractors with executing exhaust system development for various defense ground vehicles

• GLSV provides a wide range of exhaust system solutions, including:– Tuned modular exhaust systems (standard

shapes/features, tuned to performance needs)– Customized exhaust systems (tight space claims,

maximum performance, complex transitions)– Environmental bench testing (shock, vibration,

temperature)


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Exhaust: Development Cycle

Concept Design, Engineering,

Analysis

Performance Testing• Engine power, back

pressure, noise level, skin temperature, thermal growth

Prototype BuildDesign for Manufacturing

Low-Volume Initial Production

Durability Testing• Dyno: 120 hour NATO cycle

• Vibration: MIL-STD-810 Shock: MIL-STD-810

Product Support (engineering, parts)


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Exhaust: Concept Design, Engineering, Analysis

Structural Analysis: Static, Vibration, Shock, Thermal, Burst Pressure

Stress/FatigueDisplacement

Thermal Performance (skin temperatures)

Flow Performance (back pressure)

Acoustic Performance


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Exhaust: Design for Manufacturing & Assembly

Fixtures, inspection procedures, CMM

GD&T (ASME Y14.5-2009) Quality Control (ISO 9001:2008)

Interface control, space claim


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Exhaust: Prototype Manufacturing Examples


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Exhaust: Performance/Durability Testing

Lateral, Longitudinal, Vertical Shock/Vibration per MIL-STD-810G

Engine Dynamometer: Performance and Durability Testing


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Exhaust: Product Support Example

• During LRIP testing, a durability issue with the exhaust system was discovered• GLSV re-design -> prototype build: less than 1 month• GLSV re-design -> resume production schedule: 3 months

– Included determination of root cause, design, qualification analysis, durability testing, prototype, replacement of fielded units, and resumed production schedule


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Exhaust: Fabrication Team Qualifications

• Certified Welding Inspector (CWI) On-Site• (3) Welders Certified in TIG SST (6G)• (3) Welders Certified in TIG Inconel 625 (6G)• (2) Welders Certified in FCAW A36 Structural (3G)• (1) Welder Certified in MIG SST (Horizontal)• (1) Welder Certified in TIG Aluminum (2F)• (1) Welder Certified in TIG Titanium (6G)


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Exhaust: Fabrication Equipment

Fabrication Machinery:– Welders

• (2) Miller Dynasty 350A• (1) Miller Dynasty 300A• (1) Miller 185 MIG• (1) Lincoln 300A Power Mig w/ Aluminum Push-Pull Capability• (2) Lincoln 400A Power Sources with Wire Carts• (1) Miller Portable Spot Welder• (1) SCIAKY 3-Phase Resistance Seam & Spot Welder

– OOT 100 Ton Electro-Hydraulic Press w/ Rubber Extrusion and Molding Capability– 50 Ton Electro-Hydraulic Press– 15 Ton Turn Pro Manual Press– Baileigh 48” Plate Roll– Fan & Box Brake – 48” Width Capacity– CNC Water Jet w/ Plasma Head


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Exhaust: Fabrication Equipment

Fabrication Machinery, continued:– SMT CNC Bender – 3” OD capacity– Ben Pearson Manual Tube Bender w/ Flaring Capability– Ercolina 030 Mega Manual Tube Bender– Proline Planishing Hammer– Parts Tumbler/Polisher – Allsource Part Blaster– Tanner MB Bead Roller– Central Manual Bead Roller– Eastwood English Wheel


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Exhaust: Milling and Bending Equipment

Milling & Miscellaneous Machinery:

– Turning Centers• Mazak SQT 15M-Y Mark II w/ SMW Space Saver Bar Feeder• Mazak SQT 18MS Mark II• Mazak Quick Turn 30N

– Vertical CNC Machining Centers• Hurco BMC 30 HT/Nexus 510C-II• Mazak VTC-20B• Mazak Nexus 510C-II

– Manual Machining (Knee) Mills• Sharp • Enco

– ENCO 13 x 40 Manual Lathe– Clausing OD Grinder– 550° F Industrial Oven – 24” Width x 24” Depth x 15” Tall Capacity


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Exhaust: Materials

• Aluminized Steel• Carbon Steel (including Chromoly)• Stainless (300 & 400 Series)• Titanium• Aluminum (5000 & 6000 Series)• Inconel 625• All Sizes and Shapes

Titanium Exhaust

Titanium Exhaust


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Exhaust: Process Capabilities

• MIG & TIG Welding & Brazing– Including Back Purge & Dead Air Double Wall

• Resistance Welding – Seam & Spot• CNC Waterjet/Plasma Cutting• Tube Bending – CNC & Manual• Draw Forming & Stamping• Painting, Polishing, & Powder Coating• High Temp & Custom Composition Ceramic Coating• Insulation & Heat Wrapping• FARO Arm CMM Inspection System


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Exhaust: Process Capabilities

• Die Design & Manufacturing• Custom Flange Design & Manufacturing• Heat Shield Design & Manufacturing• Fabrication, Assembly, and Installation Fixture Design &

Fabrication• Anodizing (External Operation)• Chroming (External Operation)• Passivation (External Operation)• Laser Cutting (External Operation)

title: glsv exhaust systems overview · • (1) welder certified in mig sst (horizontal) • (1)...

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