WYMANGORDON

ROCHESTER INSTITUTE OF TECHNOLOGYMulti-Disciplinary Senior Design Team 12556KEVIN CONWAY (ME, Lead Engineer)MARK GONZALEZ (ME)ROBERT HAGEN (EE)JOE MAJKOWSKI (EE)JORGE VIANA (ISE, Project Manager)

FORGING LOCATOR

MSD Final Presentation

WYMAN-GORDON•Global leader in manufacturing of titanium, steel and nickel–based forgings.

• 50,000 ton press National Historic Mechanical Landmark

• 3 Primary Markets Aerospace ( Landing Gear/ Airframe structures) Energy (Various Turbine Engines and components) Military (Airframe structures / Vehicle Armor)

1. Billets are heated to 1700 F-2100 F⁰ ⁰ .2. Dies are lubricated with graphite based lubricant

(sometimes a non-stick paper).3. Forklifts transfer the hot billets from the oven to the dye.4. Workers with crowbars have roughly 60 seconds to

position the hot forging within the dye.5. The operator gets the go-ahead from the workers, the press

closes and the billet is forged.6. The press opens, workers blast the dye with compressed

air clearing the debris into the exhaust fans.7. The forged billet is removed and the process starts all over

again.

FORGING PROCESS

Hot• Impression-die < 900oF• Billets < 2100oF

Flames and Smoke• Graphite based lubricant ignites

Flying Debris• Debris is blown out of the dye using compressed air• Debris is sucked into the exhaust fans

Dirty and Dusty• Dust had encapsulated the entire forging building due to the

grinders High impact

• Large forklifts• Worker with crowbars

ENVIRONMENT

• Problem:• Current Billet Positioning Technique:

• Visual Judgment = Art Form

• Majority of the workforce is getting ready to retire.• Lack of a medium for knowledge transfer• Process is currently less systematic

• Leads to $1M in scrap and rework

• Solution:• Sensor Positioning System

CUSTOMER NECESSITY

Position the billet within + 0.25” of a predetermined position within the die.

Communicate: Position relative to the ideal position Necessary corrections

Catalog position electronically in reference to the part and job number.

Withstand the harsh environment. Minimal physical and visual interference with

operators and forklift drivers Dynamic/real time feedback throughout process

CUSTOMER REQUIREMENTS

ENGINEERING SPECIFICATIONS

Wyman Gordon Engineering Specifcations

Spec ID Importance Cust. ID Specification Description Unit of Measure Value Comments 1 C1,C3 Position Resolution mm <0.635 2 C2,C8 Sensor Speed sec 0.1 3 C1,C2 Sensor Range m 5 4 C6,C10 Impact Resistance tons 5 5 C6,C7,C10 temperature resistance F 600 6 C11 sensor cost Dollars 3000 7 C4,C12 Display visability m 5 8 Power Requirement W <1650 9 C6 Foreign Body Protection, Solid Index 6 Based on IP ratings (Dustproof)

10 C6 Foreign Body Protection, Liquid Index 5 Based on IP ratings (Hose Down, residential )11 C6,C7,C12 Equipment Interaction % <10% Setup time, adjustments12 C5,C12 Data Storage Logical 1

CONCEPT SUMMARY• Six, Time-Of-Flight sensors were chosen due

to the relatively lower cost and functionality on hot materials.

• Insulation and slide closed lids were chosen due to their ease of implementation and superb ability to keep the sensors safe and dry.

• Simple arrow displays were chosen due to the limitations of signals and logic being broadcast by the laser.

SYSTEM ARCHITECTURE

• 3 Major Components Computer Lasers Display

• Computer will be used for data storage and laser interface

• Laser will be used in order to interface with display

Laser Enclosure:• High Temperature

insulation for fire and heat protection

• View Hole for Sensor Optics

• Slide to close when not in use to protect from oil, water and debris

DESIGN SUMMARY

Bracketing System:• Height adjustment for

varying size pieces• Slide function to allow

for various positions to be measured

• Magnetic support to hold in place

DESIGN SUMMARY

FEA of Bracketing System:• Analyzed in order to ensure stability• Will not break or bend under weight of

equipment being supported.

DESIGN SUMMARY

Total System Layout:• System incorporates a mirror to allow for forklift to lower

in billet with small chance of system failure

DESIGN SUMMARY

ILR-1181 Laser Distance Sensor:•Resolution of .1mm•Measuring Range of up to 80m

•Repeatability ≤ .5mm•Alarm line and software included

DESIGN SUMMARY

DESIGN SUMMARYDisplay:

• When an alarm line is low, circuitry in respective arrow is triggered turning on red LEDs (indicating direction needed to move)

• All alarms lines being high, triggers green LED circuitry to turn on center circle giving the go ahead to operators

• 2 different types of circuit boards needed

PCB Board:• Board is utilized to control

the directional display• Utilizes alarm line logic of

16 or 24V signal as inputs

DESIGN SUMMARY

P-Spice Simulation:• Verified circuits drew as much current as

expected.

DESIGN SUMMARY

Custom Harnessing:• Decreases bulk of the system• Allows for more rugged wire to be utilized• More adjustable to customer needs

DESIGN SUMMARY

DESIGN SUMMARY

Netbook:• Utilized in order to

allow for interaction between lasers

• Program to zero lasers and record the distances before pressing

DESIGN SUMMARY

SOFTWARE

Width Thickness Computed from Distances 1 and 3

Length Thickness Computed from Distances 2 and 4

SUCCESS

• Defining and understanding the core objectives and customer’s needs

• Designing a system concept around the customer’s capabilities

• Coming under budget:• Approved Budget: $19,188.91• Final Expense: $18,773.38

• Integrating an electro-mechanical system• Creating a baseline for future development

REFLECTIONS• Visited the customer earlier

• Given the customer more knowledge of the MSD Course:• Time constraints/investments

• Guidelines

• Objectives

• Deliverables

• Been more open to an increased budget to save time

• Updated the customer more frequently on:• Scheduling

• Design concepts

• Design decisions

• Progress

RECOMMENDATIONS

• Pay attention to the customer’s needs:• Better define what the needs are and ask Why?• Document the customer’s needs• Directly correlate the needs to the design solutions

• Communicate effectively with the customer and within the team

• Definitions and Linguistics• Update the customer and the team of the progress and ideas on

a consistent basis• Time management

CONCLUSION

• Research, Design and Development is a highly detailed process

• The more time invested in planning and preliminary customer assessments for needs the less likely the process evolves into a trial and error procedure