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FORGING LOCATOR. WYMAN GORDON. ROCHESTER INSTITUTE OF TECHNOLOGY Multi-Disciplinary Senior Design Team 12556 KEVIN CONWAY (ME, Lead Engineer) MARK GONZALEZ (ME) ROBERT HAGEN (EE) JOE MAJKOWSKI (EE) JORGE VIANA (ISE, Project Manager). WYMAN-GORDON.
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FORGING LOCATOR WYMANGORDON ROCHESTER INSTITUTE OF TECHNOLOGY Multi-Disciplinary Senior Design Team 12556 KEVIN CONWAY (ME, Lead Engineer) MARK GONZALEZ (ME) ROBERT HAGEN (EE) JOE MAJKOWSKI (EE) JORGE VIANA (ISE, Project Manager)
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)
FORGING PROCESS • Parts heated to 1700⁰F-2100⁰F • Die’s lubricated with graphite based lubricant (creating smoky environment) • Operators have roughly 60 seconds to position forging • Positioning into die done by judgment/experience by forklift/on-floor operators • Inaccurate positioning leads to roughly 1 million dollars in strikeovers and scrapped metal.
CUSTOMER NECESSITY Problem: • Majority of the workforce is getting ready to retire (Silver Wave) • Current Technique = Art form (visual senses) • Lack of Knowledge Transfer • Process is currently less systematic • Leads to $1M in scrap and rework Solution: • Precisions sensory system (Forging Locator)
CUSTOMER REQUIREMENTS • Measure position of pre-form forgings within dies • Accurate to 500 thousandths (inches) • Compare measurements to an ideal position • Communicate forging position relative to ideal position • Communicate necessary corrections to the operator/supervisor • Catalog forging location electronically • Reference forging job number • Withstand environmental factors • Water, Lubricants, Heat, Impact • Minimal physical and visual interference with operators and forklift drivers • Dynamic/real time feedback throughout process
ASSUMPTIONS & CONSTRAINTS Assumptions • Components will be exposed to water, oil, heat, accidental hits • GUI does not have to work within current program implemented • Designed for simple geometry, taking complex geometry into account • Outlet power locally available for equipment Constraints • Work Area : Close proximity or isolated • Accuracy of sensors in locating pre-forms • Limited interaction with forging faculty