WYMAN GORDON

1. FORGING LOCATOR WYMANGORDON • MSD Final Presentation 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)

2. 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)

3. FORGING PROCESS • Billets are heated to 1700⁰F-2100⁰F. • Dies are lubricated with graphite based lubricant (sometimes a non-stick paper). • Forklifts transfer the hot billets from the oven to the dye. • Workers with crowbars have roughly 60 seconds to position the hot forging within the dye. • The operator gets the go-ahead from the workers, the press closes and the billet is forged. • The press opens, workers blast the dye with compressed air clearing the debris into the exhaust fans. • The forged billet is removed and the process starts all over again.

4. ENVIRONMENT • 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

5. CUSTOMER NECESSITY • 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

6. CUSTOMER REQUIREMENTS • 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

7. ENGINEERING SPECIFICATIONS

8. 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.

9. 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

10. DESIGN SUMMARY 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

11. 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

12. DESIGN SUMMARY FEA of Bracketing System: • Analyzed in order to ensure stability • Will not break or bend under weight of equipment being supported.

13. DESIGN SUMMARY Total System Layout: • System incorporates a mirror to allow for forklift to lower in billet with small chance of system failure

14. DESIGN SUMMARY ILR-1181 Laser Distance Sensor: • Resolution of .1mm • Measuring Range of up to 80m • Repeatability ≤ .5mm • Alarm line and software included

15. DESIGN SUMMARY Display: • 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

16. DESIGN SUMMARY PCB Board: • Board is utilized to control the directional display • Utilizes alarm line logic of 16 or 24V signal as inputs

17. DESIGN SUMMARY P-Spice Simulation: • Verified circuits drew as much current as expected.

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

19. DESIGN SUMMARY

20. DESIGN SUMMARY Netbook: • Utilized in order to allow for interaction between lasers • Program to zero lasers and record the distances before pressing

21. SOFTWARE Length Thickness Computed from Distances 2 and 4 Width Thickness Computed from Distances 1 and 3

22. 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

23. 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

24. 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

25. 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