WYMAN
GORDON
FORGING
LOCATOR
DETAILED DESIGN REVIEW
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)
OUTLINE
I. Introduction of Wyman-Gordon
i.
ii.
iii.
Forging Process
Manufacturing Environment
Customer Necessity & Requirements
II. Detailed Design – Electrical Feasibility
i.
ii.
iii.
iv.
Sensors and System Orientation
Processing System Design
Data Logging System Design
Electrical Display Design
III. Detailed Design – Mechanical Feasibility
i. Sensor System Bracket Design
ii. Sensor Enclosure Design
iii. Display Design
OUTLINE (continued)
IV. Bill of Materials
i.
Mechanical Sub-Systems
a.
b.
c.
ii.
Sensor System Bracket
Sensor Enclosure
Display Enclosure
Electrical Sub-Systems
a.
b.
c.
d.
Sensors
Processing System
Data Logging System
Electrical Display
V. Risk Assessment
VI. Schedule
WYMAN-GORDON
Global leader in manufacturing of titanium,
steel and nickel–based forgings.
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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
1. Billets are heated to 1700⁰F-2100⁰F.
2. Dyes are lubricated with graphite based lubricant
3.
4.
5.
6.
7.
(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.
ENVIRONMENT
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Hot
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Dyes < 900oF
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Billets < 2100oF
Flames and Smoke
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Graphite based lubricant ignites
Flying Debris
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Debris is blown out of the dye using compressed air
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Debris is sucked into the exhaust fans
Dirty and Dusty
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Dust had encapsulated the entire forging building due to the
grinders
High impact
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Large forklifts
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Worker with crowbars
CUSTOMER NECESSITY
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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 REQUIREMENTS
 Position the billet within + 0.25” of a
predetermined position within the dye.
 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
SYSTEM LAYOUT
•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
OPTONCDT ILR1181 LASER DISTANCE SENSOR
Time of flight sensor
Data acquisition and interface software available
RS232 or RS422 serial interfaces
Has been utilized on measuring red hot materials.
Class 2 laser (No eye protection) Red 650 nm
output
Alarm function to supply up to half an amp
Can reference measurement from any point
Measuring Range Black Material .4m - 17m
Resolution .1mm
 Repeatability less than .5 mm
Linearity ±2mm (+15°C … +30°C), ±5mm (+30°C
… +50°C)
TIME OF FLIGHT SENSOR
 Sends out a laser pulse and
measures time to receive the beam
back.
 Theoretically the infrared pulse will
have more power than the noise
floor making it visible to the sensor.
 Word of mouth that this has
worked on materials emitting infrared
noise
 Test plan has been produced to
confirm accuracy of laser on heated
pieces of material.
PROGRAM INTERFACE
PROGRAM INTERFACE
(CONTINUED)
DATA ACQUISITION
• Data exported into column format in
excel.
• File name/path specified in program
• 3 values exported
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Time
Distance
Error
LOGIC SETUP

Set each alarm to trigger High when box is within
spec or too close to the sensor
Logical high for each
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High = 24V Low = 16V
Alarm zones will intersect to within spec (Red zone)
When inside the tolerance zone all four alarms are
logical high, triggering green light indication

When outside tolerance triggers respective arrow
circuit with low signal
Low
Piece
outside zone
High
 When an alarm line is low, circuitry in respective arrow is
triggered turning on red LEDs (indicating direction needed to
move)
DISPLAY
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
ARROW CIRCUIT SIMULATION
 Ground is the signal line
When high circuit essential an open(no current
flow)
When low, voltage differential of 8V creates
current flow of 8.546mA
LEDs have maximum rating of 10mA
LEDs will not be supplied to much current and will
turn on
CIRCLE CIRCUIT SIMULATION

All inputs high, no current to diodes, Power BJT is
on which allows current to flow through the BJT
and the LED's to draw power
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9 Green Diodes, max rating of 20 mA

Resistors set to 330 ohms to limit current.
CIRCLE CIRCUIT SIMULATION
All inputs are low. Current drawn for LEDs is minimal
at 30pA.
CIRCLE CIRCUIT SIMULATION
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Worst case only one input is low.

Circuit still draws small current of 56.6pA

LEDs should not glow with this current.
DISPLAY CIRCUIT PCB
Bottom
Top
Silk Screen
WIRING HARNESS
 RS-422 uses 24/4 shielded wire
Other connections 244AWG
MECHANICAL DESIGN
ENCLOSURE
• Protective housing for Sigma-Epsilon
Sensors
• Thermal insulation is primary function
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Die Temp 700-900 °F
High temperature insulation for use in fire
protection
• Aluminum Housing
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1/8” thick sheet top
¼” Al Block bottom support
Weight: 9.5 lbs.
• External Port for Sensor Harness
• View hole for Sensor Optics
• Air Purge System
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Increase visibility of line-of-sight to environment
Additional cooling of sensor (secondary
function)
ENCLOSURE
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Determine the necessary thermal conductivity
(k-factor) of the insulation (0.875” thk) to
provide acceptable operating temperatures
for the sensor (50°C)
Radiation dominated heat transfer problem
Assumptions:
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qrad = qconv
The bulk temperature for convection was 900 °F (773
K)
h = 15 W/m2*K (free convection of air)
Excluded Forced convection within box
Aluminum outer case
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0.125” thick (0.00317 m)
ɛ = 0.18 , k = 218 W/m*K
Area = 29.44 in2 (0.0189 m2)
Results
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@ 0.875” thk, k = 0.116 W/m*K (0.067 Btu/h-ft-F )
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Chosen Material: k @ 427 °C (900 °F) : 0.115 W/m*K
ENCLOSURE SUPPORT
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Provides Horizontal and Vertical Motion
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Allows sensors to view distinct billet
geometries
Aluminum/Steel Build
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Al blocks, Al Square Tubing, Steel Blocks
Weight: 24 lbs.
Horizontal Travel
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Steel Rail Guide (double track T-slot)
Supports Enclosure & Vertical Adjustment
Fixed w/ Set screw to Rail.
Vertical Adjustment (Telescoping Bars)
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5” Adjustable Height
Height Maintained w/ Set screw (0.375”)
Die Measuring Configuration
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Sensor w/o Telescoping feature
Located lower (rests on Steel Rail Guide)
ENCLOSURE SUPPORT
Exploded View
(CONTINUED)
Die Measuring Configuration
SET SCREW ANALYSIS
• Find necessary pressure applied
from set screw to hold sensor up
• Basic Static Problem w/ friction
• Parameters
• Weight: 14.24 lbs.
• Friction coefficient (Al –Al dry): 1.05
• Area of contact( minimal): 2.625 in2
• Results
• The Set-screws require a maximum of
5.2 psi of pressure to maintain static
equilibrium
RAIL SUPPORT SYSTEM
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Rests on Shoe of Die Press
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Provides horizontal motion to all
sensors
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Length: 4 ft.
Aluminum/Steel Build
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Al Sheet, Al Square Tubing, Steel Block
Weight w/o sensors: 43lbs. ( 88 lbs. in
configure shown)
Magnetic Feet Attachment (not shown)
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Prevents movement before/during/after press
processing
Maintains location for accurate readings
MAGNET HOLD DOWN SUPPORT
STRUCTURE ANALYSIS
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Static Analysis
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Determine if Rail system can support weight of sensors
Results
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Maximum Stress : 123 psi on guide rail (compressive yield stress = 36ksi)
Maximum Strain: 9.1565 microns/in
DISPLAY ENCLOSURE
DISPLAY ENCLOSURE
AIR PURGE SYSTEM
AIR PURGE SYSTEM
AIR PURGE SYSTEM
TEST AND ASSEMBLY PLANS
OSHA REQUIREMENTS
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ILR-1181-30 Time of Flight Sensor manufactured by MircoEpsilon
Class II Laser: described as a low-power visible laser that emits
above Class I levels but at a radiant power not above 1 mW.
Human aversion reaction to bright light will protect a person
Accident data on laser usage have shown that Class II lasers
are normally not considered hazardous from a radiation
standpoint unless illogically used.
Direct exposure on the eye by a beam of laser light should
always be avoided with any laser, no matter how low the
power.
Sensor will be enclosed, so no protection will be needed.
More information:
http://www.osha.gov/dts/osta/otm/otm_iii/otm_iii_6.html
SUMMARY OF HAZARDS
 UV and Near-Infrared (NIR) wavelength
ranges do not apply to Class II Lasers.
 VIS (Visible) wavelength ranges do apply to
Class II Lasers.
 NO fire or diffuse ocular hazards.
 Direct ocular hazards will occur only after
0.25 seconds of being exposed.
BILL OF MATERIAL (BOM)
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Divided in 3 sections: Electrical, Mechanical and
Supplementary Parts.
Consists of Part Description, Part Number,
Manufacturer, Vendor, Unit Price, Quantity, Price,
Lead Time, and Link.
Most vendors authorized by RIT.
Biggest Expense: TOF Sensor by Micro-Epsilon at
$1,840 each ($11,040 total).
Initial Budget of $15,000, flexible according to needs.
Total expenses with a 5% Contingency on the Total
Price: $19,300
RISK ASSESSMENT
MAJOR RISKS
 Lead Times
 Sensors not being adequate for
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customer needs.
Components not interfacing.
Miscommunication with customer.
Failures due to temperature or interference.
Exposure to Water.
Tolerances are not met.
The equipment is not deployable at location.
MILESTONES
-Senior Design Review (Week 5-MSD I)
-Detailed Design Review (Week 10-MSD I)
-Present BOM to Wyman Gordon (Week 10-MSD I)
-Testing TOF Sensor (Week 11-MSD I)
-Purchase Requisitions (Week 1-Week 3 MSD II) à Once Budget is approved.
-Building, Testing and Incorporation of System (Week 4 to Week 8-MSD II)
-Imagine RIT Presentation (Saturday May 5th, 2012)
-Project Review Presentation, Poster Session., and Technical Paper (Week 10-MSD II)
-Visit Wyman Gordon for Installation of System ( Week 10- MSD II)
-Final Project Management Review + Uploading of all documentation (Week 11-MSD II).