WYMAN
GORDON
FORGING
LOCATOR
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)
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
1. Billets are heated to 1700⁰F-2100⁰F.
2. Dies 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





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
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
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
ENGINEERING SPECIFICATIONS
Wyman Gordon Engineering Specifcations
Spec ID
Importance
Cust. ID
Specification Description
Unit of Measure
Value
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
Power Requirement
W
<1650
8
Comments
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, adjustments
12
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
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
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
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
DESIGN SUMMARY
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
SOFTWARE
Length Thickness
Computed from
Distances 2 and 4
Width Thickness
Computed from
Distances 1 and 3
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