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

WYMAN-GORDONGlobal 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)

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.

FORGING PROCESS

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 NECESSITY

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

CUSTOMER REQUIREMENTS

ENGINEERING SPECIFICATIONS

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

ASSUMPTIONS & CONSTRAINTS

FUNCTION TREE

Positioning System

Measure Pre-Form

Locate Preform

Calculate Deviance

Confirm/Deny Alignment

Provide Visual Cue

Record Location Data Save Data

Withstand Environmental

Factors

Resist Water Damage

Resist Lubrication Exposure

Resist Heat Damage

Resist Smoke Exposure

PUGH ANALYSIS

RISK ASSESSMENT

Wyman Gordon Forging Locator

Project ManagementJORGE

Planning

Agenda

Document Control

Prepare Reports

Supplier Relations

Budget Control

Mechanical AspectsMARK/KEVIN

Mechanical Design

CAD Drawings

Develop List of Components

Develop Fabrication Process

Mechanical Analysis

Structural Analysis

Thermal Analysis

Shock Testing

Dust & Water Testing Under IP Standards

Mechanical/Electrical Interface

Incorporation of Cable Clearance

Construct Electronic Support

Electrical AspectsJOE/ROBERT

Microprocessor Coding

Determine Language

Determine Type of Microprocessor

Power Distribution

Determine Number of Sensors

Determine Number of Displays

Determine Cooling Distribution

Electrical Design

Signal/Channel Distribution

WORK BREAKDOWN

SCHEDULE