WYMAN GORDON ROCHESTER INSTITUTE OF TECHNOLOGY Multi-Disciplinary Senior Design Team KEVIN CONWAY (ME, Lead Engineer) MARK GONZALEZ (ME) ROBERT HAGEN (EE) JOE MAJKOWSKI (EE) JORGE VIANA (ISE, Project Manager) FORGIN G LOCATO R

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)

 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 Management JORGE Planning Agenda Document Control Prepare Reports Supplier Relations Budget Control Mechanical Aspects MARK/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 Aspects JOE/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