Design Group: Wei-Yuan Chu Adrian Conrad Thomas Hylton Scott Jean Nicholas Metzger IUPUI Faculty...

Design Group:Wei-Yuan ChuAdrian ConradThomas HyltonScott JeanNicholas Metzger

IUPUI Faculty Advisor:Dr. Jie Chen

Rolls-Royce Advisor:Timothy Fuesting

Establish a Need Identify the Customer Determine Customer Requirements Develop Engineering Specifications Concept Development & Evaluation Design Product Evaluate Product to Specifications Manufacture and Testing Product Release

Rolls-Royce EngineeringTimothy FuestingMary Gambone

Rolls-Royce dry box operatorassemble and safely use fixture to clean airfoils

Rolls-Royce maintenance / tool & dyemaintain / repair system

Manufacturersimple to make parts

Environmentenvironmentally safe / recyclable

Operator Safetyno possible contact with skin

Works as Requiredremoves debris / high pressure (≈4000 psi)

Fits in the space occupied by former system Easy to Use

little operator training required Easy to Assemble Easy to Maintain Simple to Manufacture No Harm to the Environment

recyclable

Provide high pressure water through the handheld spray nozzle

Provide high pressure water through the fixture Fixture Operating Height Under 8” Fixture must be Compact Fixture must have High Backpressure Tolerance Multiple Water Flow Directions Number of Adjustable Features Number of days between maintenance should be

high Corrosion Resistance

Fixture Design allows for securing the airfoil in either inner or outer rod configuration.

Outer Configuration is required for airfoils with obstructed interior passages.

Swiveling quick disconnects provide rotation of the fixture, as well as easy removal.

Water InExisting

Hose and Water Gun

Fixture

Water Out

H24506 Eaton Weatherhead H245 Hose (3/8" ID, 11/16 " OD x 1 ft.)

LL3-S21Hansen Quick Disconnect - Female End Socket

(3/8 Body Size)

LL3-T20 Hansen Quick Disconnect - Male End Plug (3/8 Body Size)

06S-106Eaton Weatherhead Rigid Male Hose End (3/8"

ID, 3/8-18 NPT)

96-100Apollo Stainless Steel Uni-Body Saturn Ball Valve

(3/8' ID, 3/8-18 NPT)

6709Eaton Weatherhead 3-way Multiple Shut-off

Valve (3/8 - 18 NPT)

A.Base plateB.Quick disconnectionparts and rubberpadsC.Slider arborD.Socket rods

connectlarge contact andsmall contact

E. Quickdisconnections

andcontacts

F.Rubber andcontacts

G.Fixed arbor

H.Distance

controller

I.Arbor top andarbor

J.Screws connectarbor and plate

Engineering Targets tested through various methods of analysis.

Each of the engineering targets represented in numerical values.

Each requirement must meet the customers’ standards.

Utilized the modified Bernoulli Equation

Assumptions: Steady Flow, Incompressible, No heattransfer

Results: Fixture inlet pressure: 3,582 psi Spray Gun Outlet Pressure: 3,013 psi

Using the maximum values listed at AZOM for 304 stainless steel of 20% Cr, 0% Mo, and 10% N to calculate the PRE (Pitting Resistance Equivalent)

Corrosion occurs with the breakdown of the protective surface film on the steel commonly caused from exposure to sulfide and chloride ions

Quenching, adding Molybdenum, and Nitrogen to the metal helps prevent corrosion

Consisting of mostly stainless steel components and high pressure connections the design consisted of:• 35 Components

Rolls Royce had most components in house causing a reduced retail price• Approximate Non reduced Total Cost: $

1,918.44

Fixture’s operating height: 4.5”

Designed to function under comfortable operating conditions within the parameters of the dry box.

4.5”

Analysis using ANSYS Workbench

Worst Case Scenario• Maximum Pressure

Uniformly Distributed Force• (4000 psi = 27.579 Mpa)• Perpendicular to Large Contact Faces

Coarse Mesh

High Stress Areas• Refined Locations: • Large Contact Holes • Arbor Base Edges

Analysis to look at• Total Deformation• Tensile Stresses

Locate Problem Areas

Max Stress Locations• Less than Stainless Steel Yield Strength of 515 MPa.

Inner Rod Assembly

Max Tensile Stress: 312 MPa

Outer Rod Assembly

Max Tensile Stress: 407 MPa

Inner Rod Assembly

Max Deformation: .23 mm

Outer Rod Assembly

Max Deformation: .16 mm

Goal Target Range Actual Requirement Met?

Water Pressure transmitted through spray nozzle 2,000 PSI - 4,000 PSI 3,013 PSI

Water Pressure transmitted through fixture 3,000 PSI - 4,000 PSI 3,582 PSI

Number of Flow Directions 2 Directions 2 Directions

Fixture Operating Height < 8 in 4.5 in

Compact and able to fit in alloted space 60 in2 - 140 in2 60 in2

Number of Adjustable Features 1 - 3 Features 3 Features

Support Tensile Strength < 74.6 KSI 45.2 KSI

Corrosion Resistance 0.5 PRE - 1.5 PRE 1.8 PRE

Fixture is designed to Engineering Requirements

Replace Threaded Rods with Rack & Pawl for use in Production

Base with interchangeable posts for blasting ends

Flange Bearing Style Base