ME 462 Capstone Design

Group Members: Kelly Moore, Bart Sudhoff, Danny Compton, Katie Iaizzo, Mary Croucher

Advisors: Dr. Jie Chen and Dr. Roger Knutson

12 Decmeber 2007

IntroductionBackgroundDesign ObjectivesMaterial SelectionCost EvaluationConcept DesignProduct EvaluationConclusionRecommendationsAnswer Questions

Russell FoundationFounded By Bishop Michael Russell and his

Father In 2003Faith Based Community Development

OrganizationRenders Self-sufficiency Programs to Help

Stabilize Families and CommunitiesProvides Jobs for Local CommunitiesEnvironmentally Friendly Initiatives

Reasons For DesignReduce Traffic Congestion

around Chicago-Indiana Area

Provide High Speed Transportation

Create Jobs in Indiana Pioneering Environmentally

Friendly Mass Transit Solutions

Preliminary Design

Customer RequirementsTravel 75 MPHSupport Renewable Energy SourceEasy AssemblyEasy MaintenanceSmooth Rail TransitionAppearanceSupport 160,000 lb loadMinimize Stopping TimeMinimize CostMinimize Environmental Effects

Engineering RequirementsMinimize Resistance (Rail)Maximize Allowable Stress (Structure)Equipment HoursLabor HoursMinimize Rail Height DifferencePublic Appearance RatingMaximize Allowable Stress (Rail)Maximize Allowable Stopping ForceMinimize Cost Minimize Environmental Effects on Material

Column Support•Box beam•Concrete base•Bolted to cross-support

Cross Support•Box beam•Bolted to column•Supports rails

Standard I-Beam W27 x 368•Standard Size•Internal height equal to 25.43 inches•Fits standard 22 inch tire diameter

Column Support Assembly•All parts bolted and welded

Full Assembly

Types of SteelTwo common types used: ASTM A992 and

ASTM 588More common steel types reduce costHigh strength, low alloy steel, which used

recycled metalsSaves on cost of manufacturingEnvironmentally friendly

Physical PropertiesASTM A588 ASTM A992

Contains Chromium for weather resistance

Made using 95% recycled material

Develops oxide coating Inexpensive

50 ksi yield strength 50 ksi yield strength

Structural Steel

ASTM A-588 ASTM A-992

Price per cwt from Nucor-Yamato Steel

$51.10 $46.60

Price per 80ft Beam $6483.85 $5971.32

Price difference per section

$512.53

Price ComparisonConsider long term maintenance and repair

costNorthwestern University experiment

A992 corrodes 64% more over time than A588A992 would last less than half as long as A588

(weathering steel)

Nuts and BoltsQuantity Description

Unit Price

Total Price

48Grade 8 Plain Alloy Steel Hex Head Cap Screw 1-1/8"-7 Thread, 6" Length

$7.16 Each

$343.68

24Grade 8 Plain Alloy Steel Hex Head Cap Screw 1-1/8"-7 Thread, 5" Length

$6.25 Each

$150.00

15

Grade 8 Plain Steel Hex Nut 1-1/8"-7 Screw Size, 1-11/16" Width, 31/32" Height, Packs of 5

$6.12 Pack

$91.80

    Total $585.48

Loading (Structure)Deadweight Load

80,000 lbs (355868 N)

per RailBraking Force

9.8 m/s2 * 80,000 lbsFixed Supports

Base – Ground Interface

Open End Rails

Equivalent Stress (Structure)Maximum

5.53e7 Pa

Shear Stress (Structure)Maximum

2.81 e7 Pa

Total Deformation (Structure)Maximum

16.75 mmLocation

Mid-span

Factor of Safety (Structure)Minimum

6.15Location

Beam-Near Connection

Fatigue Analysis (Beam)

Loading (Beam)Deadweight load

40,000 lbs per Flange

Fixed SupportsOpen Ends of Beam

Total Deformation (Beam)Maximum

9.5 mm

Fatigue Life (Beam)Minimum

8.03e5 cycles

Concluding RemarksOur designed is based on the customer Our designed is based on the customer

requirements and goals of the Russell requirements and goals of the Russell Foundation.Foundation.

The factor of safety meets required limit of 5-7The factor of safety meets required limit of 5-7Fatigue life exceeded 8.0 eFatigue life exceeded 8.0 e55 cycles cyclesA588 steel resists weathering without excessive A588 steel resists weathering without excessive

costcostSingle column design minimizes footprintSingle column design minimizes footprintDesigned to easily integrate renewable energy Designed to easily integrate renewable energy

sourcessources

Structure Span LengthPreliminary Testing

Larger Beam39 in. Interior

Beam height Factor of Safety

Increased to 9.53Custom Beam

Standard Size Not Available

http://www.uspto.gov/patft/index.htmlhttp://www.delphion.com/home

Project definition packet, Russell Foundation“IndianaFreight and IndianaMonorail,” Roger Knutson; Russell

Foundation; Advance Transit Solutions, LLC, May 2007

http://www.wisegeek.com/what-is-a-steel-i-beam.htmhttp://en.wikipedia.org/wiki/I-beam

Machinist’s Handbook 12th Edition, Lang, page 397http://www.matweb.com