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