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Unique Applications of NX

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Contact Information

Glenn Brzyski

Moog Inc.

East Aurora, NY 14052

E-mail: gbrzyski@moog.com

Phone: 716-687-7642

Bio

29 years as a Designer/Drafter

On the job training

21 years with Moog Inc.

Started with 2D CAD system (Cadra)

Evolved to 3D CAD system (Unigraphics V11)

11 years on Unigraphics/NX

Certified by ASME to Y14.5M-1994 standard in 2005 as Geometric Dimensioning and Tolerancing Professional Senior (GD&TP)

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Who Is Moog?

The Moog I work for is Not:

the synthesizer company

the auto parts company

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Who is Moog?

Moog Inc. is a worldwide designer, manufacturer, and integrator of precision control components and systems. Our high-performance systems control military and commercial aircraft, satellites and space vehicles, launch vehicles, missiles, automated industrial machinery, marine applications, and medical equipment. Moog provides innovative actuation solutions and space-rated electronics for launch vehicle applications. We have extensive experience with electrohydraulic, electromechanical and electrohydrostatic actuation systems and also provide fluid and gas control products for the main propulsion and roll control systems and rocket engines. Moog’s systems and components equip such vehicles as the Space Shuttle, International Space Station, Delta IV, Atlas V, and Ariane 5.

What I really work on

ARES I Roll Control Thruster Valve

Kayak and Propeller Projects

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Kayak History

Why did I create a kayak?

What’s the magic?

Wanted to design my own

Was it possible?

What tools were conveniently available?

NX4

Method Used

Top Down Assembly Structure

Each form was created as a component as seen from the Assembly Navigator

Design Intent is propagated to each of the kayak forms when changing the following:

Overall Length

Beam (Width)

Designed Waterline (Draft)

Sheer Angle

Chine Angle

Side Profile (Buttocks)

Top Profile (Plan-form)

Tools Used

Datum Csys

Offset Datum Planes

Sketcher

Copy Feature/Paste

Mesh Surface

Shell

Wave Geometry Linker

Modeling Spreadsheet (Excel)

Datum Coordinate System (Datum Csys)

Insert > Datum/Point > Datum CSYS

It represents the starting point for all of the offsets found normally in boat construction

Datum Csys is a collection of (3) datum planes, (3) datum axes, an a origin point, all in one feature in the Part Navigator

In this case, it resides on absolute (0,0,0) in the part file

All datum planes that contribute to the shape of the kayak are offset from this (Designed Waterline, Sheer Angle, etc.)

Offset Datum Planes

Created the necessary spacing of the forms (12” on center)

Created the “Designed Waterline” datum plane offset from the Datum Csys

Designed Waterline datum plane

Sketcher

Multiple Sketches with the same geometry (forms) were used (5 arcs and 4 lines)

Side profile (Buttocks) and Top Profile (Plan-form) were created

Sheer and Chine sketches were also created to develop the shape of the hull and deck

Top Profile Sketch

Form Sketches

Side Profile Sketch

Sketcher Tip

Two different sketches that are attached on datum planes orientated 90 degrees from each other can be inter-related geometrically by the use of points that are Coincident

The creation or Timestamp order of the sketches is important

The sketches can only be linked in this manner if Positioning Dimensioning and a Fixed Point are not used

Coincident points

Copy Feature/Paste

Edit > Copy Feature or Copy > Paste

Allowed very quick copying of the original sketch without starting from scratch each time

Sketches were pasted with new expressions and as a new parent

Mesh Surface

Through Curves function created the shape of the hull as a solid body

Selection of the individual section strings must be consistent in order to get the proper result

In this case, the arrows defining the direction of the individual sections string point in the same direction

Shell

Formerly called “Hollow” in Unigraphics V18

Insert > Offset Scale > Shell

Allows the inside shape of the hull to conform to the outside with a consistent wall thickness (.25”)

Wave Geometry Linker

Linked Sketches from the top level assembly were pushed down to each of their respective components so that solid bodies could be created

All geometry will be updated when the Design Intent is changed (ex: Overall Length)

Modeling Spreadsheet (Excel)

Expressions were imported

In the Modeling Spreadsheet: Tools > Extract Expr (Expressions)

Calculations were made using full Excel functionality

Solid model was updated: Tools > Update NX Part

Kayak Analysis Glenn M. Brzyski

Mass=Based on the average between White Ash and Mahogany

Displacement Volume= 4.155 ft 3̂ At designed waterline

Salt Water Density= 62.3 lbs/ft 3̂ Weight Displaced= 259

Draft= 4

Length of kayak= 15 ft

Beam= 24 in

LWL (Length at Waterline)= 178.008 in Length/Beam Ratio= LWL/BWL

BWL (Beam at Waterline)= 22.911 in

(LCB) Longitudinal Center of Bouyancy= 100.066 in %LCB to LWL=

(VCB) Vertical Center of Bouyancy= -2.464 in less than 50% results in 'Fish' formmore than 50% result in 'Swede' form

(TCB) Transverse Center of Bouyancy= 0 in Swede form is preferable

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The Results

Propeller History

Why did I create a fixed pitch wooden propeller?

What’s the magic?

Wanted to make the best selection possible for the type of airplane that it is being used on

Was it possible?

What tools were conveniently available?

NX4

Brothers Harry, Martin and Ira (left to right) Sensenich were ahead of their time in snow transportation. They made this snowmobile in the late 1920s to retrieve family mail from a box that was half a mile away from their home on the Kissel Hill Road. The propeller that helped power the machine was bought, and when it broke, they decided to start making their own out of wood. This led to Harry and Martin founding the Sensenich Brothers Propeller Company.

Method Used

Top Down Assembly Structure Design Intent changes are

propagated down to the fixture which checks the profile and shape of the blade

Checking Fixture

Type of Aircraft

Tools Used

Datum Csys

Offset Datum Planes

Sketcher

Copy Feature/Paste

Studio Spline

Mesh Surface

Wave Geometry Linker

Modeling Spreadsheet (Excel)

Datum Coordinate System (Datum Csys)

Datum Csys resides on absolute (0,0,0) of the part file

Geometry for the propeller is positioned at the Y axis and symmetrical to the datum plane shown

Design Intent is to have all changes in size and shape emanate from the Datum Csys

Axis used

Datum Plane used

Offset Datum Planes

Created the necessary spacing of the airfoils (offsets based on 10% intervals from root to tip)

Datum plane angles are based on a previous sketch (Blade Angle Diagram) using Geometric Expressions

Sketcher

Multiple sketches with the same airfoil sections were used and modified as the twist of the prop approached the root

Airfoil changed shape from flat bottom at the tip for 60% of the blade to being fully symmetrical at the hub

Blade plan-form shape sketch was also created Plan-form sketch

Airfoil sketches

Copy Feature/Paste

Allowed quick copying and placement of the original airfoil sketch without starting from scratch each time

Sketches can be linked to each other or treated as new parents depending on Design Intent

Sketches were pasted as new parents and linked to the appropriate expressions and geometry

Studio Spline

Insert > Curve > Studio Spline

“Connected the dots” of the points of each of the airfoil sketches

Associative to the points

Used for the Through Curves function

Studio Splines

Mesh Surface

Through Curves function was used to create the solid geometry

Wave Geometry Linker

Linked Bodies of the propeller were pushed down to each of the fixture components and then subtracted from the extrusions

This provided a view on a drawing of each airfoil which can be later transferred to the profile checker fixture made of plywood

Modeling Spreadsheet (Excel)

Expressions were imported

In the Modeling Spreadsheet: Tools > Extract Expr (Expressions)

Calculations were made using full Excel functionality

Solid model was updated: Tools > Update NX Part

Geometric Pitch=

RPM x Pitch of Prop x .000947 = Speed (MPH)

This approximates the aircraft forward speed

Pitch of Prop= 40

Forward Speed= 84.57 MPH Recommended Propellers for Rotax 582 by Tennessee Propellers, Inc.

Reduction 2.58:1

Dia/Pitch

Reduction 3.00:1

Dia/Pitchp = Density of air 0.002378 slug/cu-ft at sea level 64 X 44 68 X 48HP = Horsepower of engine 65 66 X 42 70 X 46N = Engine revolutions 2232.55814 rev/min 68 X 40 72 X 44n = Engine revolutions 37.21674419 rev/sec 70 X 38P = Power 35750 ft-lb/sec 72 X 36v = Airspeed 124.0631665 ft/secV = Airspeed 84.56930233 miles/hrd = Propeller diameter 5.67 ft

Non-dimensional coefficient= square root (pv/Pn^3) Propeller Efficiency

c = 0.652224 Propeller tip speed should be 3.93 times the speed of the aircraftfor maximum propeller efficiency

Performance CoefficientPe = J * Pc

.325* square root (V^5/HP*N 2̂)Pe = 69.9%

The Results

AIRFOILSECTION 100%

AIRFOILSECTION 90%

AIRFOILSECTION 80%

AIRFOILSECTION 70%

AIRFOILSECTION 60%

AIRFOILSECTION 50%

AIRFOILSECTION 40%

AIRFOILSECTION 30%

AIRFOILSECTION 20%

5.000

1.000.256

2.953

68.00

FULL SCALE

A

A

SECTION A-A

2.25

BOTTOM VIEW

B

TOP VIEW

B

SECTION B-B

Questions?