Upload
jacob-yosha
View
216
Download
0
Embed Size (px)
Citation preview
8/12/2019 Spirit Aero Systems Final Presentation Web
1/36
SPIRIT AEROSYSTEMS FINAL REVIEW
Jerid Sutton
Daniel Smith
8/12/2019 Spirit Aero Systems Final Presentation Web
2/36
8/12/2019 Spirit Aero Systems Final Presentation Web
3/36
DESIGN TEST CONCEPTS
Load Distribution
Fastener arrangement
and spacing has amajor effect on the
distribution of a load
8/12/2019 Spirit Aero Systems Final Presentation Web
4/36
LOAD TRANSFER THEORY
If the fastener is bigger in diameter it
attracts more of the load
In a flexible joint the first fastener transfers
the most load
Fastener configuration effects load
distribution
8/12/2019 Spirit Aero Systems Final Presentation Web
5/36
SPIRIT DESIGN CONSIDERATIONS
Aluminum (2024-T3)
to 2 total joint thickness
Fasteners
1. Bolts and Nuts (Hi-Loks)
2. Rivets
3. 3/16 to 3/8 diameters
4. Materialstitanium, A-286 Steel, Nickel
Alloy
8/12/2019 Spirit Aero Systems Final Presentation Web
6/36
TEAM DESIGN CONSIDERATIONS
Availability of testing equipment
Using Aluminum 2024-T1 1/8 and 3/16
Plate
Blind Rivets
3/16 Diameter
Aluminum
Stainless Steel
Titanium
8/12/2019 Spirit Aero Systems Final Presentation Web
7/36
TEAM DESIGN CONSIDERATIONS
Nut and Bolt Combination
-3/16 Diameter
Stainless Steel
Grade 8
Grade 6
8/12/2019 Spirit Aero Systems Final Presentation Web
8/36
PSU TESTING CAPABILITIES
Standard Tension Tests
11,000 lb Maximum Tensile Force
Software
Pro-Mechanica FEA
ALGOR FEA
8/12/2019 Spirit Aero Systems Final Presentation Web
9/36
STANDARD TEST PROCEDURE
Search ASTM standards for tension testing
procedures
Predict stress in predetermined specimen
using stress and strain
Verify testing device by comparing results to
predicted ultimate strength of the specimen
8/12/2019 Spirit Aero Systems Final Presentation Web
10/36
CALCULATION COMPARISON
1040 Cold-drawn Steel
Stress = Force/Area
Sample Calculation 6,250 lb/(.25in X .5in) = 50,000 psi
Compare with Pro-Mechanica Analysis Results
8/12/2019 Spirit Aero Systems Final Presentation Web
11/36
TENSILE TEST RESULTS IN PRO MECHANICA
8/12/2019 Spirit Aero Systems Final Presentation Web
12/36
MANUFACTURING PLAN
Manufacturing Plan
Group Name: Spirit Fatigue Testing
Date: 1/31/2007
Oper. # Description Machine Material Time # Parts
1 Plate Specimen Water Jet .375 Plate 1hr 40
Cut-outs 2024-T3
2 Drill Fastener Holes Drill Press .375 Plate 2hrs 40
2024-T3
3 Clean Burred Edges Belt Sander Test Specimen 1hr 40
Within Tolerance 2024-T3
4-A Bolting Test Ratchet Test Pieces .5hr 20Specimen Together
4-B Riveting Test Riveting Die Test Pieces 1hr 20
Specimen Together
8/12/2019 Spirit Aero Systems Final Presentation Web
13/36
RIVETED JOINT CONCEPT
Two partial dog-bone specimen held together
by inline rivets
Requires Spirit to assemble the specimen
Surface finish has to be capable of adhering
a strain gage
8/12/2019 Spirit Aero Systems Final Presentation Web
14/36
FIRST JOINT DESIGN
8/12/2019 Spirit Aero Systems Final Presentation Web
15/36
FINAL SPECIMEN DRAWING
8/12/2019 Spirit Aero Systems Final Presentation Web
16/36
TOLERANCE AND QUALITY ISSUES
Measured every specimen cut out and
scrapped anything that was not within .1 of
tolerance
Some holes that were drilled didnt properly
line up so those parts were scrapped as well
When parts were cut out and drilled we had
to debur edges so there were no sharpcorners for safety reasons
8/12/2019 Spirit Aero Systems Final Presentation Web
17/36
RIVET INSTALLATION
8/12/2019 Spirit Aero Systems Final Presentation Web
18/36
CLOSE UP OF INSTALLATION TOOL
8/12/2019 Spirit Aero Systems Final Presentation Web
19/36
RIVET INSTALLATION BLOCK
8/12/2019 Spirit Aero Systems Final Presentation Web
20/36
8/12/2019 Spirit Aero Systems Final Presentation Web
21/36
RIVET SHEAR STRENGTH CALCULATION
Yield Strength or 2024 = 47000psi
YS = F/6x[ d2/4]
47000 = F/6x (.250)
2
/4 F = 14,628lbs to shear rivets
The Zwick tensile test machine can only go
to 10,000lbs safely so it is not possible tobreak the specimen here.
8/12/2019 Spirit Aero Systems Final Presentation Web
22/36
STRAIN GAGE FUNDAMENTALS
Fundamentally, all strain gages are designed
to convert mechanical motion into an
electronic signal. A change in capacitance,
inductance, or resistance is proportional tothe strain experienced by the sensor. If a
wire is held under tension, it gets slightly
longer and its cross-sectional area isreduced. This changes its resistance (R) in
proportion to the strain sensitivity (S) of the
wire's resistance.
8/12/2019 Spirit Aero Systems Final Presentation Web
23/36
STRAIN READING
8/12/2019 Spirit Aero Systems Final Presentation Web
24/36
PREPARING FOR TESTING
8/12/2019 Spirit Aero Systems Final Presentation Web
25/36
STRAIN GAGES
8/12/2019 Spirit Aero Systems Final Presentation Web
26/36
RECORDING STRAIN
8/12/2019 Spirit Aero Systems Final Presentation Web
27/36
TEST PIECE IN MACHINE
8/12/2019 Spirit Aero Systems Final Presentation Web
28/36
8/12/2019 Spirit Aero Systems Final Presentation Web
29/36
FINITE ELEMENT ANALYSIS IN PRO-E
8/12/2019 Spirit Aero Systems Final Presentation Web
30/36
ELONGATION PREDICTION
8/12/2019 Spirit Aero Systems Final Presentation Web
31/36
TEST RESULTS FROM ONE SPECIMENForce (lbs) 1000 2000 3000 4000 5000
Force (N) 4448 8896 13344 17792 22240
Strain
1 411 487 505 530 651
2 426 356 219 186 151
3 418 267 217 196 140
4 262 121 6 50 125
5 348 118 41 10 45
6 21 290 425 551 6777 7 150 245 158 330
8 118 246 206 229 247
9 40 84 129 145 150
10 21 81 76 90 94
Strain Concentrations (sum)
1 411 898 1403 1933 2584
2 426 782 1001 1187 1338
3 418 685 902 1098 12384 262 383 389 439 564
5 348 466 507 517 562
6 21 311 736 1287 1964
7 7 157 402 560 890
8 118 364 570 799 1046
9 40 124 253 398 548
10 21 102 178 268 362
Gage readings are to 10-5
Elongation (mm) 1.6 2.7 3.6 4.5 5.4
8/12/2019 Spirit Aero Systems Final Presentation Web
32/36
INTERPRETATION OF RESULTS
At this point we have a few excel programs
from Spirit but need their assistance in
manipulating them to work with our results.
The excel program supplied by Spirit is madeto correspond with many different numbers of
fasteners and we do not know yet how to get
it to calculate the load at only 3.
8/12/2019 Spirit Aero Systems Final Presentation Web
33/36
Material Provided By Cost to us
.072 Plate PSU FreeRivets Spirit Free
Strain Gages PSU Free
Equipment PSU & Spirit Free
8/12/2019 Spirit Aero Systems Final Presentation Web
34/36
Week 1 Week 2 Week 3 Week 4
Tasks
October Concept
Literature Review
Pricing
November Budget
Funding Proposal
Final Proposal
December Concept Review Break Break
8/12/2019 Spirit Aero Systems Final Presentation Web
35/36
Week 1 Week 2 Week 3 Week 4
Tasks
January Concept Review
Design And Review
February Design And Review
Manufacturing Plan
March Manufacturing Break
Spirit Conciliation 1 Break
Apr i l Strain Gage Application AndTesting
Testing Results Review
May Spirit Conciliation 2
8/12/2019 Spirit Aero Systems Final Presentation Web
36/36
QUESTIONS?