The document is a presentation for a final project at the Air Force Research Laboratory. It discusses the design, analysis, prototype testing, and management of a new tabletop torsion tester to more effectively test small specimens. The current torsion tester is 5 meters long, making it inaccurate for small samples. The presentation outlines the design requirements, concept selection process, components of the new tester design, prototype testing results, budget, and project timeline. It concludes that the team successfully designed and manufactured a tabletop torsion tester that meets the requirements for AFRL within budget and schedule.
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Experimental verification and finite element analysis of a sliding door syste...Altair
A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by rollforming and strech bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strenght on different directions, rigidity for mechanisms, door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manuel operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.
Speakers
Caner Güven, Analysis Engineer, Rollmech Automotive
With programs such as U.S. Army Future Vertical Lift (FVL), how can I predict rotorcraft drivetrain life and solve premature failures before they occur?
Behrooz Jalalahmadi, PhD., Lead Scientist for DigitalClone Component, has outlined how prognostic models are used to extend drivetrain life in design and operation. These slides will demonstrate how Sentient Science solved fretting fatigue failures on a spline component in a Blackhawk platform by evaluating new coatings and duty cycles with computational testing. Life extension programs for bearings and gears in the Blackhawk will also be shown.
Cutting Aerospace Validation Costs in Half Using Computational TestingSentient Science
Learn how advances in computational testing in the aerospace industry lead to reduced cost and time for validations of new designs and modifications. Dr. Raja Pulikollu expands on the American Helicopter Society (AHS) International Vertiflite article "Testing the Digital Gearbox".
Use physics-based modeling and computational testing to:
-Reduce qualification costs associated with physical testing of design prototypes
-Accelerate product development cycle by virtual evaluations of design alternatives
-Enable life predictions for key components that are based on first principles and material science
-Expand the ability to validate design effectiveness under a wider variety of environmental and loading conditions
Modeling Tribological Contacts in Wind Turbine GearboxesSentient Science
Sentient Science outlines how we build a multi-physics solver for rolling contact and fatigue modeling that predicts where both long and short crack nucleate and initiate before system failure occurs.
Experimental verification and finite element analysis of a sliding door syste...Altair
A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by rollforming and strech bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strenght on different directions, rigidity for mechanisms, door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manuel operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.
Speakers
Caner Güven, Analysis Engineer, Rollmech Automotive
Marina at Keppel Bay presents a world of possibilities for the adventurous explorer. With a fleet of luxury yachts available for private rental and charter, escape on an unforgettable voyage to Singapore's picturesque waterfront spots and idyllic islands. These spacious pleasurecrafts make the perfect setting for entertaining in style and elegance.
Raport M&A Index Poland, 3Q 2016 - Oczekiwana fala fuzji i przejęć nie dotarł...FORDATA VDR
Zapraszamy do zapoznania się z kolejnym wydaniem Raportu M&A Index Poland, opracowanego przez Panią Alicję Kukla-Kowalską - eksperta FORDATA wraz z Panem Janem Kospin z firmy doradczej Navigator Capital.
PRINTING, PUBLISHING, DISTRIBUTION IN INDIAJohn Regis
WE HAVE OUR OWN DIVISION FOR PRINTING PUBLISHING AND DISTRIBUTION ALL ACROSS INDIA AND WORLD.
WE DO PRINT OF ALL TYPES OF BROCHURES, CATALGOUES, FOLDERS, MAGAZINES, PROMOTIONAL MATERIALS. ETC
Empresas Eléctricas en la Mira de las Redes SocialesQuantico Trends
Estudio realizado por Quantico Trends - Industria Electrica en Perú. Del 1 de Enero al 31 de Julio de 2015. Enfoque en las principales eléctricas: Edelnor y Luz del Sur.
Chalmers Presentation: Flow Field In A Single-Cylinder Spark Ignition Engine ...Antonio D'Andrea
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Investigation performed on Darmstadt spray-guided research engine, using LES turbulence modelling.
Stiffened Panels structures are widely used because they make the structure more cost-effective by offering a desirable strength/weight ratio, and is in so far that even small weight reduction of each of them can significantly affect the total empty weight of the structure. The reduction in the structural weight of ships gives valuable advantages such as; increasing their cargo-carrying efficiency, decrease in material cost supersedes the higher production costs, also lighter vessels requires engines with lower power, which means less emission of hazardous gases produced by marine diesel engines.
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Marina at Keppel Bay presents a world of possibilities for the adventurous explorer. With a fleet of luxury yachts available for private rental and charter, escape on an unforgettable voyage to Singapore's picturesque waterfront spots and idyllic islands. These spacious pleasurecrafts make the perfect setting for entertaining in style and elegance.
Raport M&A Index Poland, 3Q 2016 - Oczekiwana fala fuzji i przejęć nie dotarł...FORDATA VDR
Zapraszamy do zapoznania się z kolejnym wydaniem Raportu M&A Index Poland, opracowanego przez Panią Alicję Kukla-Kowalską - eksperta FORDATA wraz z Panem Janem Kospin z firmy doradczej Navigator Capital.
PRINTING, PUBLISHING, DISTRIBUTION IN INDIAJohn Regis
WE HAVE OUR OWN DIVISION FOR PRINTING PUBLISHING AND DISTRIBUTION ALL ACROSS INDIA AND WORLD.
WE DO PRINT OF ALL TYPES OF BROCHURES, CATALGOUES, FOLDERS, MAGAZINES, PROMOTIONAL MATERIALS. ETC
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Estudio realizado por Quantico Trends - Industria Electrica en Perú. Del 1 de Enero al 31 de Julio de 2015. Enfoque en las principales eléctricas: Edelnor y Luz del Sur.
Chalmers Presentation: Flow Field In A Single-Cylinder Spark Ignition Engine ...Antonio D'Andrea
Investigation Of The Flow Field In A Single-Cylinder Spark Ignition Engine Using OPENFOAM ”.
Investigation performed on Darmstadt spray-guided research engine, using LES turbulence modelling.
Stiffened Panels structures are widely used because they make the structure more cost-effective by offering a desirable strength/weight ratio, and is in so far that even small weight reduction of each of them can significantly affect the total empty weight of the structure. The reduction in the structural weight of ships gives valuable advantages such as; increasing their cargo-carrying efficiency, decrease in material cost supersedes the higher production costs, also lighter vessels requires engines with lower power, which means less emission of hazardous gases produced by marine diesel engines.
In this research a barge’s deck is evaluated by means of finite element analysis and optimized by parametric sensitivity analysis and numerical optimization methods, and the results would show that the deck structure could be developed further by utilizing the optimization techniques to reduce their weight by up to 9%.
A Study on Process Improvement in the Assembly Line of Switch Manufacturingijceronline
The paper is about the process improvement in the assembly line at switch manufacturing company and to improve the process by focusing into the areas viz. Process flow, Time study and rework minimization. This improvement are made by using cause-and-effect diagram, critical path method and root cause analysis. The analysis will help to reduce the amount of rework that occurs during manufacturing of modular switches in the assembly line process
1. 9/20/2015Group 13
Final Presentation
By: Brendan Keane, Logan McCall, Reggie Scott, Mark Swain
Instructor: Dr. Nikhil Gupta
Sponsor: Dr. Philip Flater (Air Force Research Laboratory Eglin AFB)
Advisor: Dr. Simone Hruda
2. 9/20/2015
Group 13 Speaking:
1 of 27 Final Presentation
Introduction
Design and Analysis
Prototype Testing
Project Management
Conclusion
Overview
Reginald Scott
3. Group 13 Speaking:
2 of 27 Final Presentation
9/20/2015
Current torsion tester at the
Air Force Research
Laboratory (AFRL) Munitions
Directorate at Eglin AFB is
approximately 5 meters in
length
Small sample geometries
result in inaccuracy and
inefficiency
Introduction
Figure 2.1: Existing Torsion Machine
“DISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)”
Reginald Scott
4. Group 13 Speaking:
3 of 27 Final Presentation
9/20/2015
Small specimens are a
result of original plate
stock dimensions
Specimens tested:
Aluminum 2024
Titanium 64
Specimen Geometry
Original plate stock
Blank removed
Sample machined
Figure 3.1: Specimen production
Dimension Measurement (mm)
Total Length 58.4
Gauge Length 12.7
Width 14.3
Inner Diameter 9.09
Fillet Radius 27.9
Grip Length 20
Table 3.1: Specimen dimensions
“DISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)”
Reginald Scott
5. Group 13 Speaking:
4 of 27 Final Presentation
9/20/2015
Maximum torque output: 100Nm
Machine must fit in an area (footprint) of 1m2
Monotonic (one direction) free-end torsion loading
Free end must allow for axial motion
Compatible with measurement equipment used by AFRL
Budget - $2,000
Design Requirements
Reginald Scott
6. Group 13 Speaking:
5 of 27 Final Presentation
9/20/2015
Goal Statement:
Design a more effective way of testing small specimens in
free-end torsion
Design Requirements
Reginald Scott
7. Group 13 Speaking:
6 of 27 Final Presentation
9/20/2015
DIC (Digital Image Correlation)
“DISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)”
Figure 6.2 Example DIC use in torsion
sample
Figure 6.1 DIC setup at Eglin AFRL
Brendan Keane
8. Group 13 Speaking:
7 of 27 Final Presentation
9/20/2015
Current method used by
AFRL to measure applied
stress:
Strain gage placed on
elastic bar
Use shear modulus
relationship to output
stress
Load Measurement
Figure 7.1: Stress vs. strain plot showing the
shear modulus relationship
G =
𝜏
𝛾
Brendan Keane
9. 9/20/2015
Group 13 Speaking:
8 of 27 Final Presentation
Torsion Tester
Load Generation
Manual Power
Motor & Transmission
Load Application Gripping Mechanism
Load Measurement Compatibility
Linear Motion Friction Reduction
Frame
Material Selection
User Safety
Breakdown of Design
Brendan Keane
10. 9/20/2015
Group 13 Speaking:
9 of 27 Final Presentation
Load Generation
Design Cost Weight Accuracy Complexity Maintenance Variability Total
Weight Factor 0.25 0.05 0.25 0.1 0.1 0.25
(1) Crank System 5 3 1 5 5 1 2.9
(2) Hydraulic 1 1 5 1 1 5 3
(3) AC Motor 3 3 5 3 3 5 4
(1) (2) (3)
Brendan Keane
15. 9/20/2015
Group 13 Speaking:
14 of 27 Final Presentation
Figure 5.1: CAD representation of design
Design Overview
Logan McCall
Steel Shaft
32”
13”
16. Group 13 Speaking:
15 of 27 Final Presentation
9/20/2015
Vendor: Grainger
Rpm: 18
Gear ratio: 95:1
Max torque: 116 Nm
Weight: 26 lbs
Load Generation: AC Gearmotor
Figure 15.1: AC Gearmotor
Logan McCall
17. Group 13 Speaking:
16 of 27 Final Presentation
9/20/2015
Vendor: Automation
Direct
Single phase input, three
phase output
Digital keypad
Forward and reverse
Expandable
Motor Control: VFD
Variable Frequency Drive (VFD)
Figure 16.1: VFD keypad
Logan McCall
18. Group 13 Speaking:
17 of 27 Final Presentation
9/20/2015
Vendor: LittleMachineShop
Weight: 6.4 lbs
Outer diameter: 3.94 in (10 cm)
Inner diameter: 1.02 in (2.59 cm)
Load Application: 6-Jaw Chuck
Figure 17.1: 6 Jaw Chucks holding specimen
Logan McCall
19. 9/20/2015
Group 13 Speaking:
18 of 27 Final Presentation
Load Measurement
Coupler material: Al 6061
Coupler properties
Shear modulus: 26 GPa
Shear strength: 76 MPa
Outer diameter: 1.75 in (4.45 cm)
Inner diameter: 0.75 in (1.90 cm)
Figure 18.1: FEA performed on coupler
showing strain developed under a
simulated load
Logan McCall
20. Group 13 Speaking:
19 of 27 Final Presentation
9/20/2015
Vendor: Grainger
½ inch steel rails
Slot design to ensure
alignment
Linear Motion: 2 Rail Ball Bearing Guide
Figure 19.1: Linear guide system
Logan McCall
21. 9/20/2015
Group 13 Speaking:
20 of 27 Final Presentation
Frame Design
Steel frame
Shape: hollow square
shaped cross-section
Dimensions:
1/8 in inner supports –
304 stainless steel
1/8 in outer frame –
low carbon 1015 steel
Figure 20.1: CAD drawing of frame (bottom view)
Logan McCall
24. 9/20/2015
Group 13 Speaking:
23 of 27 Final Presentation
Tester was successful in breaking
aluminum specimen
Fracture was at center
During initial testing, free end chuck had
slight rotation
Solution: Force fit new connecting
rod into free end
Cylindrical grips slipped during initial
testing
Solution: Use hex-grip specimen or
increase friction on cylindrical
specimen
Testing Results
Figure 23.1: Fractured
specimens
Mark Swain
25. 9/20/2015
Group 13 Speaking:
24 of 27 Final Presentation
Budget
44%
25%
18%
10%
3%
Load Generation Load Application
Linear Motion Housing
Miscellaneous
Budget: $2,000
Spent: $1,844
Net: + $156
Mark Swain
26. 9/20/2015
Group 13 Speaking:
25 of 27 Final Presentation
Project Progression
Fall
Background research
Design breakdown
Component research
Design analysis
Optimal part selection
Budget breakdown
Purchase orders
Spring
Delivery of parts
Machining
Assembly
Motor/VFD testing
Prototype testing
Troubleshooting
Final assembly
Mark Swain
27. 9/20/2015
Group 13 Speaking:
26 of 27 Final Presentation
Conclusion
Maximum torque output: 100Nm
Machine must fit in an area (footprint) of 1m2
Monotonic (one direction)free-end torsion loading
Free end must allow for axial motion
Compatible with measurement equipment used by AFRL
Budget - $2,000
Mark Swain
28. 9/20/2015
Group 13 Speaking:
27 of 27 Final Presentation
The team was successfully
designed and
manufactured a tabletop
torsion tester for AFRL
What we learned:
Focus on the main
customer requirements
Consult as many
resources as possible
Teamwork is essential
Unforeseen
circumstances
Conclusion
Figure 27.1: Final assembly
Mark Swain
30. 9/20/2015
Group 13 Speaking:
29 of 27 Final Presentation
Carter, B. (2008). Texas Instruments: Op Amp Noise Theory and Applications. Retrieved
September 22, 2014
Flater, P. (2014). Tabletop Torsion Test. Eglin, FL: Air Force Research Laboratory.
Ilic, M. (2014, October 11). Clamp for centering. Retrieved from GRABCAD:
https://grabcad.com/library/stega-za-centriranje-clamp-for-centering-1
Lathe Chuck. (2014, October 7). Retrieved from GRABCAD:
https://grabcad.com/library/lathe-chuck-3
Linear Motion Systems. (2014, September 28). Retrieved from Stock Drive Products:
https://sdp-si.com/eStore/coverpg/linearmotion.htm
References
Mark Swain