may 16, 2003 team #27 ea-6b flaperon actuator team members: eric sullivan (project manager) (project...
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May 16, 2003May 16, 2003Team #27Team #27
EA-6B Flaperon EA-6B Flaperon ActuatorActuator
Team Members:Team Members:
Eric Sullivan Eric Sullivan (Project Manager)(Project Manager)
Joseph ClarkJoseph Clark
Casey PoethCasey Poeth
Josselin LegeayJosselin Legeay
Janice WiselyJanice Wisely
Advisor:Advisor:
Dr. DeBartoloDr. DeBartolo
May 16, 2003May 16, 2003Team #27Team #27
AgendaAgenda
The Model -The Model - Josselin LegeayJosselin Legeay
Timeline -Timeline - Janice WiselyJanice Wisely
Testing -Testing - Eric SullivanEric Sullivan Testing Setbacks -Testing Setbacks - Eric SullivanEric Sullivan Results -Results - Casey PoethCasey Poeth
RecommendationsRecommendations– Clevis Design - Clevis Design - Joseph ClarkJoseph Clark
– Material Change - Material Change - Joseph ClarkJoseph Clark Corrosion Issues - Corrosion Issues - Josselin LegeayJosselin Legeay
May 16, 2003May 16, 2003Team #27Team #27
The ModelThe Model
Scaled downScaled down
Stiffening Stiffening RidgeRidge
1 2
3
May 16, 2003May 16, 2003Team #27Team #27
Timeline - Timeline - GANTTGANTT2/7 2/14 2/21 2/28 3/7 3/14 3/21 3/28 4/4 4/11 4/18 4/25 5/2 5/9 5/16
L7
L3
L4
L5
L6
J
K
L1
L2
F5
G
H
I
F6
F1
F2
F3
F4
D2
E1
E2
F
A
B
C
D1
May 16, 2003May 16, 2003Team #27Team #27
TestingTesting
May 16, 2003May 16, 2003Team #27Team #27
TestingTesting
6 Tests6 Tests– 3 w/ ridge3 w/ ridge– 3 w/o ridge3 w/o ridge
ProcedureProcedure– Set-upSet-up– Pre-loadPre-load– TestTest
May 16, 2003May 16, 2003Team #27Team #27
Testing SetbacksTesting Setbacks
Clevis DesignClevis Design
Apparatus Inconsistency Apparatus Inconsistency
Data Acquisition TechniquesData Acquisition Techniques
May 16, 2003May 16, 2003Team #27Team #27
ResultsResults
May 16, 2003May 16, 2003Team #27Team #27
Deflection of all samples
0.023
0.024
0.025
0.026
0.027
0.028
0.029
0 500000 1000000 1500000 2000000 2500000
Cycles
Test 1
Test 2A
Test 2B
Test 3
Test 4A
Test 4B
Test 6
Test 5
ResultsResults
Test 1: 745,155Test 2: 766,682Test 3: 957,059Test 4: 1,573,111Test 5: 2,000,000Test 6: 1,029,879
May 16, 2003May 16, 2003Team #27Team #27
RecommendationsRecommendations
May 16, 2003May 16, 2003Team #27Team #27
Clevis Clevis DesignDesign
One Piece DesignOne Piece Design
Three Piece DesignThree Piece Design
May 16, 2003May 16, 2003Team #27Team #27
Material Material ComparisonComparison
MaterialTensile Strength
(ksi)
Young's Modulus
(106 psi)
Thermal Expansion (strain/F)
Price / lb ($)
2014 T-6 Aluminum
55.98 - 71.07 10.44 - 11.17 12.33 - 13.44 0.50 - 0.81
4130 Steel (annealed)
72.52 - 89.92 29.15 - 31.33 6.11 - 7.22 0.17 - .30
Titanium alpha- beta Alloy
144.3 - 145.8 14.50 - 15.95 4.44 - 5.44 13.24 - 18.53
High-Tensile Manganese Bronze
107.3 - 134.9 12.92 - 13.18 11.28 - 11.5 0.70 - 0.74
May 16, 2003May 16, 2003Team #27Team #27
Cu
H2
Fe
Zn
Al
Cu2+
H+
Fe2+
Zn2+
Al3+
+0.34V
0.00V
-0.44V
-0.76V
-1.66V
MnMn2+ -1.18V
Corrosion Corrosion issuesissues
Copper could attack Copper could attack the aluminumthe aluminum
Could result in Could result in failure modesfailure modes
Aluminum oxide Aluminum oxide (Al(Al22OO33) is impervious ) is impervious and coherentand coherent
Corrosion stops Corrosion stops when the layer is when the layer is 1nm thick1nm thick
May 16, 2003May 16, 2003Team #27Team #27
ConclusionsConclusions
Clevis designClevis design
Material ChangeMaterial Change
Increase Number of Increase Number of Tests Tests – S-N curveS-N curve– Statistical verification Statistical verification
May 16, 2003May 16, 2003Team #27Team #27
¿ Questions ?¿ Questions ?
May 16, 2003May 16, 2003Team #27Team #27
ExpendituresExpenditures
Item Description Specifications Price / Unit Quantity CostLocking Ring 4130 Steel $85.00 12 $1,020.00End Cap 4130 Steel $76.00 6 $456.00Housing without ridge 2014 T-6 Aluminum $86.00 3 $258.00Housing with ridge 2014 T-6 Aluminum $129.00 3 $387.00Hanging Scale 50 lbs (8 oz graduations) $56.70 1 $56.70Spanner Wrench adjustible 2" to 4.75" $28.22 1 $28.22
3 1/2" X 16" alum 2014 - T6 round stock $98.40 10 $984.00
Clevis Grips created by Instron ® $4,000.00 2 $8,000.00
Total $11,190
May 16, 2003May 16, 2003Team #27Team #27
Maximum Working Maximum Working ForceForce
P= 3000 psi
Aef f = 4.879 in2
# Chambers 2Working
Force29274 lbf
May 16, 2003May 16, 2003Team #27Team #27
Pre-loading ForcePre-loading Force
Pre-loading force greater than Pre-loading force greater than maximum working force.-maximum working force.-
.2*
TorqueF
d
P= 4500 psi
Aef f= 6.49 in2
Torque= 15 ft-lbf
Preload Force
29532 lbf