Spirit Aero Systems Final Presentation Web

8/12/2019 Spirit Aero Systems Final Presentation Web

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SPIRIT AEROSYSTEMS FINAL REVIEW

Jerid Sutton

Daniel Smith


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DESIGN TEST CONCEPTS

Load Distribution

Fastener arrangement

and spacing has amajor effect on the

distribution of a load


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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


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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


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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


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TEAM DESIGN CONSIDERATIONS

Nut and Bolt Combination

-3/16 Diameter

Stainless Steel

Grade 8

Grade 6


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PSU TESTING CAPABILITIES

Standard Tension Tests

11,000 lb Maximum Tensile Force

Software

Pro-Mechanica FEA

ALGOR FEA


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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


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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


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TENSILE TEST RESULTS IN PRO MECHANICA


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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


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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


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FIRST JOINT DESIGN


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FINAL SPECIMEN DRAWING


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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


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RIVET INSTALLATION


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CLOSE UP OF INSTALLATION TOOL


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RIVET INSTALLATION BLOCK


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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.


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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.


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STRAIN READING


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PREPARING FOR TESTING


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STRAIN GAGES


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RECORDING STRAIN


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TEST PIECE IN MACHINE


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FINITE ELEMENT ANALYSIS IN PRO-E


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ELONGATION PREDICTION


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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


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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.


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Material Provided By Cost to us

.072 Plate PSU FreeRivets Spirit Free

Strain Gages PSU Free

Equipment PSU & Spirit Free


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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


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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


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QUESTIONS?

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