Title: Rolls Royce High Pressure Water Jet Cleaning System Final Presentation
1Rolls Royce High Pressure Water Jet Cleaning
System Final Presentation
Design Group Wei-Yuan Chu Adrian Conrad Thomas
Hylton Scott Jean Nicholas Metzger
IUPUI Faculty Advisor Dr. Jie Chen Rolls-Royce
Advisor Timothy Fuesting
2Design Process
- Establish a Need
- Identify the Customer
- Determine Customer Requirements
- Develop Engineering Specifications
- Concept Development Evaluation
- Design Product
- Evaluate Product to Specifications
- Manufacture and Testing
- Product Release
3Airfoil
4Airfoil Ends
5Dry Box for Blasting
6Who is Our Customer ?
- Rolls-Royce Engineering
- Timothy Fuesting
- Mary Gambone
- Rolls-Royce dry box operator
- assemble and safely use fixture to clean
airfoils - Rolls-Royce maintenance / tool dye
- maintain / repair system
- Manufacturer
- simple to make parts
- Environment
- environmentally safe / recyclable
7What Does the Customer Want ?(Initial Survey)
- Operator Safety
- no possible contact with skin
- Works as Required
- removes debris / high pressure (4000 psi)
- Fits in the space occupied by former system
- Easy to Use
- little operator training required
- Easy to Assemble
- Easy to Maintain
- Simple to Manufacture
- No Harm to the Environment
- recyclable
8Engineering Specifications
- Provide high pressure water through the handheld
spray nozzle - Provide high pressure water through the fixture
- Fixture Operating Height Under 8
- Fixture must be Compact
- Fixture must have High Backpressure Tolerance
- Multiple Water Flow Directions
- Number of Adjustable Features
- Number of days between maintenance should be high
- Corrosion Resistance
9Conceptual Design
10Design for Airfoil Variation
- Fixture Design allows for securing the airfoil in
either inner or outer rod configuration. - Outer Configuration is required for airfoils with
obstructed interior passages.
11Off the Shelf Products
- Swiveling quick disconnects provide rotation of
the fixture, as well as easy removal.
12Video File of Fixture Model
13Hydraulic Routing
14Connections
A. Base plate B. Quick disconnection parts and
rubber pads C. Slider arbor D. Socket rods
connect large contact and small contact
15Connections
- E.
- Quick
- disconnections and
- contacts
- F.
- Rubber and
- contacts
- G.
- Fixed arbor
16Connections
H. Distance controller I. Arbor top
and arbor J. Screws connect arbor and plate
17Product Evaluation
- Engineering Targets tested through various
methods of analysis. - Each of the engineering targets represented in
numerical values. - Each requirement must meet the customers
standards.
18Fixture/Spray Gun Pressure
- Utilized the modified Bernoulli Equation
- Assumptions Steady Flow, Incompressible, No heat
- transfer
- Results
- Fixture inlet pressure 3,582 psi
- Spray Gun Outlet Pressure 3,013 psi
19Corrosion Resistance
- Using the maximum values listed at AZOM for 304
stainless steel of 20 Cr, 0 Mo, and 10 N to
calculate the PRE (Pitting Resistance Equivalent) - Corrosion occurs with the breakdown of the
protective surface film on the steel commonly
caused from exposure to sulfide and chloride ions - Quenching, adding Molybdenum, and Nitrogen to the
metal helps prevent corrosion
20Cost Analysis
- Consisting of mostly stainless steel components
and high pressure connections the design
consisted of - 35 Components
- Rolls Royce had most components in house causing
a reduced retail price - Approximate Non reduced Total Cost 1,918.44
21Fixture Operating Height
- Fixtures operating height 4.5
- Designed to function under comfortable operating
conditions within the parameters of the dry box.
4.5
22Stress Tolerance
- Analysis using ANSYS Workbench
- Worst Case Scenario
- Maximum Pressure
- Uniformly Distributed Force
- (4000 psi 27.579 Mpa)
- Perpendicular to Large Contact Faces
23Meshing Technique
- Coarse Mesh
- High Stress Areas
- Refined Locations
- Large Contact Holes
- Arbor Base Edges
24Analyzing ANSYS Results
- Analysis to look at
- Total Deformation
- Tensile Stresses
- Locate Problem Areas
- Max Stress Locations
- Less than Stainless Steel Yield Strength
- of 515 MPa.
25Max Stress Locations
Inner Rod Assembly
Outer Rod Assembly
Max Tensile Stress 312 MPa
Max Tensile Stress 407 MPa
26Total Deformation
Inner Rod Assembly
Outer Rod Assembly
Max Deformation .23 mm
Max Deformation .16 mm
27Results
28Conclusions Recommendations
- Fixture is designed to Engineering Requirements
- Replace Threaded Rods with Rack Pawl for use in
Production - Base with interchangeable posts for blasting ends
- Flange Bearing Style Base
29Questions