Rolls Royce High Pressure Water Jet Cleaning System Final Presentation

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Rolls 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
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Design 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

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Airfoil
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Airfoil Ends
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Dry Box for Blasting
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Who 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

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What 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

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Engineering 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

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Conceptual Design
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Design 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.

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Off the Shelf Products

• Swiveling quick disconnects provide rotation of
  the fixture, as well as easy removal.

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Video File of Fixture Model
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Hydraulic Routing
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Connections
A. Base plate B. Quick disconnection parts and
rubber pads C. Slider arbor D. Socket rods
connect large contact and small contact
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Connections

• E.
• Quick
• disconnections and
• contacts
• F.
• Rubber and
• contacts
• G.
• Fixed arbor

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Connections
H. Distance controller I. Arbor top
and arbor J. Screws connect arbor and plate
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Product 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.

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Fixture/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

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Corrosion 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

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Cost 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

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Fixture Operating Height

• Fixtures operating height 4.5
• Designed to function under comfortable operating
  conditions within the parameters of the dry box.

4.5
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Stress Tolerance

• Analysis using ANSYS Workbench
• Worst Case Scenario
• Maximum Pressure
• Uniformly Distributed Force
• (4000 psi 27.579 Mpa)
• Perpendicular to Large Contact Faces

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Meshing Technique

• Coarse Mesh
• High Stress Areas
• Refined Locations
• Large Contact Holes
• Arbor Base Edges

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Analyzing 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.

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Max Stress Locations
Inner Rod Assembly
Outer Rod Assembly
Max Tensile Stress 312 MPa
Max Tensile Stress 407 MPa
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Total Deformation
Inner Rod Assembly
Outer Rod Assembly
Max Deformation .23 mm
Max Deformation .16 mm
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Results
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Conclusions 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

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Questions