paint shop track beam system joel escobales fabian robinson kyle lindsay eml 4905 senior design...
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PAINT SHOP TRACK BEAM SYSTEM
Joel Escobales
Fabian Robinson
Kyle Lindsay
EML 4905 Senior Design Project
Florida International University
Department of Mechanical Engineering
Miami, FL
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• Self-contained, full-service
aircraft landing gear
overhaul facility
• Repair and overhaul landing
gear, wheels, brakes, and
accessories for 43 different
types and subtypes of
commercial and military
aircraft
Allen Aircraft Radio Landing Gear Services
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BOEING 777 MAIN LANDING GEAR OUTER CYLINDER
Length ≈ 10 ftWeight ≈ 1300 lbs
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CURRENT PAINT SHOP
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CURRENT PAINT SHOP CONFIGURATION
3 Paint Booths(Paint Booth #2 is NOT accessible from track beam)
2 Small
Ovens
Design Alternate 1, 2, 3Design Alternate 4
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DESIGN ALTERNATES
Pros
• Spacious design
• Larger oven space
• Multiple options
Cons
• Production stoppage
• Two paint booths
Pros
• Larger oven space
• Three paint booths
• Multiple options
Cons
• Limited production
• Paint booth at each
oven entrance
Pros
• Least expensive
design
• Quick
implementation
Cons
• Limited oven space
• Limited future
improvement
Pros
• Larger oven space
• Does not halt
production
Cons
• Longest construction
• Most expensive
alternate
#1 #2 #3 #4
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PROPOSED PAINT SHOP LAYOUT (#4)
Section Length (in) Description1 180 Straight2 48 Switch3 108 Straight4 94.25 60" Radius Quarter Circle5 228 Straight6 48 Switch7 94.25 60" Radius Quarter Circle8 156 Straight9 94.25 60" Radius Quarter Circle
10 72 Straight11 48 Switch12 94.25 60" Radius Quarter Circle13 156 Straight14 94.25 60" Radius Quarter Circle15 120 Straight16 94.25 60" Radius Quarter Circle17 108 Straight
Section Length (in) Description18 48 Switch19 94.25 60" Radius Quarter Circle20 120 Straight21 48 Switch22 72 Straight23 48 Switch24 228 Straight25 94.25 60" Radius Quarter Circle26 180 Straight27 94.25 60" Radius Quarter Circle28 516 Straight29 94.25 60" Radius Quarter Circle
TOTAL
3474 inches of track beam290 feet of track beam187 feet straight track beam
6 48" switch10 60" radius, 90° Curve
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PROPOSED PAINT SHOP LAYOUT
Support Trusses are placed:
• At the center of each curved section
• Before and after each switch
• On straight sections so the longest
unsupported section of track beam is no
greater than 12’
Cross Beams
Qty Length (in) Total Length (ft)
27 108 243
Vertical Supports
Qty Length (in) Total Length (ft)
54 102 459
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TRACK BEAM ANALYSIS
Maximum Shear Force = ±2,724 lbs
Maximum Bending Moment = 16,056 lb-ft
Choosing a Design
Factor (DF):
• Important to account for
larger components of the
future
• Must cover any
unaccounted for forces
• Depends on purpose and
owner’s specifications
It was agreed to use DF of
4.0 for the track beam
system analysis.
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TRACK BEAM ANALYSISActual Stresses
Allowable Stresses
Stress Check
Stress Level and
Case
Allowable Compression
Stress
Allowable Tension Stress
Allowable Shear Stress
Allowable Bearing Stress
1 0.60Fy 0.60Fy 0.35Fy 0.75Fy
A992 SteelFy = 60 ksi 30 ksi 30 ksi 17.5 ksi 37.5 ksi
Combined Stress Ratio
Vertical Deflection
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TRACK BEAM ANALYSISLocal Flange Bending Stresses
Underside of flange at flange-to-web transition – Point 0:
Underside of flange directly beneath wheel contact point – Point 1:
Topside of flange at flange-to-web transition – Point 2:
Resultant Biaxial Stresses (0.66Fy = 33 ksi)
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TRACK BEAM SELECTIONW6x16
• Track beam analysis was performed on all
Standard (S) and Wide (W) Flange I-Beams
available on the U.S. Market (ASTM A992 Carbon
Steel)
• Since the price of these standard beams are
based on the amount of material, the beam with
the smallest cross sectional area that satisfies all
conditions is the most economical choice for this
project
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SUPPORT COLUMN ANALYSIS & SELECTION
Dynamic Load = (DL*DLF) + (TL*DLF)
+ LL
= 1539 lbs
DL – Dead Load
DLF – Dead Load Factor
TL – Trolley Load
LL – Lifted Load
Secant Formula
Hollow Structural Section (HSS)
Column with Eccentric Loading
ShapeBo
Design Wall
Thickness, t
Nominal
Weight
Area, A
Surface
Area
in in lb/ft in2 ft2 / ft
HSS4X4X1/2 4.00 0.500 21.63 6.36 1.19
Shape
in psi psi
HSS4X4X1/2
0.5487
10618
67532
ASTM A500C Carbon Steel
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GUSSET PLATE & BASE PLATE
ANALYSIS & SELECTIONGusset Plate (Haunch) Design Rules of Thumb• Haunch Length – 10% of total overhead beam length
• Theoretical → (108 in)(0.10) = 10.8 in• Actual → 20 in = 18.5%
• Haunch Depth – 2% of total overhead beam length• Theoretical → (108 in)(0.02) = 2.2 in• Actual → 10 in = 9.3%
Base Plate Design – LRFD Method
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PROTOTYPE DESIGN & TESTING
Point LoadDisplacement
(in)
Below cross beams <0.0625
5” from cross beams <0.0625
4.5” from midspan 0.125
1” center and other 3”
from cross beam0.0625
SolidWorks Simulation 0.110
1:6 Scale Prototype- Load: 320 lb = 1477 lb Equivalent Load- Track beam: 24 inch Unsupported
Section- Cross beam: 18 inch- Support column: 17 inch - Base plate- Gusset plate
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FINAL COST ESTIMATECategory Description Price
Area PreparationRemove hazmat room,
hoist, computer server & demolish storage closet
$48,780
MaterialsPaint booths, track / cross beam, support columns,
oven lamps, etc.
$277,12
9
FeesGeneral contractor,
engineering fee, building permits and contingency
$104,40
2
Total
$479,091
- It is estimated that the paint
shop will pay for itself within 6
years or less
- 48 man hours will be saved
from the overhaul process for
each Boeing 777 MLG Outer
Cylinder
- Contingency is priced at 10%
of material and area
preparation
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ENGINEERING CHALLENGES
• Safety
• Strength
• Efficiency
• Cost
• Space
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Applicable Standards from the following organizations will be adhered
to:
• American Society of Mechanical Engineers (ASME) Code of
Ethics
• American Institute of Steel Construction (AISC)
• Crane Manufacturers Association of America, Inc. (CMAA)
• Occupational Safety and Health Administration (OSHA)
• Miami-Dade County (MDC) Building Codes
• United States Environmental Protection Agency (EPA)
• Boeing Standard Overhaul Practices Manual (SOPM)
• Boeing Component Maintenance Manual (CMM)
STANDARDS
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TEAM RESPONSIBILITIES
Joel Escobales – Research
Fabian Robinson – Design
Kyle Lindsay – Development
Each member will lead a section of this
project with the assistance of the other
teammates.
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TIMELINE Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15
Problem Definition
Literature Survey
Project Formulation
Design Alternatives
Project Management
Engineering Design & Analysis
Prototype Construction
Testing & Evaluation
Design Considerations
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GLOBAL LEARNINGThings to consider when implementing this project on a global
scale:
• Language differences
• Units / measurements
• Country’s regulations and standards
• Work force
• Safety
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CONCLUSION AND FUTURE WORK
• Allow AAR to safely and efficiently
move next generation of larger
airplane components through
paint shop
• Use engineering knowledge to
improve other aspects of the paint
shop including air circulation and
thermal efficiency of ovens &
lamps
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