Transcript Rolls Royce High Pressure Water Jet Cleaning System Final

Design Group:
Wei-Yuan Chu
Adrian Conrad
Thomas Hylton
Scott Jean
Nicholas Metzger
IUPUI Faculty Advisor:
Dr. Jie Chen
Rolls-Royce Advisor:
Timothy Fuesting
 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

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

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
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Easy to Assemble
Easy to Maintain
Simple to Manufacture
No Harm to the Environment
recyclable
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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
 Fixture
Design
allows for securing
the airfoil in either
inner or outer rod
configuration.
 Outer
Configuration is
required for airfoils
with obstructed
interior passages.
 Swiveling
quick
disconnects provide
rotation of the fixture,
as well as easy
removal.
Existing
Hose and
Water Gun
Water In
Fixture
Water Out
H24506
LL3-S21
LL3-T20
06S-106
96-100
6709
Eaton Weatherhead H245 Hose (3/8" ID, 11/16 "
OD x 1 ft.)
Hansen Quick Disconnect - Female End Socket
(3/8 Body Size)
Hansen Quick Disconnect - Male End Plug (3/8
Body Size)
Eaton Weatherhead Rigid Male Hose End (3/8"
ID, 3/8-18 NPT)
Apollo Stainless Steel Uni-Body Saturn Ball Valve
(3/8' ID, 3/8-18 NPT)
Eaton Weatherhead 3-way Multiple Shut-off
Valve (3/8 - 18 NPT)
A.
Base plate
B.
Quick disconnection
parts and rubber
pads
C.
Slider arbor
D.
Socket rods connect
large contact and
small contact
E.
Quick
disconnections and
contacts
F.
Rubber and
contacts
G.
Fixed arbor
H.
Distance controller
I.
Arbor top and
arbor
J.
Screws connect
arbor and plate
 Engineering Targets
tested through various
methods of analysis.
 Each
of the engineering targets represented in
numerical values.
 Each
requirement must meet the customers’
standards.
 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

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
 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
 Fixture’s
operating height: 4.5”
4.5”
 Designed
to function under comfortable
operating conditions within the parameters of
the dry box.
 Analysis
using ANSYS Workbench
 Worst Case Scenario
• Maximum Pressure
 Uniformly Distributed Force
• (4000 psi = 27.579 Mpa)
• Perpendicular to Large Contact Faces
 Coarse
 High
Mesh
Stress Areas
• Refined Locations:
• Large Contact Holes
• Arbor Base Edges
 Analysis
to look at
• Total Deformation
• Tensile Stresses
 Locate Problem Areas
 Max
Stress Locations
• Less than Stainless Steel Yield Strength
of 515 MPa.
Outer Rod Assembly
Max Tensile Stress: 407 MPa
Inner Rod Assembly
Max Tensile Stress: 312 MPa
Outer Rod Assembly
Max Deformation: .16 mm
Inner Rod Assembly
Max Deformation: .23 mm
Goal
Target Range
Actual
Water Pressure transmitted through spray nozzle
2,000 PSI - 4,000 PSI
3,013 PSI
Water Pressure transmitted through fixture
3,000 PSI - 4,000 PSI
3,582 PSI
Number of Flow Directions
2 Directions
2 Directions
Fixture Operating Height
< 8 in
4.5 in
Compact and able to fit in alloted space
60 in2 - 140 in2
60 in2
Number of Adjustable Features
1 - 3 Features
3 Features
Support Tensile Strength
< 74.6 KSI
45.2 KSI
Corrosion Resistance
0.5 PRE - 1.5 PRE
1.8 PRE
Requirement Met?
 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