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Spirit Aerosystems Final Review

Jerid Sutton Daniel Smith. Spirit Aerosystems Final Review. To prove an already employed analysis tool, improve it, or create new analysis tools for joints and fasteners. In doing this we would predict load distribution through the fasteners in the joint.

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Spirit Aerosystems Final Review

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  1. Jerid Sutton Daniel Smith Spirit Aerosystems Final Review

  2. To prove an already employed analysis tool, improve it, or create new analysis tools for joints and fasteners. In doing this we would predict load distribution through the fasteners in the joint. • Being able to predict load transfer at a fastener could be very useful to a stress analyst. Concept Goal

  3. Design Test Concepts • Load Distribution • Fastener arrangement and spacing has a major effect on the distribution of a load

  4. 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 Load Transfer Theory

  5. Aluminum (2024-T3) • ½” to 2” total joint thickness • Fasteners • Bolts and Nuts (Hi-Loks) • Rivets • 3/16” to 3/8” diameters • Materials – titanium, A-286 Steel, Nickel Alloy Spirit Design Considerations

  6. Availability of testing equipment • Using Aluminum 2024-T1 1/8” and 3/16” Plate • Blind Rivets • 3/16” Diameter • Aluminum • Stainless Steel • Titanium Team Design Considerations

  7. Nut and Bolt Combination • ¼”-3/16” Diameter • Stainless Steel • Grade 8 • Grade 6 Team Design Considerations

  8. Standard Tension Tests • 11,000 lb Maximum Tensile Force • Software • Pro-Mechanica FEA • ALGOR FEA PSU Testing Capabilities

  9. 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 Standard Test Procedure

  10. 1040 Cold-drawn Steel • Stress = Force/Area • Sample Calculation • 6,250 lb/(.25in X .5in) = 50,000 psi • Compare with Pro-Mechanica Analysis Results Calculation Comparison

  11. Tensile Test Results in Pro Mechanica

  12. Manufacturing Plan

  13. 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 Riveted joint concept

  14. First joint design

  15. Final Specimen drawing

  16. Measured every specimen cut out and scrapped anything that was not within .1” of tolerance Some holes that were drilled didn’t 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 sharp corners for safety reasons Tolerance and quality issues

  17. Rivet installation

  18. Close up of installation tool

  19. Rivet installation block

  20. 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 to break the specimen here. Rivet shear strength calculation

  21.  Fundamentally, all strain gages are designed to convert mechanical motion into an electronic signal. A change in capacitance, inductance, or resistance is proportional to the strain experienced by the sensor. If a wire is held under tension, it gets slightly longer and its cross-sectional area is reduced. This changes its resistance (R) in proportion to the strain sensitivity (S) of the wire's resistance. Strain Gage Fundamentals

  22. STRAIN READING

  23. PREPARING FOR TESTING

  24. STRAIN GAGES

  25. RECORDING STRAIN

  26. TEST PIECE IN MACHINE

  27. CLOSE-UP OF TEST PIECE IN MACHINE

  28. Finite Element Analysis in Pro-e

  29. Elongation prediction

  30. Test Results From One Specimen

  31. 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 made to correspond with many different numbers of fasteners and we do not know yet how to get it to calculate the load at only 3. Interpretation of Results

  32. Questions?

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