May 16, 2003 Team #27 EA-6B Flaperon Actuator Team Members: Eric Sullivan (Project Manager) (Project Manager) Joseph Clark Casey Poeth Josselin Legeay.

May 16, 2003May 16, 2003Team #27Team #27

EA-6B Flaperon EA-6B Flaperon ActuatorActuator

Team Members:Team Members:

Eric Sullivan Eric Sullivan (Project Manager)(Project Manager)

Joseph ClarkJoseph Clark

Casey PoethCasey Poeth

Josselin LegeayJosselin Legeay

Janice WiselyJanice Wisely

Advisor:Advisor:

Dr. DeBartoloDr. DeBartolo

May 16, 2003May 16, 2003Team #27Team #27

AgendaAgenda

The Model -The Model - Josselin LegeayJosselin Legeay

Timeline -Timeline - Janice WiselyJanice Wisely

Testing -Testing - Eric SullivanEric Sullivan Testing Setbacks -Testing Setbacks - Eric SullivanEric Sullivan Results -Results - Casey PoethCasey Poeth

RecommendationsRecommendations– Clevis Design - Clevis Design - Joseph ClarkJoseph Clark

– Material Change - Material Change - Joseph ClarkJoseph Clark Corrosion Issues - Corrosion Issues - Josselin LegeayJosselin Legeay

May 16, 2003May 16, 2003Team #27Team #27

The ModelThe Model

Scaled downScaled down

Stiffening Stiffening RidgeRidge

1 2

3

May 16, 2003May 16, 2003Team #27Team #27

Timeline - Timeline - GANTTGANTT2/7 2/14 2/21 2/28 3/7 3/14 3/21 3/28 4/4 4/11 4/18 4/25 5/2 5/9 5/16

L7

L3

L4

L5

L6

J

K

L1

L2

F5

G

H

I

F6

F1

F2

F3

F4

D2

E1

E2

F

A

B

C

D1

May 16, 2003May 16, 2003Team #27Team #27

TestingTesting

May 16, 2003May 16, 2003Team #27Team #27

TestingTesting

6 Tests6 Tests– 3 w/ ridge3 w/ ridge– 3 w/o ridge3 w/o ridge

ProcedureProcedure– Set-upSet-up– Pre-loadPre-load– TestTest

May 16, 2003May 16, 2003Team #27Team #27

Testing SetbacksTesting Setbacks

Clevis DesignClevis Design

Apparatus Inconsistency Apparatus Inconsistency

Data Acquisition TechniquesData Acquisition Techniques

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ResultsResults

May 16, 2003May 16, 2003Team #27Team #27

Deflection of all samples

0.023

0.024

0.025

0.026

0.027

0.028

0.029

0 500000 1000000 1500000 2000000 2500000

Cycles

Test 1

Test 2A

Test 2B

Test 3

Test 4A

Test 4B

Test 6

Test 5

ResultsResults

Test 1: 745,155Test 2: 766,682Test 3: 957,059Test 4: 1,573,111Test 5: 2,000,000Test 6: 1,029,879

May 16, 2003May 16, 2003Team #27Team #27

RecommendationsRecommendations

May 16, 2003May 16, 2003Team #27Team #27

Clevis Clevis DesignDesign

One Piece DesignOne Piece Design

Three Piece DesignThree Piece Design

May 16, 2003May 16, 2003Team #27Team #27

Material Material ComparisonComparison

MaterialTensile Strength

(ksi)

Young's Modulus

(106 psi)

Thermal Expansion (strain/F)

Price / lb ($)

2014 T-6 Aluminum

55.98 - 71.07 10.44 - 11.17 12.33 - 13.44 0.50 - 0.81

4130 Steel (annealed)

72.52 - 89.92 29.15 - 31.33 6.11 - 7.22 0.17 - .30

Titanium alpha- beta Alloy

144.3 - 145.8 14.50 - 15.95 4.44 - 5.44 13.24 - 18.53

High-Tensile Manganese Bronze

107.3 - 134.9 12.92 - 13.18 11.28 - 11.5 0.70 - 0.74

May 16, 2003May 16, 2003Team #27Team #27

Cu

H2

Fe

Zn

Al

Cu2+

H+

Fe2+

Zn2+

Al3+

+0.34V

0.00V

-0.44V

-0.76V

-1.66V

MnMn2+ -1.18V

Corrosion Corrosion issuesissues

Copper could attack Copper could attack the aluminumthe aluminum

Could result in Could result in failure modesfailure modes

Aluminum oxide Aluminum oxide (Al(Al22OO33) is impervious ) is impervious and coherentand coherent

Corrosion stops Corrosion stops when the layer is when the layer is 1nm thick1nm thick

May 16, 2003May 16, 2003Team #27Team #27

ConclusionsConclusions

Clevis designClevis design

Material ChangeMaterial Change

Increase Number of Increase Number of Tests Tests – S-N curveS-N curve– Statistical verification Statistical verification

May 16, 2003May 16, 2003Team #27Team #27

¿ Questions ?¿ Questions ?

May 16, 2003May 16, 2003Team #27Team #27

ExpendituresExpenditures

Item Description Specifications Price / Unit Quantity CostLocking Ring 4130 Steel $85.00 12 $1,020.00End Cap 4130 Steel $76.00 6 $456.00Housing without ridge 2014 T-6 Aluminum $86.00 3 $258.00Housing with ridge 2014 T-6 Aluminum $129.00 3 $387.00Hanging Scale 50 lbs (8 oz graduations) $56.70 1 $56.70Spanner Wrench adjustible 2" to 4.75" $28.22 1 $28.22

3 1/2" X 16" alum 2014 - T6 round stock $98.40 10 $984.00

Clevis Grips created by Instron ® $4,000.00 2 $8,000.00

Total $11,190

May 16, 2003May 16, 2003Team #27Team #27

Maximum Working Maximum Working ForceForce

P= 3000 psi

Aef f = 4.879 in2

# Chambers 2Working

Force29274 lbf

May 16, 2003May 16, 2003Team #27Team #27

Pre-loading ForcePre-loading Force

Pre-loading force greater than Pre-loading force greater than maximum working force.-maximum working force.-

.2*

TorqueF

d

P= 4500 psi

Aef f= 6.49 in2

Torque= 15 ft-lbf

Preload Force

29532 lbf