Russell Foundation Monorail Support System ME 462 Capstone Design Group Members: Kelly Moore, Bart Sudhoff, Danny Compton, Katie Iaizzo, Mary Croucher Advisors: Dr. Jie Chen and Dr. Roger Knutson 12 Decmeber 2007

Introduction Background Design Objectives Material Selection Cost Evaluation Concept Design Product Evaluation Conclusion Recommendations Answer Questions

Background

Russell Foundation Founded By Bishop Michael Russell and his Father In 2003 Faith Based Community Development Organization Renders Self-sufficiency Programs to Help Stabilize Families and Communities Provides Jobs for Local Communities Environmentally Friendly Initiatives

Reasons For Design Reduce Traffic Congestion around Chicago-Indiana Area Provide High Speed Transportation Create Jobs in Indiana Pioneering Environmentally Friendly Mass Transit Solutions

Preliminary Design

Customer Requirements Travel 75 MPH Support Renewable Energy Source Easy Assembly Easy Maintenance Smooth Rail Transition Appearance Support 160,000 lb load Minimize Stopping Time Minimize Cost Minimize Environmental Effects

Engineering Requirements Minimize Resistance (Rail) Maximize Allowable Stress (Structure) Equipment Hours Labor Hours Minimize Rail Height Difference Public Appearance Rating Maximize Allowable Stress (Rail) Maximize Allowable Stopping Force Minimize Cost Minimize Environmental Effects on Material

Concept Design

Column Support Box beam Concrete base Bolted to cross-support

Cross Support Box beam Bolted to column Supports rails

Standard I-Beam W27 x 368 Standard Size Internal height equal to 25.43 inches Fits standard 22 inch tire diameter

Column Support Assembly All parts bolted and welded

Full Assembly

Material Selection

Types of Steel Two common types used: ASTM A992 and ASTM 588 More common steel types reduce cost High strength, low alloy steel, which used recycled metals Saves on cost of manufacturing Environmentally friendly

Physical Properties ASTM A588 ASTM A992 Contains Chromium for weather resistance Made using 95% recycled material Develops oxide coating Inexpensive 50 ksi yield strength

Cost Evaluation

Price per cwt from Nucor-Yamato Steel Price difference per section Structural Steel ASTM A-588 ASTM A-992 Price per cwt from Nucor-Yamato Steel $51.10 $46.60 Price per 80ft Beam $6483.85 $5971.32 Price difference per section $512.53

Price Comparison Consider long term maintenance and repair cost Northwestern University experiment A992 corrodes 64% more over time than A588 A992 would last less than half as long as A588 (weathering steel)

Nuts and Bolts Quantity Description Unit Price Total Price 48 Grade 8 Plain Alloy Steel Hex Head Cap Screw 1-1/8"-7 Thread, 6" Length $7.16 Each $343.68 24 Grade 8 Plain Alloy Steel Hex Head Cap Screw 1-1/8"-7 Thread, 5" Length $6.25 Each $150.00 15 Grade 8 Plain Steel Hex Nut 1-1/8"-7 Screw Size, 1-11/16" Width, 31/32" Height, Packs of 5 $6.12 Pack $91.80   Total $585.48

Product Evaluation

Loading (Structure) Deadweight Load 80,000 lbs (355868 N) per Rail Braking Force 9.8 m/s2 * 80,000 lbs Fixed Supports Base – Ground Interface Open End Rails

Equivalent Stress (Structure) Maximum 5.53e7 Pa

Shear Stress (Structure) Maximum 2.81 e7 Pa

Total Deformation (Structure) Maximum 16.75 mm Location Mid-span

Factor of Safety (Structure) Minimum 6.15 Location Beam- Near Connection

Fatigue Analysis (Beam)

Loading (Beam) Deadweight load 40,000 lbs per Flange Fixed Supports Open Ends of Beam

Total Deformation (Beam) Maximum 9.5 mm

Fatigue Life (Beam) Minimum 8.03e5 cycles

Conclusion

Concluding Remarks Our designed is based on the customer requirements and goals of the Russell Foundation. The factor of safety meets required limit of 5-7 Fatigue life exceeded 8.0 e5 cycles A588 steel resists weathering without excessive cost Single column design minimizes footprint Designed to easily integrate renewable energy sources

Recommendations

Structure Span Length Preliminary Testing Larger Beam 39 in. Interior Beam height Factor of Safety Increased to 9.53 Custom Beam Standard Size Not Available

References http://www.uspto.gov/patft/index.html http://www.delphion.com/home Project definition packet, Russell Foundation “IndianaFreight and IndianaMonorail,” Roger Knutson; Russell Foundation; Advance Transit Solutions, LLC, May 2007 http://www.wisegeek.com/what-is-a-steel-i-beam.htm http://en.wikipedia.org/wiki/I-beam Machinist’s Handbook 12th Edition, Lang, page 397 http://www.matweb.com

Questions