1. 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

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

3. Background

4. 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

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

6. Preliminary Design

7. 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

8. 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

9. Concept Design

10. Column Support
Box beam
Concrete base
Bolted to cross-support

11. Cross Support
Box beam
Bolted to column
Supports rails

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

13. Column Support Assembly
All parts bolted and welded

14. Full Assembly

15. Material Selection

16. 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

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

18. Cost Evaluation

19. 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 $ $
Price difference per section
$512.53

20. 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)

21. 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

22. Product Evaluation

23. 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

24. Equivalent Stress (Structure)
Maximum
5.53e7 Pa

25. Shear Stress (Structure)
Maximum
2.81 e7 Pa

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

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

28. Fatigue Analysis (Beam)

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

30. Total Deformation (Beam)
Maximum
9.5 mm

31. Fatigue Life (Beam)
Minimum
8.03e5 cycles

32. Conclusion

33. 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

34. Recommendations

35. 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

36. References http://www.uspto.gov/patft/index.html
Project definition packet, Russell Foundation
“IndianaFreight and IndianaMonorail,” Roger Knutson; Russell Foundation;
Advance Transit Solutions, LLC, May 2007
Machinist’s Handbook 12th Edition, Lang, page 397

37. Questions