1. Mast Storage Rack NNSY Sean Ellis, Philip Crist, Max Carpenter, Gershom Obeng

2. The Problem Submarine masts are stored horizontally Damage to O-rings Uses excessive floor space Inefficient process flow Masts are failing upon reinstallation Seals losing tolerances Leak hydraulic fluid

3. The Solution Design a rack to store mast vertically Relieves pressure on O-rings Small footprint Better location

4. Mast Dimensions Snorkel 688 CLASS: 5” – D; 12’ 4” – L; 800-1000 Ibs 726 CLASS: 12” – D; 14’ 6.5” – L; 3000 Ibs Periscope LIFTING: 2.5” – D; 16’ 7” – L FAING: 5.25” – D; 11’ 8” – L Radar 2.5” – D; 5.375’ – L

5. Requirements Hold numerous masts Set of 8 per submarine Accommodate various mast diameters 3”-12” Diameters Adjustable clamps to secure masts Strong Weight: 1,000 – 3,000 Ibs per mast 10,000 Ibs Total

6. Design Base Vertical Truss Clamp

7. Base Design I-beams bolted to floor supporting sheet metal base plate Drain pan for residual oils I-beams located directly under masts Considered all joints welded Simple hand calculations Static, point forces Compressive stresses

8. Base Calculations

9. Vertical Truss Design I-beams welded to base, steel angles for bracing Analyzed rack as if mast were tilted 5° Clamp attaches to I-beams Adjustable vertically PATRAN/NASTRAN FEA model Accurate stress/deflection results *Single section

10. Truss Calculations

11. Technical Drawing

12. Clamp Design Modular design to allow for easy replacement Adjustable along height of rack “U-brackets” to attach on face of rack Standard hardware items Hand calculations for bolt strength

13. Clamp Calculations

14. Max Load Test Clamp 5 DEGREE TILT 10 DEGREE TILT Minimum Conditions tested at max load6000 LBS Stress (PSI)Safety Factor Stress (PSI) 4 Safety Factor5 3/8 10-UNCA36 36,000275901.30482276301.30293 A995/A572-50 50,000383001.30548383401.30412

15. Technical Drawings

16. Cost Analysis (Welded) Welded MethodEstimated Costs MaterialDimensionsQuantityHours Required24 Steel Angle2"x2"x64"4# of Workers1 2"x2"x24"10Total Weight (lbs)4010 I-Beam (A36)8"x8"x4'7Steel Cost per lb$0.65 4"x4"x10'8Welding Inches1155.8 4"x4"x15'2Cost per Foot$2.44 Steel Plate (A36)4'x x0.5"1FastenersPer Bolt Sheet Metal (A36)6"x0.1"x15'21/2"-13x4"$1.76 Fasteners1/2"-13x4"203/4"-10x6"$5.33 3/4"-10x6"403/4"-10x8"$8.24 3/4"-10x8"40Raw Steel$0.65 per lb Raw Steel for Clamp24"x1.5"x0.5"9 15 lbs 7.5"x7.5"x1.5"9 30 lbs Total Estimated Cost$3,682.76

17. Cost Analysis (Bolted) Bolted MethodEstimated Costs MaterialDimensionsQuantityHours Required24 Steel Angle2"x2"x64"4# of Workers1 2"x2"x24"10Total Weight (lbs)4010 I-Beam (A36)8"x8"x4'7Steel Cost per lb$0.65 4"x4"x10'8Welding Inches672 4"x4"x15'2Cost per Foot$2.44 Steel Plate (A36)4'x x0.5"1FastenersPer Bolt Sheet Metal (A36)6"x0.1"x15'21/2"-13x2"$1.06 Fasteners1/2"-13x2"1601/2"-13x4"$1.76 1/2"-13x4"203/4"-10x6"$5.33 3/4"-10x6"403/4"-10x8"$8.24 3/4"-10x8"40Raw Steel$0.65 per lb Raw Steel for Clamp24"x1.5"x0.5"9 15 lbs 7.5"x7.5"x1.5"9 30 lbs Total Estimated Cost$3,753.99

18. Gantt Chart

19. Questions?