1. PAINT SHOP TRACK BEAM SYSTEM Joel Escobales Fabian Robinson Kyle Lindsay EML 4905 Senior Design Project Florida International University Department of Mechanical Engineering Miami, FL

2. Self-contained, full-service aircraft landing gear overhaul facility Repair and overhaul landing gear, wheels, brakes, and accessories for 43 different types and subtypes of commercial and military aircraft Allen Aircraft Radio Landing Gear Services

3. BOEING 777 MAIN LANDING GEAR OUTER CYLINDER Length ≈ 10 ft Weight ≈ 1300 lbs

4. CURRENT PAINT SHOP

5. CURRENT PAINT SHOP CONFIGURATION 3 Paint Booths (Paint Booth #2 is NOT accessible from track beam) 2 Small Ovens Design Alternate 1, 2, 3 Design Alternate 4

6. DESIGN ALTERNATES Pros Spacious design Larger oven space Multiple options Cons Production stoppage Two paint booths Pros Larger oven space Three paint booths Multiple options Cons Limited production Paint booth at each oven entrance Pros Least expensive design Quick implementation Cons Limited oven space Limited future improvement Pros Larger oven space Does not halt production Cons Longest construction Most expensive alternate #1 #2 #3 #4

7. PROPOSED PAINT SHOP LAYOUT (#4) SectionLength (in)Description 1180Straight 248Switch 3108Straight 494.2560" Radius Quarter Circle 5228Straight 648Switch 794.2560" Radius Quarter Circle 8156Straight 994.2560" Radius Quarter Circle 1072Straight 1148Switch 1294.2560" Radius Quarter Circle 13156Straight 1494.2560" Radius Quarter Circle 15120Straight 1694.2560" Radius Quarter Circle 17108Straight SectionLength (in)Description 1848Switch 1994.2560" Radius Quarter Circle 20120Straight 2148Switch 2272Straight 2348Switch 24228Straight 2594.2560" Radius Quarter Circle 26180Straight 2794.2560" Radius Quarter Circle 28516Straight 2994.2560" Radius Quarter Circle TOTAL 3474inches of track beam 290feet of track beam 187feet straight track beam 648" switch 1060" radius, 90° Curve

8. PROPOSED PAINT SHOP LAYOUT Support Trusses are placed: At the center of each curved section Before and after each switch On straight sections so the longest unsupported section of track beam is no greater than 12’ Cross Beams QtyLength (in)Total Length (ft) 27108243 Vertical Supports QtyLength (in)Total Length (ft) 54102459

9. TRACK BEAM ANALYSIS Maximum Shear Force = ±2,724 lbs Maximum Bending Moment = 16,056 lb-ft Choosing a Design Factor (DF): Important to account for larger components of the future Must cover any unaccounted for forces Depends on purpose and owner’s specifications It was agreed to use DF of 4.0 for the track beam system analysis.

10. TRACK BEAM ANALYSIS Stress Level and Case Allowable Compression Stress Allowable Tension Stress Allowable Shear Stress Allowable Bearing Stress 10.60F y 0.35F y 0.75F y A992 Steel F y = 60 ksi 30 ksi 17.5 ksi37.5 ksi

11. TRACK BEAM ANALYSIS

12. TRACK BEAM SELECTION W6x16 Track beam analysis was performed on all Standard (S) and Wide (W) Flange I-Beams available on the U.S. Market (ASTM A992 Carbon Steel) Since the price of these standard beams are based on the amount of material, the beam with the smallest cross sectional area that satisfies all conditions is the most economical choice for this project

13. SUPPORT COLUMN ANALYSIS & SELECTION Dynamic Load = (DL*DLF) + (TL*DLF) + LL = 1539 lbs DL – Dead Load DLF – Dead Load Factor TL – Trolley Load LL – Lifted Load Secant Formula Hollow Structural Section (HSS) Column with Eccentric Loading Shape Bo Design Wall Thickness, t Nominal Weight Area, A Surface Area in lb/ftin 2 ft 2 / ft HSS4X4X1/24.000.50021.636.361.19 Shape inpsi HSS4X4X1/20.54871061867532 ASTM A500C Carbon Steel

14. GUSSET PLATE & BASE PLATE ANALYSIS & SELECTION Gusset Plate (Haunch) Design Rules of Thumb Haunch Length – 10% of total overhead beam length Theoretical → (108 in)(0.10) = 10.8 in Actual → 20 in = 18.5% Haunch Depth – 2% of total overhead beam length Theoretical → (108 in)(0.02) = 2.2 in Actual → 10 in = 9.3%

15. PROTOTYPE DESIGN & TESTING Point LoadDisplacement (in) Below cross beams<0.0625 5” from cross beams<0.0625 4.5” from midspan0.125 1” center and other 3” from cross beam 0.0625 SolidWorks Simulation0.110 1:6 Scale Prototype -Load: 320 lb = 1477 lb Equivalent Load -Track beam: 24 inch Unsupported Section -Cross beam: 18 inch -Support column: 17 inch -Base plate -Gusset plate

16. FINAL COST ESTIMATE CategoryDescriptionPrice Area Preparation Remove hazmat room, hoist, computer server & demolish storage closet $48,780 Materials Paint booths, track / cross beam, support columns, oven lamps, etc. $277,129 Fees General contractor, engineering fee, building permits and contingency $104,402 Total $479,091 -It is estimated that the paint shop will pay for itself within 6 years or less -48 man hours will be saved from the overhaul process for each Boeing 777 MLG Outer Cylinder -Contingency is priced at 10% of material and area preparation

17. ENGINEERING CHALLENGES Safety Strength Efficiency Cost Space

18. Applicable Standards from the following organizations will be adhered to: American Society of Mechanical Engineers (ASME) Code of Ethics American Institute of Steel Construction (AISC) Crane Manufacturers Association of America, Inc. (CMAA) Occupational Safety and Health Administration (OSHA) Miami-Dade County (MDC) Building Codes United States Environmental Protection Agency (EPA) Boeing Standard Overhaul Practices Manual (SOPM) Boeing Component Maintenance Manual (CMM) STANDARDS

19. TEAM RESPONSIBILITIES Joel Escobales – Research Fabian Robinson – Design Kyle Lindsay – Development Each member will lead a section of this project with the assistance of the other teammates.

20. TIMELINE Aug-14Sep-14Oct-14Nov-14Dec-14Jan-15Feb-15Mar-15Apr-15 Problem Definition Literature Survey Project Formulation Design Alternatives Project Management Engineering Design & Analysis Prototype Construction Testing & Evaluation Design Considerations

21. GLOBAL LEARNING Things to consider when implementing this project on a global scale: Language differences Units / measurements Country’s regulations and standards Work force Safety

22. CONCLUSION AND FUTURE WORK Allow AAR to safely and efficiently move next generation of larger airplane components through paint shop Use engineering knowledge to improve other aspects of the paint shop including air circulation and thermal efficiency of ovens & lamps