1. Team 7: Vincent Borsello, Michael Brill, Daniel Gempesaw, Travis Mease
Sponsor: Revenge Advanced Composites
Advisor: Dr. James Glancey

2. Revenge Advanced Composites
Composites in marine applications
Industry-leading technology
Currently designing a new composite boat

4. Advantages of Composites
Design a new composite shock mitigating marine seat and its manufacturing process
Problems with current seats:
Weight (metals), size
Tradeoff: shock mitigating seats vs. payload
Advantages of Composites
Lightweight
Strength only where needed
Carbon fabric is approximately five times less dense than steel.

5. Seat Attachment Mechanism Damping Mechanism Frame Shockwave
Insert picture of benchmark seats. Go over all common components.
Shockwave
Seat (144 lbs)
Ullman Atlantic
Seat (100 lbs)

6. Focus: Minimize the weight of the Support Structure while maintaining strength
Several parts were pre-selected by our sponsor, Revenge Advanced Composites
Semi-active shock absorber
The seat will be configured to match our design
Boat navigation Controls will be integrated into the prototype
Insert solidworks assembly and show the components that we are designing (structure) not seat and shock. Stress these things;
Notes:
-Seat is an illustrative CAD model….not the actual design (Our sponser will be addressing this problem)

7. Dynamic Load Damping Capabilities Product Life: 1400 working hours
50% Weight Reduction
Relative to Shockwave Seat (144 lbs)
Dynamic Load Damping Capabilities
20 G’s Vertical, 4 G’s Fore/Aft, 4 G’s Lateral
Product Life: 1400 working hours
~150 instances of worst case vertical load
Reduced Footprint/Size
Less than 28 x 40 in^2
Manufacturing
Best Practices for Pre-impregnated fibers (Prepreg)
Later slide with a table comparing what our goals were and then where we ended up… show factors of safety we designed for 20 G’s vertical it can really handle 21.

8. Arm Base Clevis Pivot Point C-channel Direct load path
Minimal footprint
Clevis
Integrate shock into design
Pivot Point
Bushing, Rod, Plates 3 1 4 2

9. Material Considerations
Dimensions & geometry
Force analysis of structure
Material Considerations
Strength and Stiffness
Curing/Outlife Characteristics
Weathering/Corrosion
Analyze all modes of failure (6)
Manufacturing Issues
Mold Designs
Ply Patterns
Vertical ≈ 20 G’s
Fore/Aft ≈ 4 G’s
Lateral ≈ 4 G’s
Integrate concept design,
Modes of failure: Tear-out(material going through walls), Compression, Bending, Deflection, Shear, Pull out (bolts)

10. 8 Shape/Geometry of Structure Applied Loads
Varying Thickness Capability
Bolt Layout
Bolt Sizes
Washer Dimensions
Bearing Size
Pivot Point Mechanism
Arm to Seat Attachment
Structure to Boat Attachment
Load Paths
Composite Ply Layout
Hole Distance From Edges
Clevis Attachment
Rider Comfort
Material Selection
Core Dimensions
Adhesive Selection
Support Plate Dimensions
Seat Dimensions
Hole Sizes
Composite Manufacturability
-Determing each bullet always required several forms of failure analysis
-Many of these variables can be broken down into more detailed stuff 8

11. Derive resultant forces in the entire system
Pivot point, shock mechanism, in arm & base
Side FBD of Mechanism for illustration purposes

12. Next step: consider critical areas
Knowing the forces in system, use stress and deflection analysis to derive thickness
Next step: consider critical areas
Approximate arm & base as simple C-channels to calculate moments of inertia

13. Failure modes for bolts:
Tension
Pull-out
Inter-laminar shear
Compression
Thickness=t d1
Shear Area d2
Top-down view of base flange
Depiction of Tear-out failure

14. Pivot pin was found to fail due in tear-out
Low inter-laminar shear strength of composites
Solution: Bond on a metal doubler plate
R_bearing
X_a
Y_a
R_rod
Cantilever Arm
The plot on the left depicts the load carrying capabilities with a doubler plate, analyzing the failure of the adhesive.

15. Attachment of shock to arm & base
Designed to specifications of Active-Shock
ActiveShock is specified by RAC
Side view of Clevis Plate
Top-down view of Clevis Plate

16. De-molding Bridging Vacuum Molding Draft Angle – 2 degrees
Minimum Radius of Curvature – 1 inch
Vacuum Molding
Extending Mold Surfaces for Vacuum Bagging
Insert picture of cad model and then lead up to actual picture, picture of bridging.

17. 1 2
Pre Mold Phase: Cutting of carbon fiber into specific pieces so that they can be laid up “perfectly” into the part…make a joke here about our cutting skills (1,2).
Travis measuring and cutting the foam core…state the importance of the core…talk about how we will see it laid up in the part later on. (3)
Steve…our hero advisor…thank him for never having faith in us…unloading the mold…talk about how the mold was outsourced b/c of lead times…wouldn’t have been possible to build it ourselves…what its made out of. (4) 3 4

18. 5 7 6 The Mold right in the box! (5)
Vince and Mike applying tape around the edges of the mold…a very important process that allows for the application of a vacuum bag and is crucial for proper sealing…need to debulk. (6)
Vince, Mike and Travis applying wax…discuss the importance of application of multiple layers of wax…makes surface so smooth that tape will not stick to it and can be blown off. (7) 6

19. 9 8
After a final layer of coating the first ply of carbon fiber is applied to the mold. The puzzle pieces begin to fall into place. It is important that each piece lies flush with the adjacent. (8)
We did a real nice job with the first ply, no bubbles or buildup and aesthetically pleasing. (9)
First debulking cycle…talk about the two layers on top of the prepreg…white is so it vacuums uniformly and the layer underneath is to prevent the fabric from sticking to the prepreg. (10)
Vacuum complete…its crucial to have enough vacuum bag so that it can compress all the way down into the corners…even vacuum…will apply a debulking cycle after 3-4 layers of ply, important for the material to collapse onto itself. (11) 10 11

20. 12 14
Closer look at the vacuum bag and the hose for removing air…sealing around this region is crucial for proper debulking. (12)
Application of the core applied after a few plys have been placed down. (13)
Cutting special adhesive layer designed for ply-core interfaces. (14)
Debulking is a compacting process where you apply a load from a vacuum is applied and relaxed to get the fibers as compacted as possible. 13

21. 16 15
After the mold is cured under vacuum overnight we have the challenge of removing the part from the mold. (15, 16)
The part finally removed. (17) 17

22. 19
Layup
Mold
Part 18 20

23. 22 21 23 25 24 26

24. Item Weight (lbs) Base 7.69 Arm 3.86 Seat 12.6 Shock 15 Tooling 9.1
Total
48.2
Picture of prototype with wiegtht table of each indiv component

25. All Target Values have been validated except for Fatigue Life.
Metrics
Target Values
Actual Values
Percent Reduction
Weight
50 % of 144 lbs
48 lbs
67%
G-Loads
N/A
Vertical
20 G’s
22 G’s
Fore Aft
4 G’s
6 G’s
Lateral
Product Life
1400 hours
Unknown -
Footprint
<28 x 40 (1120 in2)
22 x 24 (528 in2)
53%
All Target Values have been validated except for Fatigue Life.
Prototype Mold and Parts Cost: $20,000
Describe why fatigue life wasn’t met…future project to validate…tested over x hours

26. Target the lowest factor of safety Different seat
Fatigue Tests
Different Materials
Carbon Fiber
Titanium
Bolt on Boat Testing
Target the lowest factor of safety
Different seat
Finish coating/ aesthetics
Fatigue tests…where we go from here.

27. Michel Lourdemarianadin Hope Deffor Steven Beard Jon Sadowsky RAC
Stephen Andersen
Jim Glancey
Michel Lourdemarianadin
Hope Deffor
Steven Beard
Jon Sadowsky
RAC
Special Warfare Group 7
Insert special warfare pictures,