1. Design Group: Wei-Yuan Chu Adrian Conrad Thomas Hylton Scott Jean Nicholas Metzger IUPUI Faculty Advisor: Dr. Jie Chen Rolls-Royce Advisor: Timothy Fuesting

2.  Establish a Need  Identify the Customer  Determine Customer Requirements  Develop Engineering Specifications  Concept Development & Evaluation  Design Product  Evaluate Product to Specifications  Manufacture and Testing  Product Release

6.  Rolls-Royce Engineering Timothy Fuesting Mary Gambone  Rolls-Royce dry box operator assemble and safely use fixture to clean airfoils  Rolls-Royce maintenance / tool & dye maintain / repair system  Manufacturer simple to make parts  Environment environmentally safe / recyclable

7.  Operator Safety no possible contact with skin  Works as Required removes debris / high pressure (≈4000 psi)  Fits in the space occupied by former system  Easy to Use little operator training required  Easy to Assemble  Easy to Maintain  Simple to Manufacture  No Harm to the Environment recyclable

8.  Provide high pressure water through the handheld spray nozzle  Provide high pressure water through the fixture  Fixture Operating Height Under 8”  Fixture must be Compact  Fixture must have High Backpressure Tolerance  Multiple Water Flow Directions  Number of Adjustable Features  Number of days between maintenance should be high  Corrosion Resistance

10.  Fixture Design allows for securing the airfoil in either inner or outer rod configuration.  Outer Configuration is required for airfoils with obstructed interior passages.

11.  Swiveling quick disconnects provide rotation of the fixture, as well as easy removal.

13. Water In Existing Hose and Water Gun Fixture Water Out

14. A. Base plate B. Quick disconnection parts and rubber pads C. Slider arbor D. Socket rods connect large contact and small contact

15. E. Quick disconnections and contacts F. Rubber and contacts G. Fixed arbor

16. H. Distance controller I. Arbor top and arbor J. Screws connect arbor and plate

17.  Engineering Targets tested through various methods of analysis.  Each of the engineering targets represented in numerical values.  Each requirement must meet the customers’ standards.

18.  Utilized the modified Bernoulli Equation Assumptions: Steady Flow, Incompressible, No heat transfer  Results:  Fixture inlet pressure: 3,582 psi  Spray Gun Outlet Pressure: 3,013 psi

19.  Using the maximum values listed at AZOM for 304 stainless steel of 20% Cr, 0% Mo, and 10% N to calculate the PRE (Pitting Resistance Equivalent)  Corrosion occurs with the breakdown of the protective surface film on the steel commonly caused from exposure to sulfide and chloride ions  Quenching, adding Molybdenum, and Nitrogen to the metal helps prevent corrosion

20.  Consisting of mostly stainless steel components and high pressure connections the design consisted of: 35 Components  Rolls Royce had most components in house causing a reduced retail price Approximate Non reduced Total Cost: $ 1,918.44

21.  Fixture’s operating height: 4.5”  Designed to function under comfortable operating conditions within the parameters of the dry box. 4.5”

22.  Analysis using ANSYS Workbench  Worst Case Scenario Maximum Pressure  Uniformly Distributed Force (4000 psi = 27.579 Mpa) Perpendicular to Large Contact Faces

23.  Coarse Mesh  High Stress Areas Refined Locations: Large Contact Holes Arbor Base Edges

24.  Analysis to look at Total Deformation Tensile Stresses  Locate Problem Areas  Max Stress Locations Less than Stainless Steel Yield Strength of 515 MPa.

25. Inner Rod Assembly Max Tensile Stress: 312 MPa Outer Rod Assembly Max Tensile Stress: 407 MPa

26. Inner Rod Assembly Max Deformation:.23 mm Outer Rod Assembly Max Deformation:.16 mm

28.  Fixture is designed to Engineering Requirements  Replace Threaded Rods with Rack & Pawl for use in Production  Base with interchangeable posts for blasting ends  Flange Bearing Style Base