AME Capstone Senior Projects

2 01 42 01 5

Seni orPr oj ec t s Aer os pac eandMec hani c al Engi neer i ngCaps t onePr ogr am

2015

AME CAPSTONE PROJECTS

The School of Aerospace and Mechanical Engineering Capstone Projects 2015 Categories CATEGORY: PROTOTYPE DESIGN P1 Modeling of Exhaust Gas Flow over Various Catalyst

1

Student Team: Michael Evans, Brooke Hitt, Scott Maxwell, Maria Prada Sponsor: MIRATECH Advisor: Dr. Song

P2

Alternate Closure Mechanisms for Safety Valves

2

Student Team: Antonio Marquez, Andrew Roberts, Patrick Wood, Jeffrey Walker Sponsor: Baker Hughes Advisor: Dr. Stalford

P3

Design of HPHT Wireless MEMS Telemetry System for Offshore UltraDeep Water Applications

3

Student Team: Kyle Hendon, Whitaker Henson, Grant Bolding, Neal Yarberry, Jozef Quinn Sponsor: Schlumberger/AME Advisor: Dr. Stalford

P4

Pedal-Centered Sealed Gearbox System – Design and Analysis

4

Student Team: William Cook, Morgan Andersen, Allicyn Berka, Clayton Stich Sponsor: Trek Bicycle corporation Advisor: Dr. Stalford

P5

SRS / TRS Cover Design

5

Student Team: Gabriela Berrios, Peter George, Alexander Guerra, Seamus Hunt, Brent Tolbert Sponsor: Union Pacific Advisor: Dr. Stalford

CATEGORY: STUDIES S1 Design of Diffuser Anti-Rotation Mechanism

6

Student Team: Cameron Riney, Andrew Williams, Ali Al Kaba, Chad Wallis, Steven Merrill Sponsor: GE Oil and Gas Advisor: Dr. Mistree

S2

Adhesives Defect Inspection System

7

Student Team: Chance Schweer, Kyle Christian, Zach Beardshear, Chris Mcmahon Sponsor: Kimberly-Clark Corporation Advisor: Dr. Song

S3

Redesign to Improve Bag Pick-Up Process in the Existing Optima Designed Stacker/Baggers 8 Student Team: Minh Phi, Tolga Ozdil, Alen Spiller, Tucker Chonka, Hailey Dinh Sponsor: Kimberly-Clark Corporation Advisor: Dr. Song

2015

AME CAPSTONE PROJECTS

S4

Energy Savings Feasibility Study to Implement Demand-Based Control on VOC Level in a Facility that Generates Toxic Vapor 9 Student Team: Sara Bondy, Tyler Totten, Kyle Mcgee, Bridget Taylor Sponsor: Tinker/CoE Advisor: Dr. Song

S5

Valve Seat Analysis and Redesign

10

Student Team: Conor McBride, Daniel Mccaskill, Melissa Oestmann,Benjamin Schoen, Joshua Woodard Sponsor: Cameron Advisor: Dr. Siddique

CATEGORY: TESTING T1 Modification of High Swirl Distribution for Low Emission NonPremixed Jet Flame Combustion

11

Student Team: Rebecca Browder, Hannah Harris, Ethan Murphy, Brianna Szymanski, Aaron Wright Sponsor: Webster Combustion Technology LLC Advisor: Dr. Song

T2

Engine Power Assembly Tester

12

Student Team: Christopher Allen, Sarah Baker, Amanda Massey, Jacob Pickle, Alex Pierson Sponsor: Union Pacific Advisor: Dr. Stalford

T3

Design of an Experimental Setup to Measure High Temperature Shear Strength of Polymeric Materials

13

Student Team: Robert Marcham, Brian Rockwell, Braden Hobaugh, John Shetley, Mohammed Abu Alrahi Sponsor: Schlumberger Advisor: Dr. Siddique

T4

Rotary Electro-Mechanical System

14

Student Team: Joe Saucedo, Johnny O Keefe, Josh Bevil, Miguel Guerrero, Derrick Anierobi Sponsor: Schlumberger Advisor: Dr. Siddique

T5

Configuration to Protect Seals Student Team: Hutton Weaver, Logan Groves, Marcus Samuels, Lauren Reiner Sponsor: Schlumberger Advisor: Dr. Siddique

15

2015

AME CAPSTONE PROJECTS

CATEGORY: INTERDISCIPLINARY I1 Create the Most Efficient ESP Plant Layout

16

Student Team: Alyass Hasan, David Nelson, Brianna Reyna, Tyler Smith Sponsor: GE Oil and Gas Advisor: Dr. Mistree and Dr. Raman

I2

Diffusers Testing System

17

Student Team: Jackson Autrey, Jordan Campbell, Wesley Kirby, Vegas Mcneal Sponsor: GE Oil and Gas Advisor: Dr. Mistree and Dr. Raman

I3

Develop Process and Specialized Cart for Transport of Manufacturing Components from Off-Site Warehouse Directly to the Factory Floor

18

Student Team: William Spears, Aubrie Hill, Tara Symens-Ingram, Adam Dachowicz, Layne Urbanzyck Sponsor: Hitachi Advisor: Dr. Mistree and Dr. Shehab

I4

Production Decline in Shale Wells Student Team: Eric Douglas and Bryan Bodie Sponsor: Baker Hughes

I5

19 Advisor: Dr. Mistree

Reducing Waste Disposal Costs

20

Student Team: Quinton Ferguson, Jonathan Foss, Ray Gibson, Tony Winkle Sponsor: Tinker/CoE Advisor: Dr. Siddique and Dr. Barker

CATEGORY: VEHICLE DESIGN V1 Sooner Off Road

21

Student Team: Ray King and James Patrick Dunbar Sponsor: OU/AME Advisor: Dr. Siddique and Dr. Bairaktarova

V2

Sooner Powered Vehicle

22

Student Team: Sarah Bedell, Warren Engles, James Ross, Michael Dillion, Garrett Lawler Sponsor: OU/AME Advisor: Dr. Siddique and Dr. Saha

V3

Sooner Racing Team Student Team: Isaac Bower and John Pate Sponsor: OU/AME

23 Advisor: Dr. Siddique

CATEGORY: AEROSPACE ENGINEERING A1: Next Generation Strategic Military Transport

24 24

Student Team: Paula Carsi, Xinyu Sun, Marc Agagah, Alvin Ngo, Flavio Moreno, Kayode Ifabiyi Sponsor: AIAA Advisor: Dr. Striz

A2:

Speedfest V Team Crimson Skies Student Team: Di Zhu, Austin Jones, Cody Shell, Justin Parks, Josiah Lund Sponsor: OU/AME Advisor: Dr. Striz

25

2015

AME CAPSTONE PROJECTS

A3:

High Altitude Research Project

26

Student Team: Joshua Page, Magdalena PĂŠrez, Bipin Varghese Sponsor: Bergey Aerospace Advisor: Dr. Striz

A4:

Supersonic Business Jet

27

Student Team: Ashley Carpenter, Corbin Graham, Allison Parker, Kylie Richardson, Blake Riojas Sponsor: Lockheed Martin Advisor: Dr. Striz

A5:

Scale Model of Reusable Spaceplane

28

Student Team: Andrew Hawkins, Jared Repplinger, Evgeniy Ilichev, Resen Prayter, Kegan Duplechin Sponsor: Northrop Grumman Advisor: Dr. Striz

INDUSTRY SPONSORS

29

2015

P1

CATEGORY: PROTOTYPE DESIGN

Modeling of Exhaust Gas Flow over Various Catalyst

Many modern engines emit exhaust which contains environmentally harmful pollutants. Catalytic converters are placed at the outlets of these vessels in order to reduce atmospheric consequences and comply with emission standards. This project’s goal was to analyze catalyst substrates and create a mathematical model that would allow MIRATECH (the corporate sponsor) to evaluate the advantages and disadvantages of a substrate without having to physically build and test each prototype. A three-dimensional model of the VORTEX substrate was designed using SolidWorks and was imported into ANSYS CFX to perform fluidflow analysis using the following parameters: inlet space velocity is a maximum of 300,000 hr-1, which led to an inlet velocity of 45.5 ft/s, sand grain roughness of 0.1mm, and an outlet at 0 Pa relative pressure. We calculated the following desired output values: pressure drop of 3.85 Pa, Reynolds number of 8782.04, Prandtl number of 0.702, and Nusselt number of 29.02.

PAGE | 1

2015

P2

CATEGORY: PROTOTYPE DESIGN

Alternate Closure Mechanisms for Safety Valves

For this Capstone project, the team had the task of designing an alternate closure mechanism for subsurface safety valves for Baker Hughes because the company is attempting to find the next big thing in the safety valve industry. An initial brainstorming session resulted in the team constructing eight initial ideas. After several design reviews and a PMI analysis, the team selected two designs for Baker Hughes to consider moving forward: a Split-Flapper design and a Rotational Flapper design. Both designs were chosen to move forward because they meet the industry standards for safety, are innovative, and provide an opportunity for Baker Hughes to change the way safety valves actuate.

PAGE | 2

2015

CATEGORY: PROTOTYPE DESIGN

P3 Design of HPHT Wireless MEMS Telemetry System for Offshore Ultra-Deep Water Applications The team has developed a mechanical device capable of connecting two fiber-optic cable ends in oil wells in order to safely retrieve real-time, distributed data from downhole to the operators for the lifetime of the well.

The reservoir measurements provided by this system are of high importance and worth to operators, especially in offshore application where the environment is harsh and the stakes are high. The implications of this design are vital to the overall cost of producing an offshore well and enhanced oil recovery. This design establishes a fiber optic cable connection without the use of downhole electronics and/or batteries to extend sensing capabilities beyond the lifetime of the well. This device connects optical cable from the inside casing face to the outside face and into reservoir pay sands. The system will be capable of withstanding high p ressure, high temperature, and corrosion while measuring and reporting critical formation parameters.

PAGE | 3

2015

P4

CATEGORY: PROTOTYPE DESIGN

Pedal-Centered Sealed Gearbox System – Design and Analysis

The objective of this project is to design and complete stress analysis for a pedal-centered sealed gearbox system in support of Trek Bicycle Corporation. Market research was conducted to determine issues with the standard cassette-derailleur style bicycle drivetrain. Common failures associated with the standard system include, but are not limited to, contamination wear and contact damage. Furthermore, the placement of this system is localized around the rear wheel, increasing the inertia and reducing the suspension compliance. The mission of this project is to design a sealed transmission-style drivetrain for off-road and commuter bicycles that will maximize reliability and efficiency, while minimizing weight. This goal is accomplished utilizing a pedal-centered gearbox location and featuring Continuously Variable Transmission (CVT) technology. The proposed design weights approximately 6 pounds, achieves a maximum efficiency of 92% and has an estimated minimum service interval of 1 year.

PAGE | 4

2015

P5

CATEGORY: PROTOTYPE DESIGN

SRS / TRS Cover Design

Union Pacific is experiencing locomotive road failures due to signal loss between the Synchronous Reference Sensor (SRS) and the Timing Reference Sensor (TRS) to the Engine Control Module (ECM), generating a loss in revenue of approximately $9,000,000 over 10 years. This signal loss is caused by contaminant buildup (i.e. dirt, oil, metal shavings, etc.) on the sensor body and sensor-signal wire interface. In order to mitigate this issue, an SRS/TRS cover design was proposed in order to isolate the sensors from the contaminants.

Several engineering requirements such as, operating temperature, engine vibration, chemical exposure, manufacturability, ease of use/installation, and cost were considered while generating an end design. The final design consists of a two-piece mechanically fastened cover made from a glass-filled nylon-based automotive grade plastic suitable for manufacturing via injection molding with integrated vibration dampening pads. The total investment for the required 2,200 unit lot size is approximately $60, 000.

PAGE | 5

2015

S1

CATEGORY: STUDIES

Design of Diffuser Anti-Rotation Mechanism

GE Oil & Gas is currently employing pins as anti-rotation mechanisms between their diffusers for surface pumping systems. These pins are failing due to unverified rotational forces and torques. A study was performed to determine the process under which the mechanism was failing. Finite Element Analysis confirmed the pin mechanisms were found to be shearing due to the 3,500 ft-lb of torque applied to the stack during the housing process of the assembly. The resultant stress acting on the pins was calculated to be 1010 ksi, severely higher than the material’s yield strength of 75 ksi.

Four new designs were created to overcome the failure resulting from the assembly torque.

Translating the previous FEA conditions to the selected designs, the resulting stresses acting on the new diffusers were determined. A final design, which reduced maximum stress to 16.6 ksi, was selected and recommended to GE.

PAGE | 6

2015

S2

CATEGORY: STUDIES

Adhesives Defect Inspection System

Our team’s objective is to provide a solution that can detect proper adhesive coverage that operates at high speeds and high temperature applications. This device needs to inspect both line and spray methods for adhesive application. The team will also provide a device that can provide real time updates and alert a technician if a problem is detected. The main objective of this device is to ensure that the paper web has a minimum of 50% adhesive coverage. This solution can save Kimberly-Clark large amounts of product, labor hours, and help to facilitate a more quality assured facility. This solution may also have a company wide application at other Kimberly-Clark production facilities. Our Team’s approach is to use a thermal imaging camera: the Flir A310. We will place the thermal camera over the web after the adhesive applicators to ensure that the adhesive has been properly distributed. Since the adhesive is applied at temperatures above 300°F, the thermal imager will measure the temperature difference between a reference temperature and the center of the web, where the adhesive is being applied. The thermal imager will also measure the average temperature of specified zones in the software to conclude whether adhesive is present or not. If the web does not meet the criteria specified, an alarm will sound and alert the technician that there is an error with the adhesive application. This quick alarm will help Kimberly-Clark avoid large product losses.

PAGE | 7

2015

CATEGORY: STUDIES

S3 Redesign to Improve Bag Pick-Up Process in the Existing Optima Designed Stacker/Baggers A Kimberly Clark diaper manufacturing plant suffers from assembly line interruptions involving a bagging process where diapers are placed into plastic bags. Static electricity and defective bags used in the process cost Kimberly Clark millions of dollars per year. Static electricity and defective bags produce problems with alignment, and bag sealing processes that result in complete failure of the assembly line. By studying the effects of static charge on the bags and the amount of deflection experienced by the bags, a new bag was designed. A thick strip of material towards the top of the bag will help prevent the bag from bending, and by using an anti-static material known as polyethylene terephthalate static charge will be prevented. By implementing this new design, the bagging process will be improved not only for Kimberly Clark, but for all other production assembly lines that use a plastic bagging process.

PAGE | 8

2015

CATEGORY: STUDIES

S4 Energy Savings Feasibility Study to Implement Demand-Based Control on VOC Level in a Facility that Generates Toxic Vapor Spray painting facilities are designed with ventilation systems that remove substantial toxic vapor called volatile organic compounds (VOCs) from the air. Tinker AFB runs there ventilation system 24/7/365 at full capacity even though they only paint 10% of the time. This yields a large waste of energy. If the VOC level is controlled by retrofitting the ventilation system to appropriate levels, substantial energy savings can be achieved by preventing the system from over-ventilating the facility. In order to do this, we simulated the current airflow and VOC emissions using ANSYS so we know where the location of the highest VOC concentration level. We installed a photoionization detector at this location to monitor the VOC levels before, during and after painting has taken place. We found that Tinker can save approximately $3,400 per month by implementing the non-paint mode function already installed in their ventilation system controls.

PAGE | 9

2015

S5

CATEGORY: STUDIES

Valve Seat Analysis and Redesign

Cameron’s DEMCO Butterfly Valve series makes up a thirty million dollar product line; however, Cameron is looking to make changes. The desire to explore manufacturing alternatives was initially motivated by the company’s lack of vendors able to supply the phenolic material used in the valve’s backer. The results of this project will provide Cameron with security in material pricing and availability. In evaluating viable product changes: materials, vendors, manufacturing processes and component design were all considered. Viable alternatives were found in each of these categories. The research conducted in this report yielded eleven alternative backer materials, one potential design alteration, two additional manufacturing options, and helped to secure one additional vendor for Cameron. A sample of backers has been ordered for testing, and the capstone team has begun running FEA on potential material/design combinations. The following report documents the team’s research and includes a proposal for Cameron

PAGE | 10

2015

CATEGORY: TESTING

T1 Modification of High Swirl Distribution for Low Emission NonPremixed Jet Flame Combustion Webster Combustion subcontracted work to our student group to develop and test three new designs for a low-NOx combustion burner. Regulations on NOx vary across the country but are becoming stricter across the board, so combustion companies must develop designs that have lower emissions. Webster’s current design methodology only utilizes two-dimensional drawings and analyses, so they requested we move one of their designs into three dimensions using SolidWorks and test the design in Ansys. The results from those initial analyses were compared with experimental test results for NOx emission: the computer analysis estimated emission of 56.4 ppm, compared to the actual value of 65 ppm, which was a very close agreement considering very few companies in industry can accurately model combustion in Ansys. After the original design was analyzed, the team developed three redesigns by altering the spud arrangement and diffuser geometry to be tested at Webster’s facilities.

PAGE | 11

2015

T2

CATEGORY: TESTING

Engine Power Assembly Tester

Union Pacific Railroad suffers an average 120 road failures per month; five of which are due to power assembly failure. The associated cost of a power assembly failure is $15,000. Our goal was to develop a nonintrusive Go/No-go testing device which determines power assembly status and predicts power assembly life expectancy. The approach was to research a predictive maintenance tool that uses ultrasonic technology to test and collect power assembly vibration data from locomotives. The tool is accompanied by a living database and a test manual written to satisfy Union Pacific Railroad standards. The results of this project will show whether this tool’s ultrasound technology is applicable for this type of analysis leading to Union Pacific’s ability to reduce road failures. Success of this project can lead to an increase in revenue for Union Pacific and allow for avenues to use this analysis on the rest of the fleet.

PAGE | 12

2015

CATEGORY: TESTING

T3 Design of an Experimental Setup to Measure High Temperature Shear Strength of Polymeric Materials Our experimental setup utilizes motion control software to drive a stepper motor linear actuator with a load cell and punch affixed to the end. This punch slowly moves down and shears through two cut samples of polymeric rings. These two ring samples are held firmly within a stainless steel sample holder that prevents them from being moved throughout the shearing process. Simultaneously, a temperature control module provides power to a heating band that has been fastened around the sample holder, thereby bringing the samples to a specified temperature and then maintaining it. Force, temperature, and time data is continuously recorded using the load cell, thermocouples, and a National Instruments data acquisition module. When the punch has sheared all the way through the sample the LabVIEW program ends the data recording process.

The recorded data is then exported to an Excel file where a Visual Basic program analyzes it in order to generate an ideal ring thickness that will be used in future ring designs.

PAGE | 13

2015

T4

CATEGORY: TESTING

Rotary Electro-Mechanical System

The purpose of the Rotary Electro-Mechanical System project is to design, manufacture, and integrate a bench top experimental setup that controls and records values for the following parameters: temperature, RPM, and pressure. The reasoning behind controlling these parameters is to adequately conduct experimental testing on ceramic rotary seals. Performance of the seals is evaluated using temperature and leak rate readings.

Furthermore, the test bench was to have the ability to switch between a completely horizontal and completely vertical orientation. Components of the system included a motor to rotate the shaft containing the seals, a torque sensor to record RPM and torque values, and a test chamber that served as housing for the seals. The entire system was integrated using NI LabVIEW.

Seafloor PAGE | 14

2015

T5

CATEGORY: TESTING

Configuration to Protect Seals

Schlumberger approached the team with a seal protection problem in their Intelligent Remote Dual Valve downhole tool. The current design inadequately protects an O-ring seal that crosses multiple ports perpendicular to the sealing bore. The team developed two possible solutions to allow for cross-port seal travel while maintaining seal integrity and the appropriate pressure differential. One solution implements micron sized perforations at the bottom of the port rather than a full port opening. This allows for little changes in the tool, while providing more surface contact for the seal and maintaining the required fluid communications. The other solution moves the O-rings to the outer shell while implementing channels on the inner mandrel to allow for fluid communication. Through developing CAD models, running FEA and CFD simulations, manufacturing prototypes and performing testing, the team will be able to provide Schlumberger with valuable data for two possible solutions to implement.

PAGE | 15

2015

I1

CATEGORY: INTERDISCIPLINARY

Create the Most Efficient ESP Plant Layout

Our customer is GE Oil and Gas Artificial Lift facility, in Oklahoma City, that manufactures Electrical Submersible Pumps (ESPs). The purpose of this particular project is to help GE redesign the entire layout of their shop floor to help them produce goods at the highest throughput level possible and reduce non-value added production costs. This project will help them reduce the amount of time it takes to produce the four products, cut non-value added production costs, and improve their overall ability to manufacture parts quickly and effectively. Six alternative layout concepts were generated and compared for the parts’ time of travel, production cost and distance travelled. Concepts 2, 5, and 6 met the minimum production rate decrease of 40% and reduced total travel distance by at least 35%. By implementing one of these using a phased-in approach, GE will be able to produce at a faster and more efficient rate.

PAGE | 16

2015

CATEGORY: INTERDISCIPLINARY

I2

Diffusers Testing System

GE Oil and Gas Well Performance Services tasked our team with creating a testing system that can measure the internal deflections of diffusers under a known axial compression load. The results from the testing system will allow GE to find the yielding point of the diffusers that they use in their electrical submersible pumps (ESPs), and ultimately provide the maximum load that the ESP diffuser/impeller stacks can handle.

This will prevent failure in the field and in turn save GE time and money. The team has designed a compression testing system that employs an actuator to apply the compressional load and LVDT sensors to measure the deflection. The system encompasses register attachments that allow the actuator to transfer the loading to the diffuser. There is also a safety containment feature that surrounds the system to contain fragments project by diffuser failure. The safety of the user was also taken into account by biomechanical modeling.

  

Biomechanical modeling allowed team to choose how each diffuser and attachment is loaded to ensure worker safety.

Modeling register attachments to fit each diffuser size allows system to impart load to all diffusers.

Test system utilizes steel frame to support maximum loading (~65,000 lbs.) and .25” thick walls to protect worker during testing

PAGE | 17

2015

CATEGORY: INTERDISCIPLINARY

I3 Develop Process and Specialized Cart for Transport of Manufacturing Components from Off-Site Warehouse Directly to the Factory Floor Hitachi Computer Products America, Inc. (HICAM) is experiencing rapid growth, and the needed floor space for necessary storage has exceeded the available space in HICAM’s current facility. To address the need for storage, HICAM has leased a new warehouse approximately three miles away from the assembly facility, as well as transport trucks to run between the facilities. Although this has helped, storing and loading internal transport carts with hard drive chassis for testing and assembly still takes unnecessary space. Also, these current carts lack the ability to transport sensitive chassis unboxed at the warehouse to the assembly facility safely. We have designed a new process to move these chassis from the warehouse where they are unboxed to the assembly floor at HICAM, as well as a cart capable of transporting these chassis during all stages of this process. The process and cart are designed for easy implementation, assembly, and maintenance.

PAGE | 18

2015

I4

CATEGORY: INTERDISCIPLINARY

Production Decline in Shale Wells

The Baker Hughes 21st Century Co-op is an interdisciplinary 5 year BS/MS program with courses in mechanical and petroleum engineering. In addition to core courses in each of the disciplines, the curriculum includes customized courses jointly offered by Baker Hughes engineers and faculty during summer internships, a senior capstone experience and graduate thesis of relevance to the industry, and graduate cross disciplinary courses. For our senior capstone experience, the issue of production decline in Shale wells was analyzed. When oil and gas is produced from Shale wells, the production decreases exponentially beginning when the first hydrocarbon is produced. Shale is present in approximately one third of the geology covering the United States. Since the invention of horizontal drilling and hydraulic fracturing, Shale has become the primary reservoir rock that hydrocarbon is extracted from in the United States. The main factors affecting production are pressure decline, pressure differentials, and the fractures closing. As a result of understanding these factors, the two proposed Master’s Thesis titles are: •

The effects of proppant on rate of production in relation to pressure decline in Shale wells.

•

The effects of proppant on the various pressure differentials in Shale wells.

PAGE | 19

2015

I5

CATEGORY: INTERDISCIPLINARY

Reducing Waste Disposal Costs

This project introduces a number of four possible solutions that relate to the reduction of waste disposal costs during the aircraft paint removal process at Tinker Air Force Base. These solutions, whether implemented individually or together as a multi-part system, will work to reduce the unnecessary costs related to the process. These solutions will also contain a “Return on Investment� of a total time of five years, or less. These solutions will function with minimal effort from the operators, and will reduce the overall labor involved, as in comparison to the process before the solutions were determined. During the development of the solutions, the use of Industrial Engineering principles were used, such as the SIMILAR process, accompanied by the use of Mechanical Engineering principles, such as determining the amount of flow seen in an open channel. The combination of both Industrial and Mechanical Engineering was key for completing this project.

PAGE | 20

2015

V1

CATEGORY: VEHICLE

Sooner Off-Road

The transmission consists of three reductions in forward drive, and two reductions in reverse drive. The additional reduction in forward drive is bypassed by the reverse driven gear by both gears sharing a common gear mate, and by the dog gear that is not engaged with the dog clutch acting as an idler. The gear reductions for forward and reverse drive are 9.44 and 5.77, respectively. The Briggs and Stratton engine outputs 14 ftlbs of torque at 3800 RPMs. At top speed the transmission outputs 100 ft-lbs of torque at 520 RPMs. The seat will be constructed with carbon fiber composite and will feature mounting tabs with integral polyurethane bushings to reduce the forces on the driver. The seat will be 0.04 inches thick and will weigh 12.4 lbs, mounting tabs included. The composite material has yield strength of 8,952 ksi which is higher than the stresses expected.

PAGE | 21

2015

V2

CATEGORY: VEHICLE

Sooner Powered Vehicle

The Sooner Powered Vehicle (SPV) team at the University of Oklahoma (OU) has designed, built, and tested a recumbent bicycle to demonstrate the best utilization of human power in the American Society of Mechanical Engineers (ASME) 2015 Human Powered Vehicle Challenge (HPVC). The design of the tadpole trike was focused on producing a durable, stable, lightweight, and safe vehicle that is versatile. The bicycle frame was constructed from AISI 4130 alloy. Finite element analysis (FEA) was performed under different conditions and the overall safety factor was found to be between 2-5. The weight of the frame was estimated to be around 37.4 lbf. The fairing utilizes a lightweight Wind-Wrap windshield with carbon fiber composite side panels to reduce air drag while protecting riders from injuries in an event of accident. The team conducted extensive analysis, computational modeling and validations, and physical testing to demonstrate the practicality, safety and performance requirements of HPVC.

PAGE | 22

2015

V3

CATEGORY: VEHICLE

Sooner Racing Team

The 2015 Sooner Racing Team has designed a high performance racecar utilizing a single cylinder engine and a fully integrated aerodynamics package. It will be taken to Michigan in May to compete against schools all around the world. Emphasis for the aerodynamics portion of this project was placed on the utilization of an under tray with outboard mounting functionality. This under tray was designed to facilitate the attachment of the wings to the outboards of the racecar, minimizing sprung mass. The under tray was designed to utilize as much tire traction as possible while maintaining low weight, complexity, and compliance. Powertrain emphasis was placed upon intake and exhaust design for maximized volumetric efficiency using hand calculations and Computational Fluid Dynamic (CFD) simulations. The effect of these systems on the response and efficiency of the powertrain was studied using an in-house dynamometer. Design goals for these components included minimizing weight and maximizing system flow.

PAGE | 23

2015

A1

CATEGORY: AEROSPACE ENGINEERING

Next Generation Strategic Military Transport

The Air Mobility Command is continually seeking to improve the performance of its fleet. Thus, a next generation airlifter is desired that can provide major improvements in performance over present aircraft.

Blended Winged Body (BWB) aircraft are known for their greater aerodynamic efficiency when compared to conventional aircraft, primarily due to their lift-producing fuselage. In prioritizing range for maximum payload and cargo space utilization, a BWB configuration was deemed superior. Efficiency of cargo loading is a challenge, which was addressed by fuselage manipulation. A rear-engine centered four-engine configuration was chosen to meet the mission requirements, and to allow for mission continuation if half the engines become inoperable. The geometry of the fuselage was obtained by designing around the maximum height and length of the required payload. This aircraft was designed to carry 120,000 lbs of payload over a range of 9,000 ft.

PAGE | 24

2015

A2

CATEGORY: AEROSPACE ENGINEERING

Speedfest V Team Crimson Skies

A remote controlled aircraft was designed and built to carry a 1:18 scale dune buggy on a course of eight figure eights around two flags, set 900 feet apart. The aircraft was then to drop the vehicle onto a ground track, which the vehicle had to complete autonomously, taking a picture at the end with an attached GoPro Hero3 camera. The car utilizes an Arduino board to perform this task for maximum score. The goal was to complete both tracks in the shortest possible time.

The aircraft design consists of a carbon fiber monocoque fuselage with foam cores for increased stiffness.

This technique allowed unique geometry to be created, which minimizes drag. To disperse the loads throughout the aircraft, birch wood frames were tied into a carbon fiber spar with a foam core to create a wing carry-through structure. Using this technique, the plane’s final weight was 6.8 lbs without the vehicle.

PAGE | 25

2015

A3

CATEGORY: AEROSPACE ENGINEERING

High Altitude Research Project

The 2015 Bergey Aerospace HARP Capstone Team has continued the task, started last year by a previous capstone team, to design and eventually build a light, piloted, naturally aspirated piston-engine powered aircraft, to reach 60,000 ft and set an altitude record.

Starting from the previous team’s conceptual design, this team focused its preliminary design effort on detailspecific systems of the aircraft. This included the design of the canopy and analysis of an ejection seat system, a detailed thermodynamic turbocharger performance study, wing loading and bending moment distribution calculations, the design of an internal wing structure, and updates to the performance/stability analyses. The basic geometry of the aircraft was then modified to take into account all updated results.

In addition to design, the capstone team helped A&P licensed aircraft mechanics dismantle a recently acquired Piper Cherokee. The rear portion of the aircraft’s fuselage will be used as part of HARP’s aircraft structure.

PAGE | 26

2015

A4

CATEGORY: AEROSPACE ENGINEERING

Supersonic Business Jet

A design for a supersonic business jet (SBJ) is proposed by a Senior Capstone Design Team, sponsored by Lockheed Martin. The goal was to design an affordable aircraft operating at the lowest cost while implementing the latest available technologies.

The mission requirements are: a range of 4,000 nm, a cruise speed of Mach 1.7, the ability to operate off 7,000 ft runways, a capacity for four crew members and eight passengers, a cabin with a minimum height of 6 ft 1 in with multiple customization options, and the ability to meet all Federal Aviation Regulations (FAR).

Since there are no SBJs currently in production, comparisons were made to existing supercruising aircraft, like the Lockheed Martin F-22 Raptor, and to past supersonic transports, like the AĂŠrospatiale-BAC Concorde and Tupolev Tu-144. The SBJ design implements two low-bypass turbofan (LBT) rubber engines, a thin ogival delta wing, and an elongated nose. The design emphasizes increased fuel efficiency at supercruise.

PAGE | 27

2015

A5

CATEGORY: AEROSPACE ENGINEERING

Scale Model of Reusable Spaceplane

The purpose of this project is to design, develop, and fly a scale model of the Northrop Grumman XS-1 Spaceplane, currently in development. The model is to launch to a minimum altitude of 1,000 ft before transitioning into an unpowered glide and performing an autonomous landing on a pre-designated runway near the launch site. The space plane model is based on a graphical image of the XS-1 concept, provided by project sponsor Northrop Grumman.

Aerodynamic, structural, and stability design studies and analyses were conducted to ensure the model would perform to specifications. The model was then constructed using a foam core, covered by a fiberglass shell, and with plywood reinforcements. The foam was subsequently removed from the body to reduce weight.

Upon completion of the model, testing was conducted to ensure that the model’s performance matched theoretical predictions. The final step of the project is to launch the space plane at a scheduled demonstration.

PAGE | 28

2015

INDUSTRY SPONSORS

PAGE | 29

2015

INDUSTRY SPONSORS

PAGE | 30

2015

INDUSTRY SPONSORS

PAGE | 31

PAGE | 32