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ME 462 Capstone Design
Group Members: Kelly Moore, Bart Sudhoff, Danny Compton, Katie Iaizzo, Mary Croucher
Advisors: Dr. Jie Chen and Dr. Roger Knutson
12 Decmeber 2007
IntroductionBackgroundDesign ObjectivesMaterial SelectionCost EvaluationConcept DesignProduct EvaluationConclusionRecommendationsAnswer Questions
Russell FoundationFounded By Bishop Michael Russell and his
Father In 2003Faith Based Community Development
OrganizationRenders Self-sufficiency Programs to Help
Stabilize Families and CommunitiesProvides Jobs for Local CommunitiesEnvironmentally Friendly Initiatives
Reasons For DesignReduce Traffic Congestion
around Chicago-Indiana Area
Provide High Speed Transportation
Create Jobs in Indiana Pioneering Environmentally
Friendly Mass Transit Solutions
Preliminary Design
Customer RequirementsTravel 75 MPHSupport Renewable Energy SourceEasy AssemblyEasy MaintenanceSmooth Rail TransitionAppearanceSupport 160,000 lb loadMinimize Stopping TimeMinimize CostMinimize Environmental Effects
Engineering RequirementsMinimize Resistance (Rail)Maximize Allowable Stress (Structure)Equipment HoursLabor HoursMinimize Rail Height DifferencePublic Appearance RatingMaximize Allowable Stress (Rail)Maximize Allowable Stopping ForceMinimize Cost Minimize Environmental Effects on Material
Column Support•Box beam•Concrete base•Bolted to cross-support
Cross Support•Box beam•Bolted to column•Supports rails
Standard I-Beam W27 x 368•Standard Size•Internal height equal to 25.43 inches•Fits standard 22 inch tire diameter
Column Support Assembly•All parts bolted and welded
Full Assembly
Types of SteelTwo common types used: ASTM A992 and
ASTM 588More common steel types reduce costHigh strength, low alloy steel, which used
recycled metalsSaves on cost of manufacturingEnvironmentally friendly
Physical PropertiesASTM A588 ASTM A992
Contains Chromium for weather resistance
Made using 95% recycled material
Develops oxide coating Inexpensive
50 ksi yield strength 50 ksi yield strength
Structural Steel
ASTM A-588 ASTM A-992
Price per cwt from Nucor-Yamato Steel
$51.10 $46.60
Price per 80ft Beam $6483.85 $5971.32
Price difference per section
$512.53
Price ComparisonConsider long term maintenance and repair
costNorthwestern University experiment
A992 corrodes 64% more over time than A588A992 would last less than half as long as A588
(weathering steel)
Nuts and BoltsQuantity Description
Unit Price
Total Price
48Grade 8 Plain Alloy Steel Hex Head Cap Screw 1-1/8"-7 Thread, 6" Length
$7.16 Each
$343.68
24Grade 8 Plain Alloy Steel Hex Head Cap Screw 1-1/8"-7 Thread, 5" Length
$6.25 Each
$150.00
15
Grade 8 Plain Steel Hex Nut 1-1/8"-7 Screw Size, 1-11/16" Width, 31/32" Height, Packs of 5
$6.12 Pack
$91.80
Total $585.48
Loading (Structure)Deadweight Load
80,000 lbs (355868 N)
per RailBraking Force
9.8 m/s2 * 80,000 lbsFixed Supports
Base – Ground Interface
Open End Rails
Equivalent Stress (Structure)Maximum
5.53e7 Pa
Shear Stress (Structure)Maximum
2.81 e7 Pa
Total Deformation (Structure)Maximum
16.75 mmLocation
Mid-span
Factor of Safety (Structure)Minimum
6.15Location
Beam-Near Connection
Fatigue Analysis (Beam)
Loading (Beam)Deadweight load
40,000 lbs per Flange
Fixed SupportsOpen Ends of Beam
Total Deformation (Beam)Maximum
9.5 mm
Fatigue Life (Beam)Minimum
8.03e5 cycles
Concluding RemarksOur designed is based on the customer Our designed is based on the customer
requirements and goals of the Russell requirements and goals of the Russell Foundation.Foundation.
The factor of safety meets required limit of 5-7The factor of safety meets required limit of 5-7Fatigue life exceeded 8.0 eFatigue life exceeded 8.0 e55 cycles cyclesA588 steel resists weathering without excessive A588 steel resists weathering without excessive
costcostSingle column design minimizes footprintSingle column design minimizes footprintDesigned to easily integrate renewable energy Designed to easily integrate renewable energy
sourcessources
Structure Span LengthPreliminary Testing
Larger Beam39 in. Interior
Beam height Factor of Safety
Increased to 9.53Custom Beam
Standard Size Not Available
http://www.uspto.gov/patft/index.htmlhttp://www.delphion.com/home
Project definition packet, Russell Foundation“IndianaFreight and IndianaMonorail,” Roger Knutson; Russell
Foundation; Advance Transit Solutions, LLC, May 2007
http://www.wisegeek.com/what-is-a-steel-i-beam.htmhttp://en.wikipedia.org/wiki/I-beam
Machinist’s Handbook 12th Edition, Lang, page 397http://www.matweb.com