Supersonic Wind and Imaging Flow Tunnel

Supersonic Wind and Supersonic Wind and Imaging Flow TunnelImaging Flow Tunnel

David McNeillDavid McNeillCharles MurphyCharles MurphyMatthew OsbornMatthew OsbornDavid SpringerDavid Springer

Kendria AltKendria AltJoshua ClementJoshua Clement

Shannon FortenberryShannon FortenberryKatelynn GreerKatelynn Greer

Interim Review 1Interim Review 1

ContentsContents

Design SummaryDesign Summary Test SectionTest Section

• Stress AnalysisStress Analysis• Thermal AnalysisThermal Analysis

Testing PlanTesting Plan Schedule StatusSchedule Status Budget StatusBudget Status

Design SummaryDesign Summary

Visualization SystemVisualization System

Post CDR-Issues:Post CDR-Issues:•Light Intensity UnknownLight Intensity Unknown - Variable Intensity Power Source- Variable Intensity Power Source

Tunnel SystemTunnel System CDR-Issues: CDR-Issues: •Thermal Analysis Window - ResolvedThermal Analysis Window - Resolved• RFA – FOS on Window - ResolvedRFA – FOS on Window - Resolved

Post CDR-Issues:Post CDR-Issues:•FOS on Nozzle - ResolvedFOS on Nozzle - Resolved

Nozzle AnalysisNozzle AnalysisVersion 2Version 2

Stress

FOS

Displacement

*note: deformation scale is 100x

Hydrostatic Actual

FOS yield: 2.2 4.0

FOS ultimate: 3.9 7.2

Window AnalysisWindow AnalysisVersion 2Version 2

Stress

FOS

Displacement


Hydrostatic Actual

FOS yield: 4.1 7.1


Thermal AnalysisThermal AnalysisVersion 2Version 2

0 secs 4 secs 8 secs 12 secs 16 secs 20 secs

Testing OverviewTesting OverviewHP Leak LP Leak

Hydraulic Static Visualization

Acrylic Bonding

Sensor

PRV

Integration 1

Integration 2

Verification 1-6

Verification 10-12Verification 7-9

Lab

Hydraulic Static TestHydraulic Static Test Test Flange and Test Section Test Flange and Test Section

• Leak CheckLeak Check• 1.5 x MDP (1050 psi)1.5 x MDP (1050 psi)• Check for Plastic DeformationCheck for Plastic Deformation

EquipmentEquipment• Hydraulic pumpHydraulic pump

Provided by Civil Engineering LabProvided by Civil Engineering Lab• CalipersCalipers

LocationLocation• Civil Engineering Structure and Material Testing LabCivil Engineering Structure and Material Testing Lab• After HoursAfter Hours

Performed not Later than Performed not Later than 2/10/072/10/07

Visualization Test/CalibrationVisualization Test/Calibration Test Accuracy and ResolutionTest Accuracy and Resolution

• Calibrate all ComponentsCalibrate all Components• Optimize Light Source IntensityOptimize Light Source Intensity• Optimize Camera LocationOptimize Camera Location

EquipmentEquipment• Entire Visualization SystemEntire Visualization System• Cold SprayCold Spray• CouponCoupon

LocationLocation• Senior Projects RoomSenior Projects Room• Dark Light ConditionsDark Light Conditions


Integration TestsIntegration Tests Demonstrate Full System CompatibilityDemonstrate Full System Compatibility

• 11stst Integration Test Integration Test No Sound BoothNo Sound Booth Measure NoiseMeasure Noise Check for Supersonic Phenomena Check for Supersonic Phenomena Measure Temperature Changes in Test SectionMeasure Temperature Changes in Test Section

• 22ndnd Integration Test Integration Test Add Sound BoothAdd Sound Booth Repeat ResultsRepeat Results

EquipmentEquipment• Sound Level Meter (x2)Sound Level Meter (x2)• Stop WatchStop Watch• Laser ThermometerLaser Thermometer• ITLL Lab station ITLL Lab station

LocationLocation• ITLL 2B Patio ITLL 2B Patio

Performed not Later than Performed not Later than 3/02/073/02/07 Dependent on ALL Subsystem TestsDependent on ALL Subsystem Tests

Verification TestsVerification Tests

12 Full System Tests12 Full System Tests• Tests 1-6 (Mach 2)Tests 1-6 (Mach 2)

PDD RequirementsPDD Requirements• SoftwareSoftware• NoiseNoise• Run TimeRun Time• Shock Attached/Detached (Wedge)Shock Attached/Detached (Wedge)• Nozzle AccuracyNozzle Accuracy• Flow QualityFlow Quality• Complete 6 Tests without Changing Commercial Complete 6 Tests without Changing Commercial

TanksTanks

Verification Tests (cont.)Verification Tests (cont.)

• Tests 7-9 (Mach 1.5)Tests 7-9 (Mach 1.5) PDD RequirementsPDD Requirements

• NoiseNoise• Run TimeRun Time• Shock Attached/Detached (Wedge)Shock Attached/Detached (Wedge)• Nozzle AccuracyNozzle Accuracy• Flow QualityFlow Quality

• Tests 10-12 (Mach 2.5)Tests 10-12 (Mach 2.5) PDD RequirementsPDD Requirements

• NoiseNoise• Run TimeRun Time• Shock Attached/Detached (Wedge)Shock Attached/Detached (Wedge)• Nozzle AccuracyNozzle Accuracy• Flow QualityFlow Quality

Verification Tests (cont.)Verification Tests (cont.)

EquipmentEquipment• Sound Level Meter (x2)Sound Level Meter (x2)• Stop WatchStop Watch• ITLL Lab station ITLL Lab station • 1-2 TAs1-2 TAs• 4-6 Sophomore Students4-6 Sophomore Students

LocationLocation• ITLL ITLL

Dependant on ALL TestsDependant on ALL Tests Performed between Performed between 3/02/07 – 4/10/073/02/07 – 4/10/07

Sample Lab DemonstrationSample Lab Demonstration Execute a Sample Lab for ASEN 2004Execute a Sample Lab for ASEN 2004

• Performed by Sophomore VolunteersPerformed by Sophomore Volunteers• Predict Mach Number from Area RatioPredict Mach Number from Area Ratio• Execute Complete TestExecute Complete Test• Calculate Mach Number from SchlierenCalculate Mach Number from Schlieren

EquipmentEquipment• ITLL Lab Station ITLL Lab Station • 1-2 TAs1-2 TAs• 4-6 Sophomore Students4-6 Sophomore Students

Location Location • ITLLITLL


Schedule ProgressSchedule Progress

Schedule ProgressSchedule Progress Completed TasksCompleted Tasks

• Cart ModificationsCart Modifications• Tank IntegrationTank Integration• Pipe SupportPipe Support

In Work / Future TasksIn Work / Future Tasks Expected Finish DateExpected Finish Date• 11stst Test Section (Mach 2) Test Section (Mach 2) 02/09/0702/09/07• Flange Flange 02/06/0702/06/07• Manifold Manifold 02/15/0702/15/07• Hi and Low Pressure Piping Hi and Low Pressure Piping 02/15/0702/15/07• Knife Edge Interchange Knife Edge Interchange 02/15/0702/15/07• Light Source Encasing Light Source Encasing 02/15/0702/15/07

Future WorkFuture Work• Remaining Test SectionsRemaining Test Sections 04/05/0704/05/07• Schlieren Assembly Schlieren Assembly 02/15/0702/15/07• Sound Box Sound Box 02/19/0702/19/07• Schlieren EncasingSchlieren Encasing

BudgetBudget

Spent: $Spent: $4804.854804.85 We are under budget including:We are under budget including:

• Cost increases since 1Cost increases since 1stst of the year of the year• High shipping chargesHigh shipping charges

Surplus due to our 25% contingency Surplus due to our 25% contingency and over estimatesand over estimates

Applying for Spring EEF fundsApplying for Spring EEF funds

AppendicesAppendices

Boundary ConditionsBoundary Conditions

1.1. Fully Fixed at Bolt HolesFully Fixed at Bolt Holes

2.2. Simply Supported at Flange Simply Supported at Flange and Washerand Washer

3.3. Pressure Applied Normal To Pressure Applied Normal To InteriorInterior

(1)

(3)

(2)

Nozzle AnalysisNozzle AnalysisVersion 1Version 1

Hydrostatic Actual

FOS yield: 2.0 3.6


Stress

FOS

Displacement


Window AnalysisWindow AnalysisVersion 1Version 1

Stress

FOS

Displacement


Hydrostatic Actual

FOS yield: 4.0 6.9


Visualization Design SummaryVisualization Design Summary

Monochromatic/Color Schlieren Monochromatic/Color Schlieren SystemSystem• Straight pass system using 2 achromatic Straight pass system using 2 achromatic

lenses.lenses.• 45 degree angled mirror to extend second 45 degree angled mirror to extend second

focal length.focal length.• Interchange device attached to the 3-axis Interchange device attached to the 3-axis

translation stage allows for knife translation stage allows for knife edge/color filter exchange.edge/color filter exchange.

• Capture camera with lens arrayCapture camera with lens array

Testing OverviewTesting Overview

Acrylic Bonding TestAcrylic Bonding Test Test Acrylic Bond Shear StrengthTest Acrylic Bond Shear Strength

• 20 ¼ in Acrylic Test Objects20 ¼ in Acrylic Test Objects• Weld-on to ½ in Acrylic FrameWeld-on to ½ in Acrylic Frame• Add Weight to Test Object until FailureAdd Weight to Test Object until Failure

EquipmentEquipment• StrapStrap• BucketBucket• WeightsWeights

LocationLocation• Senior Projects RoomSenior Projects Room


Leak TestsLeak Tests Leak Test 3 Piping SystemsLeak Test 3 Piping Systems

• Pressurize to 50 psiPressurize to 50 psi Measure Pressure Drop Over 12 HoursMeasure Pressure Drop Over 12 Hours

• Increase Pressure to MOPIncrease Pressure to MOP• Check Seals with soap sprayCheck Seals with soap spray

EquipmentEquipment• Air Pump/Compressed AirAir Pump/Compressed Air• Pressure GaugePressure Gauge• Spray Bottle with Soap and WaterSpray Bottle with Soap and Water

LocationLocation• Aerospace Engineering Lab Aerospace Engineering Lab • After HoursAfter Hours


Sensor CalibrationSensor Calibration Calibrate Thermocouple and Pressure TransducerCalibrate Thermocouple and Pressure Transducer

• ThermocoupleThermocouple Calibrate Against another K-type ThermocoupleCalibrate Against another K-type Thermocouple Ice Water BathIce Water Bath

• Pressure TransducerPressure Transducer Calibrate against Pressure GaugeCalibrate against Pressure Gauge Settling TankSettling Tank

EquipmentEquipment• Compressed AirCompressed Air• Pressure GaugePressure Gauge• Other ThermocoupleOther Thermocouple• Ice Water BathIce Water Bath• ITLL Lab StationITLL Lab Station

LocationLocation• ITLLITLL


Pressure Relief Pressure Relief Valve CalibrationValve Calibration

Test and Calibrate the Pressure Relief ValveTest and Calibrate the Pressure Relief Valve• Pressurize Settling Tank to 660 psiPressurize Settling Tank to 660 psi

Adjust Crack PressureAdjust Crack Pressure• Increase Pressure to MDPIncrease Pressure to MDP• Measure Reseat PressureMeasure Reseat Pressure

EquipmentEquipment• Air Pump/Compressed AirAir Pump/Compressed Air• Pressure GaugePressure Gauge• Pressure TransducerPressure Transducer• ITLL Lab StationITLL Lab Station

LocationLocation• ITLL ITLL

Performed not Later than Performed not Later than 2/26/072/26/07 Dependant on Sensor Calibration TestsDependant on Sensor Calibration Tests

BudgetBudgetPart to Buy Quant Cost(ea) Total Part Purchaseed Quant Cost(ea) Total Actual Total Price DifferenceSwivel Casters 2 48.78 97.56 Custom O-ring kit 1 30.00 30.00 12.00 18.00Rigid Caster 2 45.04 90.08 Thermoplastic Hose 108 0.19 20.52 192.00 -171.48Swivel Wheel Lock 2 10.45 20.90 Quick Connect 4 53.70 214.80 120.00 94.80Compressed Nitrogen Tanks 12 7.00 84.00 Quick Connect Stern 4 0.00 0.00 56.40 -56.40Tank Holders 4 5/month 40.00 SS 1/4" T 4 10.59 42.36 29.30 13.06Bolts and Nuts For Casters 16 Max 6.00 96.00 SS 1/4" Pipe 36 1.12 40.25 42.46 -2.216-32 socket head 1 20.00 20.00 Needle Valve 1 53.00 53.00 37.70 15.306-32 nuts 1 5.00 5.00 SS Nipple 5 6.65 33.25 28.76 4.496 washers 1 5.00 5.00 Steel 1" Elbow 2 6.62 13.24 15.63 -2.39Camera 1 845.00 845.00 Steel 1" pipe 36 1.21 43.53 47.72 -4.19Camera kit 1 100.00 100.00 Steel 1" nipple 2 5.32 10.64 5.00 5.641/8" Bolts 240 0.19 45.00 Optical Grade Plexiglass 24 3.13 75.00 35.75 39.251/8" Washers 480 0.08 36.00 SS elbows 5 0.00 0.00 36.16 -36.161/2" Bolts 4 N/A 15.00 Ball Valve 1 172.00 172.00 154.92 17.08Black Plexiglas 1 41.00 41.00 600 psi Tank 1 1,100.00 1,100.00 1,119.35 -19.35Clear Plexiglas 1 16.75 16.75 Pressure Relief Valve 1 254.00 254.00 274.00 -20.00Handles 7 1.34 9.38 1/4" acrylic 1 35.00 35.00 10.00 25.00Weather strip 6 0.68 4.05 Adhesive/sealant 1 30.00 30.00 12.95 17.05Al Tubing 17 1.00 17.00 Light Mount 1 1.69 1.69 1.69 0.00L brackets 29 0.15 4.35 Iris mounted 1 49.00 49.00 51.05 -2.05Rubber Sq Chord Stock 7 0.53 3.71 Attachment 1 5.50 5.50 7.55 -2.051/4 20 Screws 80 8.96 8.96 Mirror 1 289.00 289.00 291.05 -2.05Wing nuts 8 0.98 1.96 Actuator 1 186.00 186.00 203.21 -17.21Noise Reduction Component 1 170.00 170.00 Post holder 5 6.56 32.80 130.14 -97.34Printing 2nd Semester 1 150.00 150.00 Adapter 2 9.45 18.90 37.05 -18.15Wing nut 1/4"-20, 1-3/32"x9/16" 8 0.50 8.00 Mount 3 21.50 64.50 179.05 -114.55Connection Wires 1 100.00 100.00 Lens 2 72.45 144.90 297.90 -153.00Knife Edge 1 10.00 10.00 Post 5 1.98 9.90 56.58 -46.68Additional 1/4" SS nipple 2 5.32 10.64 Base plate 1 0.00 0.00 15.94 -15.94Additional Black Acrylic 1 50.00 50.00 Filter 2 30.00 17.28 17.28 0.00Expandable Sleeving 1 50.00 50.00 Pressure Transducers 3 30.00 205.00 305.00 -100.00Military connector 1 75.00 75.00 Thermocouples 3 30.00 47.00 47.00 0.00Firewire Repeater 1 35.00 35.00 Snubber 1 0.00 0.00 10.00 -10.00Additional Tooling 4 50.00 200.00 End Mills 12 0.00 0.00 160.93 -160.93TOTAL 2,398.34 Light bulb 1 0.00 0.00 1.59 -1.59TOTAL with 25% 2997.925 Plexiglas for sound booth 1 0.00 0.00 10.00 -10.00TOTAL with purchases 7,802.78 Clips 4 0.00 0.00 1.62 -1.62

Square Tube Reinforcement 2 30.00 81.95 81.95 0.003" T-304 Steel Rod @ 3 ft. 1 835.00 835.00 332.28 502.72Printing 1st Semester 1 150.00 150.00 74.19 75.81Thank you letters 1 0.00 0.00 11.04 -11.04Pressure Reg. 1 270.00 270.00 305.00 -35.00Pressure Gauge 2 37.64 75.28 40.00 35.28Mount 1 778.00 778.00 798.00 -20.00TOTAL purchased 4,804.85 -267.90

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Supersonic Wind and Imaging Flow Tunnel