1. T HE CRUSHED E XPERIMENT By: Carlos Sanabria Justin Roose Phillip Munday

2. T HE E XPERIMENT We are to apply 10,000 psi of a quasi- hydrostatic pressure on a 6” diameter pipe 2 Figure 1 – Sketch Pipe under hydrostatic pressure

3. C ONCEPT G ENERATION 3 Figure 2 – Concepts a)Four plates with an incompressible media b)Fluid Pressure c)High strength fabric d)Hose Clamp e)Segments Plates Pipe a) b)

4. C ONCEPT G ENERATION 4 Figure 2 – Concepts a)Four plates with an incompressible media b)Fluid Pressure c)High strength fabric d)Hose Clamp e)Segments c) d)

5. C ONCEPT G ENERATION 5 Figure 2 – Concepts a)Four plates with an incompressible media b)Fluid Pressure c)High strength fabric d)Hose Clamp e)Segments e)

6. T HE D ESIGN P ROCESS Figure 3 – Transverse cross section of the pipe being compressed by six sections 6 Outer Ring Hydrostatic Press Spacing (incompressible media) Pipe

7. FEA Thinking about these sections and how close to real hydrostatic pressure these forces will be, we have to find out how many pieces (sections) we need. An FEA was done to determine the pressure distribution, failure points and strains. Figure 4 – FEA sample Using 4 sections and a distributed known load 7

8. T WO SECTIONS Figure 5 – Two sections Not an option! 8 Pressure Distribution (MPa)

9. F OUR SECTIONS Figure 6 – Four sections Still not uniform 9 Pressure Distribution (MPa)

10. S IX SECTIONS Figure 7 – Six sections Better pressure distribution 10 Pressure Distribution (MPa)

11. E IGHT SECTIONS Figure 8 – Eight sections Much Better pressure distribution… overkill? 11 Pressure Distribution (MPa)

12. F ORCE APPLICATION 12 vs. Screws vs. Hydraulic actuators Figure 9 – Force Application Side view of the two force application options

13. M ATERIAL S ELECTION Figure 12 – A single section 13 h d w F F Figure 13 – The hexagonal outer ring SteelAluminum

14. F INAL D ESIGN ( FOR 10,000 PSI ) 14 Figure 14 – Final Design for the fall semester Design for a surface pressure up to 10,000 psi

15. T HE PROBLEM : 15 The strongest actuators that can accommodate our budget are not nearly as strong as our calculations assumed Our sponsor advised that we should design around the actuator’s force

16. A VAILABLE ACTUATORS CONSIDERING OUR BUDGET Figure 15 – Model Number RW50 16

17. N EW R ING D IMENSIONS AND FORCES Figure 16 – New ring Dimensions 14. 05 in 20 Five tons of force from each actuator

18. O PTIMIZING Figure 17 – New System Layout and next steps New I -Beam Dimensions Natural Rubber Insertion Replacing Actuators 18

19. I - BEAMS h s t 12.73 in 8.11 in w h4 in w2.796 in s0.326 in t0.293 in 19 δ Figure 18 – Ring Piece Dimensions and Deflection

20. I - BEAMS 20 NOT SIGNIFICANT!

21. I – BEAMS W 4-13 21 4.16 in 4.06 in 0.28 in 0.345 in Figure 19 – I - beam dimensions

22. R EPLACING A CTUATORS BY S TATIONARY C OLUMNS 22 C OLUMNS ARE CHARACTERIZED BY IT ’ S S LENDERNESS R ATIO L = L ENGTH OF THE C OLUMN K = R ADIUS OF G YRATION

23. If the Slenderness Ratio < 10 The column is now bound by the Mechanical Properties To ensure this: L = 1.94 inch same length as hydraulic cylinders Diameter > 0.776 inch Diameter is set to be 1 inch Made out of structural steel ASTM - A36 Same as I-beams 23 R EPLACING A CTUATORS BY S TATIONARY C OLUMNS

24. 24 R EPLACING A CTUATORS BY S TATIONARY C OLUMNS Stress = 12 ksi Strain = 0.0004 Structural Steel ASTM – A36 Elastic Modulus = 29,000 ksi Yield Stress = 36 ksi

25. F INAL S YSTEM Figure 20 – Final System New I -Beam Dimensions Natural Rubber Insertion Columns

26. N EW FEA Figure 21 – FEA with a smaller force area 26 F = 10,000lbs Stress (ksi) 5 4 3 2 1

27. W ELDING POINTS Figure 22 – Welding area forces and stresses 27

28. S AFETY 28 High pressure and high forces are always dangerous to work with Need to have intimate knowledge of the system to operate Keep others in close proximity aware of the testing Eye protection is advised

29. P ROCEDURE FOR U SE 29 1. Insert pipe into the center 1. Be sure all hydraulic hoses are clear 2. Make sure everyone all safety precautions are in place 2. Calculate desired pressure (using equation 1) 3. Increase hydraulic pressure to the calculated pressure 4. Perform dynamic testing 5. Release the pressure in the hydraulics 6. Remove pipe

30. P IPE P RESSURE VS. H YDRAULIC P RESSURE 30

31. T ESTING 31 Attached a strain gauge on the inside of the pipe Get a relationship between hydraulic pressure and pressure on the pipe Put copper wire between the pipe Check to see how quasi-hydrostatic the pressure is

32. 32 C OST Table 1 PartCostQuantityTotal Hydraulic Pump$262.501 Hydraulic Cylinders$219.003$657.00 Hose and Connectors$24.664$98.64 Hydraulic Manifold$103.071 I-beam Sections$25.006$150.00 Steel Columns$9.783$29.33 Aluminum Blocks$33.526$201.12 Rubber$11.951 Pressure Gauge63.671$63.67 Pressure Adapter$52.851 Total Costs $1,630.13

33. C ONCLUSION 33 Max Pipe Pressure = 1061 psi

34. A CKNOWLEDGMENTS Dr. Eric Hellstrom Dr. William Oates Dr. Janet Wolfson Dr. Zohrob Hovsapian Dr. Srinivas Kosaraju S & H Hydraulics 34 Jeremy Phillips John Deep

35. Q UESTIONS ? 35