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

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

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)

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)

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

I - BEAMS h s t 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

I - BEAMS 20 NOT SIGNIFICANT!

I – BEAMS W in 4.06 in 0.28 in in Figure 19 – I - beam dimensions

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

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

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

N EW FEA Figure 21 – FEA with a smaller force area 26 F = 10,000lbs Stress (ksi)

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

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

P ROCEDURE FOR U SE 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

P IPE P RESSURE VS. H YDRAULIC P RESSURE 30

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

C ONCLUSION 33 Max Pipe Pressure = 1061 psi

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

Q UESTIONS ? 35