1. CM_PWR Drop Test Structural FEA

2. Objectives Simulate Drop Test from 3 feet using Algor simulation Produce an accurate Finite Element Analysis of the event

3. Materials Test 1 - Aluminum

4. Simulated Forces Test 1 & 2

5. Analysis

7. Results Maximum Principal Stress – 1235 psi 6061- O temper Aluminum Max Yield Strength ~ 8000 psi 6061- T6 Aluminum Max Yield Strength ~ 35000 psi

8. Materials Test 2 - Delrin

9. Analysis

12. Results Maximum Principal Stress – 1370 psi Delrin 500MP NC010 Max Yield Strength ~ 10200 psi

13. CM_PWR Thermal Test Structural FEA

14. Simulated Test Conditions Transient Thermal Analysis 3 Hot Spots 0-6 min – 15 watts of Heat Generated 6-7 min – ramp up to 45 watts of Heat Generated 7-8 min – Full 45 watts of Heat Generated

15. Simulated Test Conditions Initial Temperature – 32º C (90º F) Convection Coefficient – 3.2 J/(sºCm 2) Surrounding air at 32º C Density – 1.2096 kg/m 3 Prandtl No. – 0.71 Thermal Conductivity – 0.0257 W/mºC

16. Results Test 1 –Aluminum Body & Base

17. Results Test 2 – DuPont Delrin Body & Aluminum Base

18. Alternate Design Heat sink on the bottom of the base plate 5º C reduction at 6 minutes 12º C reduction at 8 minutes 48 in 2 increase in area 0.038 lbm mass addition

19. Results Test 3 – DuPont Delrin Body & Aluminum (w/ Fins) Base