Overview of Status of Analysis, Design, Fabrication, Tests, etc.
First round of material orders have been completed.
CAD geometries provided by Collins allowed our team to determine the required curvature of our door and begin designing our final CAD design.
Resources such as the machine shop staff are being utilized to create a detailed testing plan once our prototype doors are assembled.
Our optimization code is in the final stages of completion.
Accomplishments from Previous Week
Using the curvature of the Collins files, Joao was able to create a scale model of our curved baggage door.
Shane completed the first round of material orders.
Materials ordered included 13 sheets of Aluminum 6061, acrylic epoxy, an epoxy dispensing gun, aluminum rivets, and a rivet gun.
Kakeru has made significant progress on the Optimization code and has reached out to machine shop staff and other resources to begin forming a plan for applying a 3 point bend test.
The proper reference constraint points of the door were sent to our team from Collins. These points will be used as constraints in our updated FEA models and will provide more accurate results.
Goals for Next Week (list names after each item). Use specific and measurable objectives.
Shane will complete any future material orders and will play a supporting role in applying FEA on the curved baggage door model.
Joao will take the lead role in machining components once they arrive and will work on revising our report rough draft in the meantime.
Kakeru will look to finalizing the optimization code, documenting the theory behind our methods, and look ok up shear stress values MMPDS for Aluminum-6061, our rivets, and our bonding material.
Ahmed will take the lead role in FEA analysis methods on our curved CAD model. Both normal pressure forces and shear forces will need to be necessary.
The revised version of our 1st draft will be completed by the due date of May 17.
Sponsor Comments from Last Meeting and Actions Taken to Address these Comments (indicate date of comments and if via email or in person)
Our sponsors are pleased with the progress made in our project.
Regarding our concerns about shear stress, our sponsors recommended looking up the material properties for Aluminum 6061 and seeing how they compare to FEA results.
After discussing manufacturability concerns regarding the physical assembly and testing of a curved door, our sponsors confirmed that manufacturing and testing flat versions of our model is acceptable as long as we can verify the physical results through both FEA and experimentation.
Instructor Comments from Last Meeting and Actions Taken to Address these Comments (indicate date of comments and if via email or in person)
Our instructor emphasized the potential issue of shear stress in our design, since all of our stiffeners are currently in the vertical direction. FEA testing will need to be done to determine if design changes are needed.
Comments from Other Students in the Class (indicate date of comments and if via email or in person)
No further feedback was received from the other students in our class this past week.
Risks and Areas of Concern
As Professor T. mentioned, the vertical stiffener arrangement we currently have could be susceptible to shear stress failure as well as buckling along the vertical axis.
It is likely that horizontal stiffeners may need to be added.
Materials have been ordered, but it is likely that the aluminum sheets will not arrive until Week 8. We will need to make sure we have our manufacturing process planned out well so that we do not waste time once the materials arrive.
Resources or Information Required but not Available
At this point in time, all of the desired geometric constraints have been provided by Collins.
Schedule
Upcoming milestones include the completion of our final CAD design (ideally completed by this Sunday) and the assembly of a physical prototype door, which will ideally be completed by the end of Week 8.
In addition, we plan on completing the optimization code and the FEA on the curved CAD file by this Sunday.
Budget (list amount spent and amount remaining)
$917.10 has been spent as of this week (under the assumption all of the current orders go through)
Progress on Report and Webpage
The revised version of our first report draft is due this Friday, May 17th.