ME 462 Capstone Design

Group Members: Kelly Moore, Bart Sudhoff, Danny Compton,

Katie Iaizzo, Mary Croucher
Advisors: Dr. Jie Chen and Dr. Roger Knutson
12 Decmeber 2007

Introduction
Background
Design Objectives
Material Selection
Cost Evaluation
Concept Design
Product Evaluation
Conclusion
Recommendations
Answer Questions

Russell Foundation
Founded By Bishop Michael Russell and his

Father
In 2003
Faith Based Community Development
Organization
Renders Self-sufficiency Programs to Help
Stabilize Families and Communities
Provides Jobs for Local Communities
Environmentally Friendly Initiatives

Reasons For Design

Reduce Traffic Congestion

around Chicago-Indiana
Area
Provide High Speed
Transportation
Create Jobs in Indiana
Pioneering Environmentally
Friendly Mass Transit
Solutions

Preliminary Design

Customer Requirements
Travel 75 MPH
Support Renewable Energy Source
Easy Assembly
Easy Maintenance
Smooth Rail Transition
Appearance
Support 160,000 lb load
Minimize Stopping Time
Minimize Cost
Minimize Environmental Effects

Engineering
Requirements
Minimize Resistance (Rail)
Maximize Allowable Stress (Structure)
Equipment Hours
Labor Hours
Minimize Rail Height Difference
Public Appearance Rating
Maximize Allowable Stress (Rail)
Maximize Allowable Stopping Force
Minimize Cost
Minimize Environmental Effects on Material

Column Support
Box beam
Concrete base
Bolted to cross-

support

Cross Support
Box beam
Bolted to

column
Supports rails

Standard I-Beam W27 x

368
Standard Size
Internal height

equal to 25.43
inches
Fits standard 22
inch tire diameter

Column Support
Assembly
All parts bolted
and welded

Full Assembly

Types of Steel
Two common types used: ASTM A992 and

ASTM 588
More common steel types reduce cost
High strength, low alloy steel, which used
recycled metals
Saves on cost of manufacturing
Environmentally friendly

Physical Properties
ASTM A588

ASTM A992

Contains Chromium for

weather resistance

Made using 95% recycled

material

Develops oxide coating

Inexpensive

50 ksi yield strength

50 ksi yield strength

Structural Steel
ASTM A-588

ASTM A-992

Price per cwt from

Nucor-Yamato Steel

$51.10

$46.60

Price per 80ft Beam

$6483.85

$5971.32

Price difference per

section

$512.53

Price Comparison
Consider long term maintenance and repair

cost
Northwestern University experiment
A992 corrodes 64% more over time than A588

A992 would last less than half as long as A588

(weathering steel)

Nuts and Bolts

Quantity
48
24

15

Description
Grade 8 Plain Alloy Steel Hex Head Cap
Screw 1-1/8"-7 Thread, 6" Length
Grade 8 Plain Alloy Steel Hex Head Cap
Screw 1-1/8"-7 Thread, 5" Length
Grade 8 Plain Steel Hex Nut 1-1/8"-7 Screw
Size, 1-11/16" Width, 31/32" Height, Packs of
5

Unit
Price
$7.16
Each
$6.25
Each
$6.12
Pack

Total
Price
$343.68

Total

$585.48

$150.00
$91.80

Loading (Structure)
Deadweight Load
80,000 lbs (355868

N)
per Rail
Braking Force
9.8 m/s2 * 80,000 lbs
Fixed Supports
Base Ground
Interface
Open End Rails

Equivalent Stress
(Structure)
Maximum
5.53e7 Pa

Shear Stress (Structure)

Maximum
2.81 e7 Pa

Total Deformation
(Structure)
Maximum
16.75 mm

Location
Mid-span

Factor of Safety
(Structure)
Minimum
6.15

Location
Beam-

Near Connection

Fatigue Analysis (Beam)

Loading (Beam)
Deadweight load
40,000 lbs

per Flange
Fixed Supports
Open Ends of
Beam

Total Deformation (Beam)

Maximum
9.5 mm

Fatigue Life (Beam)

Minimum
8.03e5 cycles

Concluding Remarks
Our designed is based on the customer

requirements and goals of the Russell Foundation.

The factor of safety meets required limit of 5-7
Fatigue life exceeded 8.0 e 5 cycles
A588 steel resists weathering without excessive

cost
Single column design minimizes footprint
Designed to easily integrate renewable energy
sources

Structure Span Length

Preliminary Testing
Larger Beam
39

in. Interior
Beam height

Factor of Safety

Increased to 9.53
Custom Beam
Standard

Available

Size Not

http://www.uspto.gov/patft/index.html
http://www.delphion.com/home
Project definition packet, Russell Foundation
IndianaFreight and IndianaMonorail, Roger Knutson; Russell
Foundation;
Advance Transit Solutions, LLC, May 2007
http://www.wisegeek.com/what-is-a-steel-i-beam.htm
http://en.wikipedia.org/wiki/I-beam
Machinists Handbook 12th Edition, Lang, page 397
http://www.matweb.com