Facility Tour - Asme Community

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FLORIDA SECT ION V O L U M E 4 , I S S U E 1 LINKAGES J A N U A R Y 2 0 1 4 Facility Tour Cargo Loader SPECIAL POINTS OF INTEREST:  Factory Tour  Past Events  Upcoming Events  Human Powered Vehicle Competition  3D Printing Tips  ASME.org Social Networking  Referral Drive On Friday, October 18th, 2013, ten ASME members and their guests toured the JBT Aerotech production facility off of Presidents Drive in Orlando. George Vagelakos, Senior IT Engineer with JBT Corporate, led the tour. JBT Orlando makes cargo loading equipment and de-icers for all of the major cargo carriers such as FedEx and DHL, as well as most of the airlines in the world. The cargo loaders are as large as a dump truck, can carry several tons of cargo, and employ hydraulic lifts and joystick control of the cargo loading process from a single cockpit position. Mike Leon, one of the ASME members on the tour, was a former employee of JBT. Mr. Leon described the patented drive system that allowed cargo containers to move in two directions and rotate on the conveyor system, allowing cargo to be loaded in tight access situations. As large as the cargo loaders and de-icing equipment appeared when viewed close up, they are dwarfed when viewed in photos next to the airplanes they service. The division was a former FMC division, and many of their products can be seen in service at airports the world over. Assembly starts with a welded steel De-icer chassis which are painted on site. Axles, engine, cab, and all of the cargo conveyor systems are added to the chassis. The final test is conducted in a huge room allowing the cargo bed to be raised to its maximum height. Final shipments are sent all over the world to Customer sites. The facility has a hardware supplier who maintains an on site store where spare parts and tools can be purchased with the swipe of an employee badge. There is even a small vending machine where small tools can be obtained by employees using their badges. Former Chair Jim Stana arranged the tour after meeting George Vagelakos for the first time a few weeks ago. Our thanks to George for taking the time to set up the tour and conducting it after hours with the approval of JBT Safety and Security. Jim Stana Mike Leon VOLUME 4, ISSUE 1 PAGE Upcoming Events January 16 — “The Mechanics of the R&B Guitar” by Mike Sedlack. Louie and Maria’s, 9728 E. Colonial Dr. Networking 6:30pm, Dinner 7pm, Presentation 8pm RSVP by COB Jan. 14 at [email protected] *Schedule February 16-22 — National Engineers’ Week February 19 — UCF Student Design Presentations at UCF Campus subject to change March 20 — “Life with a 3D Printer” by Jim Stana April 11-13 — East Coast Human Powered Vehicle Competition at UCF Campus Recent Event "Aerodynamics of a Curveball" by LeRoy Alaways In September 2013, Dr. LeRoy Alaways presented the fascinating subject of baseball aerodynamics. National conversation of the possibility of a curveball took center stage in the New Yorker, Life, and LeRoy Alaways Look publications and among academic researchers in the 1940’s. Dr. Alaways discussed the historical background of baseball research and how he discovered and analyzed some unpublished data collected by Igor Sikorsky. He explained that the ball generates lift, drag, and cross-force components of aerodynamic forces due to the pressure and viscous shear forces that act on the ball while in flight. The spin induced on the ball by the pitcher is the basis of the deviation from the normal gravitational parabolic arc. For the curveball, the angled top spin causes the ball to drop lower than the normal arc and to deflect laterally. He also talked about the seam orientation, as it relates Ball to the number of seams the Orientation catcher sees per revolution of the ball in flight. A fourseam pitch (rotating about the z axis) can curve more LINKAGES than a two-seam pitch for low spin parameter values. The seam orientation influence decreases with increasing value of spin parameter. Lastly, Dr. Alaways asked the attendees, “Which ball goes farther after being hit with a baseball bat?” Both the fastball and curveball have a backspin after being hit, but the curveball gets more backspin due to the initial pitched topspin, generates more lift, and can go farther in the field. Dr. LeRoy Alaways has a diverse research and engineering background that includes developing a system to track javelins in-flight, building a virtual reality bobsled simulation for the US Bobsled team, and tracking baseballs at the 1996 Summer Olympic Games. He was also instrumental in designing the “world’s best” baseball pitching machine. He has over 10 years of mechanical engineering teaching experience at Villanova University, Temple University, UC-Davis, and the U.S. Military Academy, West Point. He received a Ph.D. in Engineering from the University of California, Davis, and his Ph.D. dissertation on the aerodynamics of baseballs is in the National Baseball Hall of Fame. One PDH was offered to P.E.s who attended. 2 VOLUME 4, ISSUE 1 PAGE 3 Recent Events “Axisymmetric Whole Engine Modeling” by David Cusano On October 24th, ASME Senior members met with the UCF Student members at the Fairwinds Alumni Center on the UCF campus. Dr. David Cusano, Chief Engineer and part owner of Parametric Solutions, Inc., presented the project he led: Axisymmetric whole engine modeling using CFD and Ron Lewis Thermal and Structural Analysis. Mr. Ron Lewis and Mr. Ashish Jaiswal from ANSYS also came to give an overview of the ANSYS Workbench which facilitated Dr. Cusano’s work. The goal of his project was to simulate the structural displacements caused by the natural convection cooling in a gas turbine. This was accomplished by modeling an unsteady conjugate heat transfer problem using ICEM and Workbench for meshing. The mesh was optimized to obtain accurate values of heat transfer coefficient and Nusselt number and good resolution of the flow. These results, as well as the metal temperatures, were obtained by performing CFD analysis using CFX. The tempera- ture data was then coupled to the structural analysis to obtain the disDavid placements using ANSYS. Cusano The model size was optimized at 7 million nodes and, and analysis results showed that there was a bow in the rotor shaft of 7 mils during engine cooling. Dr. Cusano has also worked for United Technologies' Pratt & Whitney, where he developed the first (for P&W) gas thrust bearing design for the Space Shuttle Main Engine Hydrostatic Bearing Test Rig. He has degrees in Aeronautical/Astronautical Engineering, Aerospace Engineering, and has a Ph.D. in Mechanical Engineering from Purdue University. In addition to the technical content, this meeting facilitated great networking opportunities for students and professionals. Our thanks to the Students’ Section and Advisor Dr. Ali Gordon for organizing this meeting. “Gas Turbine Operational Flexibility” by Joshua Kovac In August 2013, Josh Kovac from Siemens Energy talked about the operational flexibility of gas turbines. Gas turbines are uniquely suited for the gap between traditional steam turbine power plants and renewable sources. Their advantages include fast start-up and load ramp rates, which enable them to quickly deliver power resources during peak load times. They do, however, induce more thermal stress on the components due to the higher temperatures, requiring more thermal management. Mr. Kovac discussed hydraulic clearance optimization, where the rotor shaft shifts longitudinally to adjust the gap clearance between the blades and the casing. This provides mechanical aid when the materials experience thermal expansion and contraction and en- LINKAGES ables better control of turbine efficiency. Overall, gas turbines provide operational flexibility to combined cycle and gas turbine power plants, while lowering life cycle costs through extended service intervals and reduced repair costs. Josh Kovac has a Bachelor’s degree in Mechanical Engineering and a Master’s degree in Engineering Management from the University of Central Florida. Since 1996, Mr. Kovac has been engaged in advanced gas turbine development for Siemens Energy and has worked in Berlin, Germany, and Orlando, Florida. He currently is an Engineering Manager of the SGTx-8000H product line. One PDH was offered to P.E.s who attended. PAGE 4 Recent Event “Gas Turbine Exhaust Temperature Measurement System” by Richard Bunce In November for our last dinner meeting of the year, Richard Bunce presented his work with Siemens Energy involving a novel gas turbine exhaust temperature measurement system. This system uses a circular array of 8 acoustic pyrometer horns as sound transmitters and 8 microphones as receivers arranged around the outside circumference of the turbine exhaust duct. Each receiver captures the sound transmitted from each horn, which creates a grid of path intersections. The Active Acoustic Method is the fundamental principle of this measurement system: the speed of signal sound is calculated, and isentropic relations are employed to calculate the average temperature across each signal path. It then uses advanced algorithms to map the temperatures at every path intersection. This acoustic pyrometer array measurement technique has proven to be robust and effective in two test engines of different power ranges and different combustion and exhaust duct configurations. This technique was first reported at the ASME Turbo Expo in San Antonio in June 2013. Richard Bunce, P.E., is a Principal Engineer at Siemens, has worked in gas turbine blading heat transfer development, and currently works in the Siemens Gas Turbine Advanced Sensors and Instrumentation Systems group where his technical interest is temperature, pressure and flow measurement. Mr. Bunce holds 5 patents and has written several reviewed, published papers. He is a Past Chair of the Florida Section ASME and currently serves as the ASME Vice President, Global Communities in the Knowledge and Community Sector. His technical interest is the ASME International Gas Turbine Institute where he serves on the Controls, Dynamics and Instrumentation Committee. One PDH was offered to P.E.s who attended. Richard Bunce Human Powered Vehicle Competition is coming to UCF Come witness an exciting competition where university students from the East U.S. display Saturday, April 12, 2014 their talents and passion for Engineering! 6:00 am to 12:00 pm — Drag Race Event Location: Central Florida Blvd, ENG 2 Bldg. Click for more info and promo video! Friday, April 11, 2014 12:00 pm to 7:00 pm — Vehicle Display, Presentations, and Safety Inspection Location: ENG 2 Building, Harris Engineering Center Lawn, CREOL Parking Lot C LINKAGES 12:00 pm to 6:00 pm — Innovation Event Location: ENG 2 Building Sunday, April 13, 2014 6:00 am to 12:00 pm — Endurance event Location: Parking Lots C and D PAGE 5 Life with an Afinia 3D Printer “3D printing” and “additive manufacturing” are upward trending technologies in diverse industries for building concepts and working models and are quickly becoming popular and attainable technologies for the consumer. We continue here from the previous two Newsletter installments, to follow Jim Stana (past FL Section Chair) as he experiments with the Afinia 3D printer extrusion width and troubleshoots the issues he encountered when printing with different colors. Printing with Colors Afinia H-Series 3D Printer Design of Experiments LINKAGES Recently, I have been printing flat objects like key chains with multiple colors. First, let me say that the change of color is not as easy as it could be. First, you have to pause the print at an appropriate time. I always add a small pillar of material outside of the model and try to pause the print when the print is on this portion (see bottom of key tag photo). It would be nice if you could imbed a “pause” command into the STL or print file and have the head go to a "neutral corner". The head does raise up but the pause occurs wherever it happens to be printing. The nozzle also starts to immediately cool. So to keep the print head hot and make the transition to the new color as fast as possible, you hit the “pause” button, then the “withdraw” material button, and pull out the old color. If you wait too long to hit the “withdraw”, the print head will cool down and you will have to wait a little before you can pull out the first color material. Then you have to replace the spool with the new color, feed it into the plastic guide sleeve, and slip it into the print head and hit “extrude”. By then, the print head has cooled, so it might take a minute to get the feed to start again with the new color. And it extrudes for about 30 seconds so the new color comes out and starts to drip onto your new model. I will likely mount the new color and buy another guide tube to eliminate some of the steps above, but it is still not ideal. model from it. That all took a few days of evening work. The first copy printed in two colors in 35 minutes. It would be best if you could specify a neutral corner where the model was not being built, have the print head do a “change material” command and have it keep the print head hot during the process. It would allow withdrawal, and then begin to feed after you hit a ready command. An option to set the time of feed might allow someone to extrude out the old color or just allow the material to keep printing since you will cover the material with a few layers anyway. I have some other work-around ideas to make color changes easier, but I think I will keep them to myself for My wife loved the results, but the second color didn't stick well in a few places, so I would need to improve my color changing technique. Also, some of the lettering appeared well filled while others did not. I decided to tackle the second issue by running a simple design of experiments (see photo). I created a model of rectangles with different print widths and oriented them along both the x and y axes, as well as 45 degrees to the axis. The print widths varied from 1 to 2.9 mm. I had looked at a few examples of earlier prints and made the observation that the nominal print width was about a 0.5 mm wide. So when the print object was 1 mm wide, the object was created with 2 lines of print, each 0.5 mm wide. If it was wider than that, there was a gap between the print lines. As you got to 1.5 mm, 3 lines appeared. You can see the results in the photo. The numbers next to the rectangle represent the width in mm. I remodeled the key tag so that the lettering was in multiples of 0.5 mm width wherever possible. The final print of the key tag is shown in the key tag photo, while still on the print bed perf board. The outside material is the “raft” that the printer creates to ensure a good starting surface. The whole object is about 18 grams, or about $0.90.  Key Tag awhile and debug them on my own. Printing a Model with 2 Colors My wife had an idea for a logo that she wanted me to use on a keychain for her. It is for an online Master’s degree program she is currently taking from FSU. I saw this as a chance to show off my new capability. She had sketched the logo on a piece of paper. I was able to model it by first sketching it to scale, importing it into SketchUp (a 3D modeling program originally from Google), and creating a 3D Letter/Feature Widths Stay tuned for more results of Jim’s explorations on his 3D printer. VOLUME 4, ISSUE 1 PAGE 6 Join ASME.ORG Social Networking It’s as easy as: 1. Register as an “ASME.org Participant” at ASME.org homepage using your current ASME membership email address, 2. Follow the prompts and provide a few pieces of information, 3. Verify via email, and you’re in! You can then create a public profile by importing information from a LinkedIn account. Register Join the Florida Section Group today to see what’s going on in your section! Click Banners for more info! Submit Abstract (Clickable Link to FL Group) VOLUME 4, ISSUE 1 PAGE ASME Referral Drive Where Everybody Wins! Grow Membership and Earn Rewards!! BENEFITS  NEW! Social Networking Feature on ASME.org.  NEW! ASME SmartBrief — Stay abreast of trends and news in engineering.  Free membership in up to five Technical Divisions.  Online Career Center with a job board with exclusive opportunities, resume builder, salary survey and more.  ASME WorkSmart with 100 volumes, many with interactive tables & digitized graphs.  e-Mentoring offering rewarding experiences (mentor/mentee).  Engineering For Change — Use your skills to create a better world and a healthier future. Join our ASME.org Group and Connect with us!! Leadership 7 District F www.asme-florida.org Click Region for more Info! Vice President, Global Communities Richard Bunce Florida Section Chair George Cera Vice-Chair Matthew Smolowitz Secretary Andrea Wesser Treasurer Stan Wells Past Chair Jim Stana Executive Committee Members Monica Hansel, Lisa Schott, Alex Socha, Pete van Caulil, Diane Vazquez, Mark White, Terrell Yon Citrus Conference Representative Jim Stana (Acting) Newsletter Chair Diane Vazquez Webmasters Riley Exum, Alex Socha Student Chapter Liaison Caleb Amy