Customized Cyclic Test Device ME 462
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![Page 1: Customized Cyclic Test Device ME 462](https://reader035.fdocuments.in/reader035/viewer/2022070400/56813125550346895d979759/html5/thumbnails/1.jpg)
Sponsor: Carrier CorporationAdvisor: Dr. H. El-Mounayri
May 3, 2007
Design Team: Mike Abel Braden Duffin Simon Marin Joe McGuire
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Presentation OutlinePresentation OutlineBackgroundRequirementsDevelopmentFinal DesignEvaluationRecommendationsQuestions
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Design ObjectiveDesign ObjectiveDesign a custom cyclic corrosion device for
testing material samples. The device must replicate conditions
encountered in actual furnace applications.Environmental conditions include hot air,
chemical exposure, and humidity.
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Performance RequirementsPerformance RequirementsControlled temperature range of 70-
400° FahrenheitHumidity: 85%Corrosive Chemical ExposureControllable and variable cycle
transitions (30-60 sec. transitions)Other (weight, cost, size, power,
safety)
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DevelopmentDevelopmentConcepts generation included QFD, functional
flow analysis, function-concept mapping, decision matrix, etc…
Designed housing concept using ProEngineerResearched commercially available
components (heat element, fan, valves, chemical pump, etc…)
Performed analyses to determine necessary component performance
Redesigned housing to fit suitable components
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Final Design (Front View)Final Design (Front View)
HeatChamber
Heating fan
Cooling Fan
ValvesFume hoodRepresentation
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Final Design (Rear View)Final Design (Rear View)
Chamber Vent
Drain Pan
Chemical / Water spray inlets
External Cover
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Final Design (Internal View)Final Design (Internal View)
TestSamples
Chemical NozzleWaterNozzle
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Design EvaluationDesign EvaluationVerification of the requirements was
obtained from: Procured component specifications ProEngineer model geometry Part weights and dimensions Computational Fluid Dynamics (CFD)
simulations
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CFD Model and BoundariesCFD Model and Boundaries
HeatingElement
Heating Fan
Heat side valve
Cool sidevalve Cooling
Fan
Vent
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Requirements VerificationRequirements VerificationCFD Analysis
Temperature range requirement: 70-400ºF Temperature range achieved: 70-500ºF
Temperature transition time requirement: < 60 seconds
Actual time to heat chamber: > 200 seconds Actual time to cool chamber: 25 seconds
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Steady-state heating simulationSteady-state heating simulation
Flow streamlines colored by
temperature
Demonstrates capability to exceed temperature requirement
Internal temperature is 475-500 ºF
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Cooling time simulationCooling time simulationDemonstrates
cooling time capability
Simulation time is 25 seconds
Internal temperature drops from 500 to 80ºF
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Heating time simulationHeating time simulationDemonstrates
heating time capability
Simulation time is 200 seconds
Final Internal temperature is 340ºF
Needs optimization
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Requirements VerificationRequirements VerificationHumidity: 85% (predicted, not verified)Uniform Chemical Vapor Spray (based on
procured nozzle and pump specs.)
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Requirements VerificationRequirements VerificationSafe to be handled (warning: some heated
surfaces and ventilation)System maintenance and cleaning: All parts
exposed to chemicals are stainless steel. All individual part weights are below 60 lbs.
Fits in hood dimensions (verified by ProE model)
Holds 6 coupons (Target: 2)
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Requirements VerificationRequirements VerificationPowered by 110 V (based on procured
components specs.)System can be automated (All parts can be
electrically controlled)System Cost $2799 - $8389 depending on
valve choice (Target: $3000)
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Heat Cycle RecommendationHeat Cycle RecommendationObjective: decrease time to heat chamberCurrently using preheated air to facilitate heatingIncrease amount of preheated air:
Increase volume of heat chamberIncrease surface area of heat stripAdd heat stripAdd second heat chamber
Optimize air flow Entry ventsExit vent
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Valve RecommendationValve RecommendationObjective: Meet initial budget requirements,
minimize long term costsXomox butterfly valve: $3345 each
Highest quality heat and corrosion resistance2” long
McMaster swing check valve: $550 eachLower quality heat and corrosion resistance6” longLikely requires regular replacement
Design custom valve in house?
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QuestionsQuestions