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
Total
Price
$343.68
$6.25 Each
$150.00
$6.12 Pack
$91.80
Total
$585.48
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
 BeamNear 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 e5 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 Size Not
Available
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
Machinist’s Handbook 12th Edition, Lang, page 397
http://www.matweb.com