Advisor: Dr. Alaways

The goal of this project was to design a tool to increase the speed at which catapult covers on Navy aircraft carriers can be removed.  A castellated nut has to be twisted off of a tie-bolt to remove these covers.  The challenge of this task was that the tool faced several geometric restrictions and needed to apply a significant amount of torque.  Initial analysis was done to determine that at least 1.1 ft-lbs of torque was required.  These restrictions were overcome by offsetting a socket from the drive shaft of a power tool with a roller chain.  Analysis was done on the roller chain, the tool shafts, and the socket to ensure that the required torque could be transferred.  A prototype was created and initial testing showed it to be successful in rapidly removing a castellated nut.

            In the complete design process and prototype production the budget was roughly 400 dollars, which was significantly less than the allotted amount. Finite element analysis confirmed that an applied torque caused negligible socket deformation.  All design requirements were successfully met; most notably, a hand held prototype that is easily reproducible. The prototype also provides enough torque to spin off a lose nut; which was the underlying goal.

Objective: