FRESCA2 Update on the dipole design and new calculations
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Transcript of FRESCA2 Update on the dipole design and new calculations
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FRESCA2
Update on the dipole design and new calculations
EUCARD - WP7- HFM Collaboration Meeting LASA Milano
Jorge Enrique MUÑOZ GARCIA
Jorge Enrique MUÑOZ GARCIAEUCARD - WP7- HFM Collaboration Meeting LASA Milano
September 18th, 2012
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Jorge Enrique MUÑOZ GARCIA 2EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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Jorge Enrique MUÑOZ GARCIA 3EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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RMC FRESCA2
Jorge Enrique MUÑOZ GARCIA 4Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting
Introduction: related projects
Short Model Coil12.5 T peak field on the coil @ 1.9KWeight: 2 double pancake racetrack coils mounted in a bolted steel structure composed of 2 horizontal and 2 vertical pads, to obtain a “coil pack”Fe yoke / Al shell: 20 mm thick
Race-track Model Coil16 T peak field / 18.3kAWeight: 2 double pancake racetrack coils mounted in a bolted steel structure composed of 2 horizontal and 2 vertical pads, to obtain a “coil pack”Fe yoke / Al shell Øout = 0.570m
Facility for the REception of Superconducting CAbles13 T bore field / 10.8kA @ Ø100mm apertureWeight: 10 tBlock-type coil design with flared ends:
4 double-pancakes,Bladder-and-key type of structureFe yoke / Al shell: 65 mm thick, Øout = 1.030mMagnet length: 2.255 m
SMC
EUCARD - WP7- HFM Collaboration Meeting LASA Milano
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• Target: 13 T / Ø100 mm bore• Ø1.030 m; length: 2.255 m• Al shell, 65 mm thick, 1.6 m long• Iron yoke
– Holes for 4 Al-axial rods• Horizontal stainless steel pad
– 3 bladders– 2 load keys (1horizontal, 1vertical)
• Iron / Ti central post• Vertical iron pad
– 2 bladders,– 2 load keys
• Auxiliary bladders between yokes• 4 double-layer coils
Introduction: magnet overviewFRESCA2 Cross-section
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Jorge Enrique MUÑOZ GARCIA 6EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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Dummy coils: replacements of coilsFRESCA2 Cross-section
Jorge Enrique MUÑOZ GARCIA 7
Al block
Al block
Replacement of coils & pole by 2 Al-blocksdummy-coils
Mechanical test of the structure: at room temperature (warm) at cryogenic temperature (cold)
Instrumentation (strain gauges): Aperture (dummy-coils) Shell Rod
Qualification of the structure Validation of the assembly process Validation of the FEM model
EUCARD - WP7- HFM Collaboration Meeting LASA Milano
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Jorge Enrique MUÑOZ GARCIA 8EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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Jorge Enrique MUÑOZ GARCIA 9EUCARD - WP7- HFM Collaboration Meeting LASA Milano
Instrumentation: strain gaugesFRESCA2
Rods
Shell
Dummy-coil
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Jorge Enrique MUÑOZ GARCIA 10EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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iron yoke
shell
vertical pad end plate
coils
rod
wedge
Jorge Enrique MUÑOZ GARCIA 11
FRESCA2 dummy-coil: FEM modelcomponents
Shell [Aluminum]Yoke [Iron]Pad-h [stainless steel]
Shim-in [G10]Shim-mid [G10]
Pad-v [Iron]
Yoke [stainless steel]
Pad-v [stainless steel]
Dummy [Aluminum]
Key-h [stainless steel]Key-v [stainless steel]
solid95 3D 20-node structural solid element (brick)conta174 3D 8-node surface-to-surface contacttarge170 3D target segmentfriction = 0.2 everywhere that components come into contact with each other
EUCARD - WP7- HFM Collaboration Meeting LASA Milano
Rod [Aluminum]
End-plate [Nitronic]
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Jorge Enrique MUÑOZ GARCIA 12EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 2D dummy-coils
Cross-section at the middle of
FRESCA2
• Comparison of stress during assembly & cool-down: FEM simulation vs. strain gauges measurements
Outside shell 0°
Outside shell 45°Outside shell 90°
dummy aperture
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Jorge Enrique MUÑOZ GARCIA 13EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 2D dummy-coils
• Comparison of stress during h-bladder operation: Peak stress outside the shell: 50MPa
Peak compression in the dummy-aperture: 120MPa
Outside shell
dummy aperture
Cross-section at the middle of
FRESCA2
FRESCA2dummy 2D model
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Jorge Enrique MUÑOZ GARCIA 14EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 2D dummy-coils
• Comparison of stress during v-bladder operation: Peak stress outside the shell : 25MPa
Peak compression in the dummy-aperture : 30MPa
Outside shell
dummy aperture
Cross-section at the middle of
FRESCA2
FRESCA2dummy 2D model
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Jorge Enrique MUÑOZ GARCIA 15EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 2D dummy-coils
• Comparison of stress during key operation: Peak stress outside the shell : 30MPa
Peak compression in the dummy-aperture : 75MPa
Outside shell
dummy aperture
Cross-section at the middle of
FRESCA2
FRESCA2dummy 2D model
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Jorge Enrique MUÑOZ GARCIA 16EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 2D dummy-coils
• Comparison of stress during cool-down: Peak stress outside the shell : 120MPa
Peak compression in the dummy-aperture : 200MPa
Outside shell
dummy aperture
Cross-section at the middle of
FRESCA2
FRESCA2dummy 2D model
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Jorge Enrique MUÑOZ GARCIA 17EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 3D dummy-coils
Key operation
• Comparison of stress during key operation: Peak stress outside the shell : 30MPaDummy peak compression: 75MPa
dummy
shell
FRESCA2dummy 3D model
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Jorge Enrique MUÑOZ GARCIA 18EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 3D dummy-coils
Rod pre-tension
• Comparison of stress during rod pre-tension: Peak stress inside the shell @90°
Dummy stress concentration at the straight section
dummy
shell
FRESCA2dummy 3D model
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Jorge Enrique MUÑOZ GARCIA 19EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 3D dummy-coils
Cool-down
• Comparison of stress during cool-down: Peak stress inside the shell @0°
Dummy stress concentration at the straight section
Longitudinal location of strain gauges
dummy
shell
FRESCA2dummy 3D model
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Rod pre-tension
Jorge Enrique MUÑOZ GARCIA 20EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses: FRESCA2 3D dummy-coils vs. superconducting coils
Cool-down
• Comparison of stress during cool-down: Peak stress outside the shell @0°
Dummy stress concentration at the straight section
coils
rails
end shoes
wedge
pole
dummy
coil pack
coilsVs.
dummy
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Jorge Enrique MUÑOZ GARCIA 21EUCARD - WP7- HFM Collaboration Meeting LASA Milano
FEM model: assembly processExpected stresses during the assembly process
• Stress in the compression system: Aluminum rod longitudinal average stress: 160MPa @RT 225MPa @cryogenic
End-plate stress within yield stress limits*
*
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Jorge Enrique MUÑOZ GARCIA 22EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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Jorge Enrique MUÑOZ GARCIA 23EUCARD - WP7- HFM Collaboration Meeting LASA Milano
Cases of study
• FRESCA2 dummy-coils– Coils replaced by a block (this presentation)
• Validation of the assembly process• Validation of the model: comparison with the strain gauges
measurements
• FRESCA2 superconducting coils– FRESCA2 mech– FRESCA2 wedge (contact), overall friction– FRESCA2 wedge (no contact), overall friction– FRESCA2 wedge (glued, no contact)– FRESCA2 wedge (glued, contact)
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Jorge Enrique MUÑOZ GARCIA 24EUCARD - WP7- HFM Collaboration Meeting LASA Milano
outline
• Introduction: related projects & magnet overview
• Dummy-coils: replacement of superconducting coils
• Instrumentation: strain gauges
• FEM model: expected stresses during the assembly, pre-load, and cool-down
• FEM model: cases of study
• Work in progress
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• 3D FEM model:– Updating of geometries:• Update Ørod in the dummy-coil model• Wedge geometries
– Analysis & comparison of the results• Different cases of study
• Instrumentation of the structure:– Strain gauges on dummy aperture at 90°, 45°– Strain gauges on rods
Jorge Enrique MUÑOZ GARCIA 25EUCARD - WP7- HFM Collaboration Meeting LASA Milano
Work in progress
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Jorge Enrique MUÑOZ GARCIA 26EUCARD - WP7- HFM Collaboration Meeting LASA Milano
Thank you
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Assembly process: rotating device@ 927
½ yoke weight ≈ 2400 kg
Shell weight ≈ 860 kg
Jorge Enrique MUÑOZ GARCIA 27EUCARD - WP7- HFM Collaboration Meeting LASA MilanoJuan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting
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The assembled parts will be rotated to horizontal position
Yoke and shell will be transported toan assembly table
bearing rollers will be used to slide the coil-pack into the
yoke aperture
The Al-block will be transported
to the assembly table
(Coil-pack weight ≈ 2000 kg)
Assembly process: table@ 927
Jorge Enrique MUÑOZ GARCIA 28EUCARD - WP7- HFM Collaboration Meeting LASA MilanoJuan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting
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Two bladders will be used to push the ½ yokes towards the shell inner radius to allow gap keys insertion
Insertion of the keys in between the ½ yokes
Assembly process: ½ Yokes centring@ 927
Jorge Enrique MUÑOZ GARCIA 29EUCARD - WP7- HFM Collaboration Meeting LASA MilanoJuan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting
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3 vertical bladders will be used to lift the coil-pack and remove the rollers
Temporary keys will be inserted to center the coil –pack into the yoke
aperture
Assembly process: table@ 927
Jorge Enrique MUÑOZ GARCIA 30EUCARD - WP7- HFM Collaboration Meeting LASA MilanoJuan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting
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Pumping horizontal bladders & insertionof horizontal keys
Horizontal bladders insertion
Assembly process: horizontal bladder operation@ 927
Jorge Enrique MUÑOZ GARCIA 31EUCARD - WP7- HFM Collaboration Meeting LASA MilanoJuan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting
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Pumping vertical bladders & insertion of vertical keys
Final configuration after loading operation
Assembly process: vertical bladder operation@ 927
Mechanical test Room temperature Cold-down
Jorge Enrique MUÑOZ GARCIA 32EUCARD - WP7- HFM Collaboration Meeting LASA MilanoJuan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting