TMM of the CLIC Two-Beam Module T0 in the LAB – Proceedings to structural FEA

Riku Raatikainen

22.8.2011

Introduction- TMM geometry- Load condition

- Cooling concept Model description

Results Discussion

INDEX

TMM was implemented to the CLIC Two-Beam module to be tested in the lab (Type 0)

As a first step, the FEM TMM had to be re-assembled to correspond current layout (including significant geometrical simplification to the 3D design, ST0312798_01)

After the simplification, the geometry was imported to ANSYS

Fluid network generation was done in parallel with CATIA and ANSYS

Overview

3D model of the CLIC Test module in the lab (Type 0 – Type 0) - Courtesy of D.Gudkov

Waveguide

DB QP

PETSVacuum reservoir

PETS support

DB cradle and movers; DB girder

MB cradle and movers; MB girder

AS support

AS

LoadCMF

DB side

MB side

TMM geometry

DB Q DB Q

410 W410 W 410 W 410 W 410 W410 W 410 W 410 W

110 W110 W 110 W110 W150 W 150 W

EDMS 1097388

Loading condition

In the lab no cooling is applied to the DB QP → shown thermal dissipation is suggestive and to be used only to heat up the magnets

In the lab the aim is to create an environment close to the unloaded operation of the CLIC module. Thus, for example, the PETS are heated up to 110 W (maximum reservation)

MB

DB

PETS

SAS

WG

DB QP Steady temperature variation of 5°C for the

mock-up magnet was considered (based on the current reference value) – Courtesy of A. Bartalesi

Thermal dissipations in TMM (LAB)

110 W

110 W

820 W

CLIC Test Modules - Meeting #44

Cooling concept (LAB)

Item Description Value

MB input flow mass flow 68.6 kg/h

PETS+WG mass flow 37.4 kg/h

HTC MB Convection to water 5079 W/(m2·K)

HTC PETS+WG Convection to water 1407 W/(m2·K)

HTC air Convection to air 4 W/(m2·K)

Cooling boundary conditions; HTC: heat transfer coefficient.

BOOSTEC

MC

Master

Slave

Slave

Master

Adjacent girders will be interlinked with their extremities (so called cradle), allowing a movement in the transverse girder interlink plane within 3 degrees of freedom (X, Y, roll)

The ANSYS modeling was done to the level of the mounting surface of the actuator lower ends → As a results the estimated vertical and lateral stiffness of the actuator support was taken into account – both master and slave cradle end design were introduced to the model (Thanks to M. Sosin)

Modeling Highlights - Supports

Actuator stiffness was reduced to equal stiffness linear and torsional springs

Master and slave supporting system in the lab (Type 0)

Modeling Highlights – Contact modeling

Contact and joint modeling includes flexible joint and standard ANSYS component bonded connections. Flexible joints can be defined analytically as a stiffness matrices. All the module subsystems are thermally coupled (perfect thermal conductance)

All contact modeling aimed at the lightest possible computation because of overall contact and joint number is in the magnitude of several hundred

Contact and joint modeling illustration

Stiffness matrix definition for the contacts. Note that ANSYS allows also damping coefficients as a direct input

Modeling Highlights – Meshing options

The ANSYS meshing had to be adjusted and optimized and several different configurations were implemented

The current mesh includes hexa and tetrahedral methods, element size control settings, Sweep, contact sizing etc. in order to achieve fine and appropriate mesh for the coupled field simulation. The mesh is highly relevant between the contact surfaces and interconnection areas where the fluid flow interacts with the solid structure (convectional area)

At the moment the model includes approximately 4.9 million nodes. The coupled FLUID116 element is the driving parameter to the fluid-thermal results

Solution time for the whole model takes > 10 h minimum with a virtual remote Engineering PC

Created mesh for the lab module in ANSYS Workbench 13.0

Results

Temperature distribution within the module. The highest surface temperatures are in magnitude of 42 °C; on the internal beam surfaces the temperature could rise up to 44 °C

Results

The water temperature rise is approximately 10 °C as shown.

Total deformation of the module. The maximum deformation exceeds 500 µm.

Results

Results

Deformation of the MB under applied loading. The maximum deformation is 480 µm.

Item Value

Max temp. of medium 42 ˚C

Water output temp MB 35.0 ˚CWater output temp DB 35.0 ˚CHeat to water / air 3600/ 120 WMax. def . at MB line G 41 µmMax. def . at DB line G 30 µmMax. def . at MB line G, RF

480 µm

Max. def . at DB line G, RF

340 µm

Summary of the TMM results. G; gravity, RF; thermal dissipation.

Conclusion

The TMM has been successfully built to correspond the current complex. The thermal results show that during the heating ramp up the temperature of the module

rises over 40 °C. The highest temperature variations occur on the inner beam surfaces where the heaters are located.

The water temperature rise is 10 °C and the variation to the heat balance is less than 1 %. Though the thermal results can be considered reliable. Unlike with PETS average dissipation of 39 W, the 110 W thermal dissipation will drive the PETS and AS temperature closer to each other.

Structural analysis indicates deformation of several hundred micrometers during loading ramp-up. Note that the location of the maximum depends on which side the girder end a longitudinal fixed support is applied. From the fixed point MB side, for example, expands as a whole as a result of temperature variation.

The effect of gravity is naturally compensated in reality. As a upcoming actions the TMM is applied to the CLIC module Type 0 with a both

operation modes – unloaded and loaded – included. On basis of the new TMM geometry created for the lab module, different modules can be analyzed by modifying the current lab TMM module.