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Development of Robust Technology and Designs for Handling LEU-Foil Development of Robust Technology and Designs for Handling LEU-Foil Annular Targets for Production of Mo-99 that shall Fulfil the following Annular Targets for Production of Mo-99 that shall Fulfil the following Requirements and Constraints:Requirements and Constraints:
Project ObjectivesProject Objectives
1- Flexibility, in order to accommodate different target geometries, materials, and production volumes with minimum efforts and cost.
2- Affordability, for USA domestic production as well as for other countries.
3- Safety and Quality Assurance, for meeting rules and regulation.
4- Productivity, for meeting USA domestic needs for fission product Mo-99.
5- Training US Young Engineers and Scientists for developing effective nuclear technology for energy and biomedical applications of the future.
Large Scale Production of Mo-99
Production Process Design GroupSherif El-Gizawy, Brian Graybill, James Berlin,
Emily Ferner, Annemarie Hoyer
Design Analysis is Required as Part of “Safety Case” Documentation to Demonstrate Target’s Structural Integrity
during Target Assembly
The Followings are the Required Design Tasks
Develop model and perform Detailed Finite Element Analysis of an assembled LEU-foil target.
The model will include the target’s drawing process of all foils and the Aluminum tubes.
Experimental testing and Measurements to verify the developed models, (residual stresses, microstructure, surface roughness, waviness, and contact profile).
This design analysis is parametric and applicable to any target design and can be used to determine inner tube minimum wall thickness that will withstand the maximum predicted operating pressure in order to assure “zero” target structural failures during irradiation
Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July 11, 2011 3
Df
Outer TubeOuter Tube
Drawing ForceDrawing Force
α
DoInnerInnerTubeTube
PunchPunch
DeformationDeformationZoneZone
Assembly Process Analysis Assembly Process Analysis
•Process design to allow for deformation zone that covers the entire inner tube thickness.Process design to allow for deformation zone that covers the entire inner tube thickness.
•Force is applied through the punch. Deformation of the wall of the inner tube isForce is applied through the punch. Deformation of the wall of the inner tube is caused by Compressive stresses along axial, radial and hoop directions.caused by Compressive stresses along axial, radial and hoop directions.
Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July 11, 2011 4
σh
σr
σz
Fz
Draw Stress,dr = fmQdr = fm .Qfr . Where Qfr = (1+cot)
= ln(Ao/A1)
L
h12.088.0
Drawing Force, Fdr = dr* A
*, FPPower /, PTorque
Finite Element AnalysisFinite Element Analysis
Modeling of the target assembly is completed using the FEM ANSYS structural package. These analyses serve three major purposes:
1) Determine the force necessary to plastically deform the inner tube against the outer tube, resulting in a bond that will be maintained throughout irradiation.
2) Determine the residual stresses in the assembled target after assembly. It is critical that the tensile stress in the outer tube is maintained so that it will “spring open” when cut, resulting in easy removal of the inner tube and irradiated target.
3) The development of a parametric model provides a platform for faster analysis for the investigation of target shapes/dimensions that vary from the Indonesian target
Outer Tube
Inner Tube
Drawing Die
Plug
Drawing Die SetDrawing Die Set
Outer Tube
Uranium Foil
Nickel Foil
Inner Tube
LEU Foil inside the Nickel EnvelopLEU Foil inside the Nickel Envelop
Finite Element ModelsFinite Element Models•The Workbench layout of ANSYS allows for easy alteration of the original model, allowing for several geometries to be investigated without significant input from the user.•Once a dimension has been changed upstream, the rest of the model simply needs to be refreshed and/or updated to achieve the new results.
7
FEM Simulation Results for Target Drawing Using Floating Conical Plug
Design
Typical Floating Conical Plug Design
Cylinder Punch
Linear Guide Bearing
Push Rod
Hydraulic Ram
Hydraulic Pump
Quality Control Gauge
System Overview
RAM Force
Swaging Process Cut Away
RAM Force
Swaging Process Cut Away
Removal
Parametric Analysis of Annular Target/ Assembly Process DesignParametric Analysis of Annular Target/ Assembly Process DesignUsing Design of Industrial ExperimentsUsing Design of Industrial Experiments
Partial Factorial• Basic matrix setup• Partial factorial setup
allows for fewer initial experiments
• The initial setup will serve to direct a more focused, comprehensive experimental array
• Quality Characteristics Quality Characteristics (Responses , Y): (Responses , Y): 1- 1- Integrity of the Target Integrity of the Target (visual) , 2-Thermal (visual) , 2-Thermal Contact Resistance, 3- Contact Resistance, 3- Forming Pressure, 4- Gap Forming Pressure, 4- Gap Size at the Contact with Size at the Contact with Target Walls (SEM Target Walls (SEM measurements of measurements of sectioned targets).sectioned targets).
Factors
Experiment Punch Diam.Punch Angle
alpha relief thickness (t) per side Target Material1 1 1 1 12 1 2 2 23 1 3 3 34 2 1 2 35 2 2 3 16 2 3 1 27 3 1 3 28 3 2 1 39 3 3 2 3
Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July, 11, 2011 14
Foil Materials Aliened Foil Materials Aliened insideinside
The Relief areaThe Relief area
Inner Inner Aluminum Aluminum
TubeTube
Outer Outer AluminuAluminum Tubem Tube
AABB
A- Significant Voids Exist A- Significant Voids Exist B- Zero Gap CaseB- Zero Gap Case (Unsuccessful) Case(Unsuccessful) Case
Intimate Contact Evaluated by SEM for Gap ObservationIntimate Contact Evaluated by SEM for Gap Observation
Work for the next 3 months
• Complete the partial factorial• Determine which variables are most sensitive to
change• Use results to develop and execute a
comprehensive response-surface type experimental array, explore and characterize variable interactions (Phase II)
• These results will produce a single predictive equation to determine desired outputs from the input variables shown here
21122
2222
11122110 xxxxxxY
Design of Experiment (Phase II)Design of Experiment (Phase II)Response Surface Method (RSM)Response Surface Method (RSM)
Two Parameter central composite design. Two Parameter central composite design.
Parameters:Parameters: Relief Size(xRelief Size(x11), Punch Diameter(x), Punch Diameter(x22).).
Responses (Y):Responses (Y): 1-Thermal Contact Resistance, 2-Fraction 1-Thermal Contact Resistance, 2-Fraction Volume of Voids or Gab at the Contact with Target Walls, Volume of Voids or Gab at the Contact with Target Walls,
3- Forming Pressure.3- Forming Pressure.
Second Order Response surface modelsSecond Order Response surface models
Fitted 3-D surface and equation of the Torque, (lb.ft), in Titanium
0.267 0.284 0.301 0.319 0.336 0.353 0.371 0.388 0.405 0.423 above
Fitted Surface; Variable: TORQUE
TORQUE in Titanium (lb.ft)
z=-3.086263241604+.010844907560897*x-.0000078517515508477*x^2+605.22238525195*y+98596.285487694*y^2-1.46482990521*x*y+0.
Example of Typical Results
Process contour maps of torque, (lb.ft), during drilling TitaniumProcess contour maps of torque, (lb.ft), during drilling Titanium
0.267 0.284 0.301 0.319 0.336 0.353 0.371 0.388 0.405 0.423 above
Fitted Surface; Variable: TORQUE
TORQUE in Titanium (lb.ft)
SPEED (rpm)
FE
ED
(ip
r)
0.0008
0.0009
0.0010
0.0011
0.0012
0.0013
0.0014
0.0015
0.0016
460 480 500 520 540 560 580 600 620 640
Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July, 11, 2011 19
Future Work by the Production Process Design Group
20
TIG EB Forming
Sealing Ends of the Annular TargetsSealing Ends of the Annular Targets
Target Disassembly DeviceTarget Disassembly Device
SEVEN Degrees of FreedomSEVEN Degrees of FreedomRobotic Arm for Handling Robotic Arm for Handling
Targets inside Hot CellTargets inside Hot Cell