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66320-02131 WELD REPORT March 5, 2012 Bob Miller

Introduction The strongback will be used to install the panel 1A and 1B time of flight detectors to the forward carriage using the Cerenkov installation fixture (66441-E-04801). The strongback must support the panels in the horizontal position while lifting off of the truck and it must support the panels in any of the 6 sector orientations. The strongback will also be used with a 3 point lift while moving the panels from the truck to the storage racks in the FTOF Assembly Building with a gantry.

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Material ASTM A500 Steel, grade B1, round structural tubing

• Modulus of Elasticity, E = 29 Msi • Yield Strength, σy = 42100 psi • Tensile Strength, S = 58000 psi

ASTM A500 Steel, grade B1, shaped structural tubing

• Modulus of Elasticity, E = 29 Msi • Yield Strength, σy = 45700 psi • Tensile Strength, S = 58000 psi

ASTM A36 Steel, plate1

• Modulus of Elasticity, E = 29 Msi • Yield Strength, σy = 36300 psi • Tensile Strength, S = 58000 psi

ASME BTH-1-2005 Allowable Stresses The strongback qualifies as Design Category A with a Service Class 0. This results in a design factor (Nd) of 2.2 3-2 Member Design Determine if tubing has compact sections: Square tube: b/t = 4/0.188 = 21.3 (Table 3-1) Limiting Width-Thickness Ratio = 1.12√(E/Fy) = 1.12√(29E6 psi/45.7E3 psi) = 28.2 Therefore, the square tube is considered a compact section. Round tube: D/t = 8.625/0.322 = 26.8 Limiting Width-Thickness Ratio =0.07E/Fy = 0.07 * 29E6 psi / 42.1 E3 psi = 48.2 Therefore, the round tube is considered a compact section. Allowable stress (Fb) for strong axis bending of compact circular sections = 1.10Fy/Nd (equation 3-6) = 1.10 * 42,100 psi/2 = 23,155 psi Allowable stress (Fb) for strong axis bending of compact shaped sections = 1.10Fy/Nd (equation 3-6) = 1.10 * 45,700 psi/2 = 25,135 psi 3-3.4.1 Welded Connections 1 Matweb.com Material Property Data 2 ASME BTH-1-2005, pages 11-14

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a) The design strength of the welds subject to tension or compression shall be equal to the

effective area of the weld multiplied by the allowable stress of the base metal (23,155 psi).

b) Weld filler metal of 62 Ksi tensile strength or higher is required c) The allowable stress (Fv) for weld joints in shear:

a. (3-53) Fv = 0.60 Exx/1.2/Nd = 0.60 * 62,000 psi / 1.2 / 2.00 = 15,500 psi, where Exx = nominal tensile strength of the weld metal

3-3.3 Pinned Connections The allowable tensile force through the pin hole Pt = 4392 lbs The allowable single plane fracture force beyond the pin hole Pb = 11711 lbs The allowable double plane shear force beyond the pin hole Pv = 12391 lbs The maximum force on each pin is 485 lbs, therefore the pins meet ASME BTH-01-2005 Design Loads The design loads for the strongback are:

• 2200 lbs panel load • Lifting eyes will support the 2200 lbs panel and the 860 lbs strongback = 3060 lbs

Simulation ANSYS 13.0 was used to analyze the strongback using the following methods. The FTOF panel frames are not rigid, therefore the weight of the panel is modeled as a point mass at each of the five attachments points to the strongback. The load for each point was calculated by using the CG of the panel and the location of the mounting points. The Panel 1B CG is 98.5 inches from the nose mounting point. The nose mounting point carries 479 lbs, each mid mount carries 376 lbs, and each upper mount carries 485 lbs. The strongback and chamber is also lifted with a 3 point lift and a gantry. The force on each lifting point was determined by modeling the strongback with the point masses, constrained at each lifting point. The resultant force on each lifting point and the direction of the lifting straps was used to calculate the force vector at each location. The force vectors were used in the model to calculate the stress and deflections for the 3 point lifts used to transport the panels through the FTOF Assembly Building door and onto the storage carts. Each weld joint was modeled as a bonded contact and the resultant forces and moments at the contact were used to calculate the weld stresses. Four load cases were analyzed based on the intended use of the strongback:

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1. Panel in Sector 4 orientation 2. Panel horizontal when setting on the truck 3. 3 point lift with 2 trolleys while removing from truck and setting on storage rack 4. 3 point lift with panel tilted 450 to fit through door

Results The stress and deflection results for the four load cases are shown in Figures 1-12. All stresses are below the allowable stresses and all deflections are acceptable for this application.

Figure 1: Sector 4 Set Up

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Figure 2: Sector 4 Equivalent Stress

Figure 3: Sector 4 Deformation

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Figure 4: On Truck Set Up

Figure 5: On Truck Equivalent Stress

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Figure 6: On Truck Deflection

Figure 7: 3 Point Horizontal Set Up

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Figure 8: 3 Point Horizontal Equivalent Stress

Figure 9: 3 Point Horizontal Deflection

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Figure 10: Angle Lift Set Up

Figure 11: Angle Lift Equivalent Stress

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Figure 12: Angle Lift Equivalent Stress Weld Analysis The weld analysis was completed using the following method:

1. Model each weld joint as two separate parts with a bonded contact in ANSYS 2. Evaluate the equivalent stress of the model and choose the weld joints with the highest

stress or critical locations for a detailed weld stress calculation 3. Probe the force reaction and moment reactions at the contact 4. Use the force and moments to calculate the weld stress using a spreadsheet 5. Compare the weld stress to the allowable weld stress

Sixteen square tube weld joints were analyzed along with 4 round tube joints. All weld stresses were below the allowable stress. Samples of the weld stress calculations are shown in Figures 13-15.

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Figure 13: Weld Stress at Shaft to Shaft Flange

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Figure 14: Weld Stress at Right Upper Inner Frame to Mid Frame

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Figure 15: Weld Stress at Nose Pad to Nose Brace Conclusion The time of flight installation strongback meets ASME-BTH-1-2005 Below the Hook Lifting Devices code.