AWB020207 1

Impact of Adding Bolts to Inner Leg

Data extracted from HM Fan’s ANSYS Model

of Composite Modular, TF and PF Coils

Impact of Added Bolts assessed by Post Processing, not direct Modeling

AWB020207 2

AB

A

C

BC

0 of 7 bolts added at A – A joint

3 of 7 bolts added at B – A joint

3 of 3 bolts added at B – C joint

A

Per Tom Brown’s Study 3/17/06

bolts to inner leg 3

A

BC

0 of 7 bolts added at A – A joint

3 of 7 bolts added at B – A joint

3 of 3 bolts added at B – C joint A

No problem with the 3 bolts as shown.

These 3 bolts are in the clear, located on one side of the CL.

If you need one for positioning, put one here.

Per Tom Brown’s StudyUpdated 1/31/07

AWB020207 4

Friction Enhancement Helps in Regions in Compression (Blue)

Note: Above does not include effect of preload from added bolts

CC2 BC2 AB2 AA AB BC CC

AWB020207 5

All Results for 2T High Beta Scenario

Shear Load over RegionInboard

0

50000

100000

150000

cc2i

nt

cc2i

nb

bc2i

nt

bc2i

nb

ab2i

nt

ab2i

nb

aain

t

aain

b

abin

t

abin

b

bcin

t

bcin

b

ccin

t

ccin

b

Joint-Location

She

ar L

oad,

lbs

AWB020207 6

Shear Loads Components at IL of MCWF Flanges

Shear at Unbolted IL

-800000

-600000

-400000

-200000

0

200000

400000

600000

800000cc

2int

cc2i

nb

bc2i

nt

bc2i

nb

ab2i

nt

ab2i

nb

aain

t

aain

b

abin

t

abin

b

bcin

t

bcin

b

ccin

t

ccin

b

Joint

Sh

ear,

N x

z

xz

Max Shear Top/Bot is 590 KN (133 Klbs)

AWB020207 7

Compression Over Inboard Region

Normal Load over RegionExcludes Added Bolt Preload

Inboard Only

-350000

-300000

-250000

-200000

-150000

-100000

-50000

0

cc2i

nt

cc2i

nb

bc2i

nt

bc2i

nb

ab2i

nt

ab2i

nb

aain

t

aain

b

abin

t

abin

b

bcin

t

bcin

b

ccin

t

ccin

b

Joint-Location

Nor

mal

Loa

d, lb

s

AWB020207 8

Adding Bolts to Inner Leg Reduces Required Coefficient of Friction to 0.45Coefficent of Friction Needed to Prevent IL Slip

Combined Coil Model (Mod/TF/PF)Inboard Regions With and Without Added Bolts - Dead Load+EM+CD

0.000

0.150

0.300

0.450

0.600

0.750

0.900

cc2i

nt

cc2i

nb

bc2i

nt

bc2i

nb

ab2i

nt

ab2i

nb

aain

t

aain

b

abin

t

abin

b

bcin

t

bcin

b

ccin

t

ccin

b

Joint-Location

mu

Based on Bolt Preload of 45797 lb at 80K Need to Update for Minimum Expected Preload

AWB020207 9

Again, All Results for 2T High Beta ScenarioShear Load Per Bolt, Averaged over Region

Outboard

0

5000

10000

15000

cc2b

cc2t

bc2b

l

bc2b

rl

bc2b

ru

bc2t

rl

bc2t

ru

bc2t

l

ab2b

l

ab2b

r

ab2t

rl

ab2t

ru

ab2t

l

aabl

aabr

aatr

aatl

abbl

abbr

l

abbr

u

abtr

abtl

bcbl

bcbr

l

bcbr

u

bctr

l

bctr

u

bctl

ccb

cct

Joint-Location

She

ar L

oad

per

Bol

t, lb

s

AWB020207 10

Normal Load Per Bolt, Averaged over RegionExcludes Bolt Preload

Outboard Only

-20000

-15000

-10000

-5000

0

5000

10000

15000

cc2b

cc2t

bc2b

l

bc2b

rl

bc2b

ru

bc2t

rl

bc2t

ru

bc2t

l

ab2b

l

ab2b

r

ab2t

rl

ab2t

ru

ab2t

l

aabl

aabr

aatr

aatl

abbl

abbr

l

abbr

u

abtr

abtl

bcbl

bcbr

l

bcbr

u

bctr

l

bctr

u

bctl

ccb

cct

Joint-Location

For

ce L

oad

per

Bol

t, lb

s

AWB020207 11

Maximum Coefficient of Friction Required Outboard is under 0.25

Coefficent of Friction Needed to Prevent SlipCombined Coil Model (Mod/TF/PF)

Outboard Regions Dead Load+EM+CD

0.000

0.050

0.100

0.150

0.200

0.250

0.300

cc2b

cc2t

bc2b

l

bc2b

rl

bc2b

ru

bc2t

rl

bc2t

ru

bc2t

l

ab2b

l

ab2b

r

ab2t

rl

ab2t

ru

ab2t

l

aabl

aabr

aatr

aatl

abbl

abbr

l

abbr

u

abtr

abtl

bcbl

bcbr

l

bcbr

u

bctr

l

bctr

u

bctl

ccb

cct

Joint-Location

mu

Based on Bolt Preload of 45797 lb at 80K

AWB020207 12

Conclusions – Based on Bolt Averages over Regions – No Peaking Assumed

• If the coefficient of friction in the inboard region can be verifiably enhanced (ie with diamond grit) to 0.6 we should be OK and maintain the 0.15 margin the NCSX Design Requirements dictate.– At mu = 0.50, margin drops to 0.05 (ie 90% of Limit)

• If we can provide a coefficient of friction of 0.4 in the outboard region, we should again be OK and again maintain the 0.15 margin the NCSX Design Requirements dictate.

• If we can only provide a coefficient of friction of 0.3 in the outboard region, our margin is less but still positive, with the bolt shear capability providing some additional margin of safety (our belts and suspenders).– How do we fold this into criteria?

Need to Understand Peaking due to gaps in bolting pattern

AWB020207 13

Shim Identifications

cc2t

cc2b

cct

cc2int

ccb

ccint

bc2tlbc2tru

bc2trl

bc2bru

bc2int

bc2brlbc2bl

bcint

bctlbctru

bctrl

bctrl

bcbrlbcbl

aaint

aatl

aabl

aatr

aabr

ab2int

ab2tl ab2tru

ab2trl

ab2br

ab2bl

abint

abtl

abtr

abbru

abbrlabbl

-60 deg

+60 deg

0 deg

cc2inbbc2inb

ab2inb aainb

ccinbbcinb

abinb