FRESCA2 Update on the dipole design and new calculations

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

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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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


• 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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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



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Instrumentation: strain gaugesFRESCA2

Rods

Shell

Dummy-coil


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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


Rod [Aluminum]

End-plate [Nitronic]


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



• Comparison of stress during h-bladder operation: Peak stress outside the shell: 50MPa

Peak compression in the dummy-aperture: 120MPa

Outside shell

dummy aperture


FRESCA2

FRESCA2dummy 2D model



• Comparison of stress during v-bladder operation: Peak stress outside the shell : 25MPa

Peak compression in the dummy-aperture : 30MPa

Outside shell

dummy aperture


FRESCA2




• Comparison of stress during key operation: Peak stress outside the shell : 30MPa


Outside shell

dummy aperture


FRESCA2




• Comparison of stress during cool-down: Peak stress outside the shell : 120MPa


Outside shell

dummy aperture


FRESCA2




Key operation

• Comparison of stress during key operation: Peak stress outside the shell : 30MPaDummy peak compression: 75MPa

dummy

shell




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




Cool-down

• Comparison of stress during cool-down: Peak stress inside the shell @0°


Longitudinal location of strain gauges

dummy

shell


Rod pre-tension


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°


coils

rails

end shoes

wedge

pole

dummy

coil pack

coilsVs.

dummy


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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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)


outline







• 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


Work in progress


Thank you

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

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


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


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


Pumping horizontal bladders & insertionof horizontal keys

Horizontal bladders insertion

Assembly process: horizontal bladder operation@ 927


Pumping vertical bladders & insertion of vertical keys

Final configuration after loading operation

Assembly process: vertical bladder operation@ 927

Mechanical test Room temperature Cold-down


Documents

FRESCA2 Update on the dipole design and new calculations