Substrate-Paddle-Base
Peter Cooke
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Substrate-Paddle-Base
Substrate Production Paddle – Base – Feet Component
Production
LHCb Substrate
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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LHCb Substrate Production
Substrate Dimensions Materials and preparation Lay-up Inspection and Packaging Recommended Curing Instructions Summary
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Substrate Dimensions
Carbon Fibre 177 x 123mm TPG 169 x 115mm 4mm Carbon Fibre frame
suppounding TPG
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Materials Preparation TPG
400um TPG board cut to 169 x 115mm
Abrade both sides with course emery paper
Cleaned and degreased with alcohol
Left to dry
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Preparation Carbon Fibre
Supplier; Amber Composites UK Carbon fibre Pre-preg 120 gm plain
weave, epoxy resin impregnated Cut to size 177 x 123mm 2 Pieces – weave direction 0 – 90 deg 2 Pieces – weave direction +/- 45 deg Pre-preg approximate cured thickness
0.125mm per layer
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Lay-up Procedure
Release film applied to flat steel plate 1st layer 0 – 90 deg on flat plate 2nd layer +/- 45 deg on top TPG placed centrally on 2nd layer 4mm strips of pre-preg surrounding TPG –
3 layers with orientation of fibres balanced
3rd layer +/- 45 deg placed over previous 4th layer 0 – 90 deg to complete
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Lay-up continued
RED
0 – 90 Deg
BLUE
+/- 45 Deg
GREY
TPG
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Inspection & Packaging
Visual Inspection Measurement – Micrometer/Smartscope Substrates have release film applied to
each face to protect resin 10 substrates are sandwiched together
between two 6mm thick aluminium plates
Surrounded in foam and packed in carboard box
Shipped off to Stevenage Circuits
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Recommended Cure
Amber Composites Fibre; T300 Resin E722.02 45% RW Increase temp. to 120 C @ 3 C/ min Increase pressure to 90 psi Hold for 1 hour Cool to 60 C before releasing pressure
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Summary Have all material to produce up to
70 substrates Carbon Fibre stored in freezer @ -
18 C TPG stored in locked cupboard Can produce 10 per week
LHCb Paddle/Base Components
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Paddle/Base Assembly
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Component Production
Base and Feet Manufacture Paddle Fabrication Paddle cure Inspection
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Base and Feet Manufacture
Base – Cut from solid sheet of carbon fibre and machined in-house.
Invar feet – CNC Wire Eroded in-house to guarantee accuracy. Spigot on right foot tolerance 0.000 to –0.008
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Paddle Fabrication
Material; Pre-preg ACG VTM264/CF0300-42%RW 200 gram
2 x 2 Twill (Stored–18deg C) Female mould tool CNC machined and
hand finished in two halves. Dowelled and fastened together during
lay-up Tool treated with PTFE release solution
and buffed to a gloss finish
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Paddle Lay-up Carbon fibre cut to templates, 2 layers per
face. 1 @ 0/90 deg and 1@ +/-45 deg Apply fibre to each face, 0/90 then +/-45 Final thickness over major area of paddle
0.5mm Rear face – fibre flush to tool surface Front face – overlapping tool face 6 –
2mm along length 3 x 12mm wide strips added to each face
at the topmost area of the tool.
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Paddle Lay-up (cont)
Add release film and bleed ply fabric to the exposed fibre
Add a strip of breather fabric to each side
Make vacuum bag and fit into front side of tool
Place rear side of tool over dowels on the top and fasten into place
Place assembly into large vacuum bag and seal inner to outer bags
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Paddle Cure In autoclave Apply vacuum Heat to 65 deg C at 0.5 deg C/ minute At 65 deg C apply 90 psi Hold for 16 hours Cool, release pressure and vacuum De-mould the part
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Parts Inspection
Visual inspection – Inside and Out Fitted to drilling jig
Peter Cooke 28 Feb - 1 March 2006 - VELO PRR
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Summary We have enough carbon fibre
stored in freezer to produce 80 paddles
Carbon Fibre Bases ready Invar Feet ready