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FINITE ELEMENT ANALYSIS OF NSTX FLAG JOINT DESIGN

FINITE ELEMENT ANALYSIS OF NSTX FLAG JOINT DESIGN. Irving J. Zatz August 7, 2003. FEATURES OF FEA MODEL. INCLUDES ALL ESSENTIAL STRUCTURAL COMPONENTS CONTRIBUTING TO FLAG JOINT PERFORMANCE FLAGS - BOXES COLLAR - HUBS CENTER STACK - BOLTS SPLINES - UMBRELLA etc.

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FINITE ELEMENT ANALYSIS OF NSTX FLAG JOINT DESIGN

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  1. FINITE ELEMENT ANALYSIS OF NSTX FLAG JOINT DESIGN Irving J. Zatz August 7, 2003

  2. FEATURES OF FEA MODEL • INCLUDES ALL ESSENTIAL STRUCTURAL COMPONENTS CONTRIBUTING TO FLAG JOINT PERFORMANCE • FLAGS - BOXES • COLLAR - HUBS • CENTER STACK - BOLTS • SPLINES - UMBRELLA • etc.

  3. FEATURES OF FEA MODEL • NON-LINEAR VARIABLE CONTACT ALONG FACE OF JOINT • CONTACT PRESSURE CAN BE ACCURATELY MONITORED • ANY LOSS OF JOINT CONTACT CAN BE DETECTED • FRICTION COEFFICIENT CAN BE SPECIFIED

  4. FEATURES OF FEA MODEL • SHEAR KEY & PRE-LOADED BOLTS • CAN ACCURATELY DETERMINE AXIAL AND/OR SHEAR LOAD TRANSFER TO COPPER AND INSERTS

  5. LOAD CASES EXAMINED • START OF FLAT TOP (SOFT) • 3000 LB/BOLT PRE-LOAD - (FLAG) • END OF FLAT TOP (EOFT) - BASELINE • REDUCED FRICTION - (SHEAR KEY) • END OF PULSE (EOP) • PEAK TEMPERATURES - (COLLAR)

  6. ANALYTICAL ASSUMPTIONS • STATIC ANALYSIS - DOES NOT ACCOUNT FOR FATIGUE AND CREEP EFFECTS • TOLERANCES ARE PERFECT (e.g., FLAG-TO-TURN FLATNESS) • FIT-UPS ARE PERFECT (e.g., FLAG-TO-BOX POTTING)

  7. LOAD CASE (35) • BOLT PRE-LOAD 5000 LBS/BOLT • 6 kG EM LOADS-(with FLEX EFFECT) • EOFT TEMPERATURES • 0.4 FRICTION ASSUMED RESOLUTION OF VERTICAL LOADS FRICTION - 69% SHEAR KEY - 29% UPPER FLAG - 2%

  8. LOAD CASE (35C) • BOLT PRE-LOAD 5000 LBS/BOLT • 6 kG EM LOADS-(with FLEX EFFECT) • EOFT TEMPERATURES • 0.2 FRICTION ASSUMED RESOLUTION OF VERTICAL LOADS FRICTION - 34% SHEAR KEY - 51% UPPER FLAG - 15%

  9. LOAD CASE (34C) • BOLT PRE-LOAD 5000 LBS/BOLT • 6 kG EM LOADS-(with FLEX EFFECT) • EOFT TEMPERATURES • NO FRICTION ASSUMED RESOLUTION OF VERTICAL LOADS FRICTION - 0% SHEAR KEY - 78% UPPER FLAG - 22%

  10. LOAD CASE (35B) • BOLT PRE-LOAD 5000 LBS/BOLT • 6 kG EM LOADS-(with FLEX EFFECT) • SOFT TEMPERATURES • 0.4 FRICTION ASSUMED RESOLUTION OF VERTICAL LOADS FRICTION - 69% SHEAR KEY - 11% UPPER FLAG - 20%

  11. LOAD CASE (35D) • BOLT PRE-LOAD 3000 LBS/BOLT • 6 kG EM LOADS-(with FLEX EFFECT) • SOFT TEMPERATURES • 0.4 FRICTION ASSUMED RESOLUTION OF VERTICAL LOADS FRICTION - 41% SHEAR KEY - 30% UPPER FLAG - 29%

  12. LOAD CASE (35E) • BOLT PRE-LOAD 5000 LBS/BOLT • NO EM LOADS • END-OF-PULSE TEMPERATURES • 0.4 FRICTION ASSUMED RESOLUTION OF VERTICAL LOADS (LBS) FRICTION: 4100 SHEAR KEY: 900 UPPER FLAG: -5000

  13. SUMMARY OF RESULTS(RESOLVING VERTICAL FORCES)

  14. SUMMARY OF RESULTS(CONSERVATIVE ESTIMATE OF REDUCED CONTACT PRESSURE AREA OF INNER FLAG)

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