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CERN Grooved Chamber Review

CERN Grooved Chamber Review. SLAC. CERN Requirement. Extrusion from ALMAG. Design Options. Extrude (ALMAG) Minimum groove dimensions 2 mm deep, 1.21mm wide, overall depth 4mm, 22 degree angle Groove radii, top 0.003in (0.076mm), bottom 0.005in (0.127mm)

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CERN Grooved Chamber Review

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  1. CERN Grooved Chamber Review SLAC

  2. CERN Requirement

  3. Extrusion from ALMAG

  4. Design Options Extrude (ALMAG) • Minimum groove dimensions 2 mm deep, 1.21mm wide, overall depth 4mm, 22 degree angle • Groove radii, top 0.003in (0.076mm), bottom 0.005in (0.127mm) • Rework bottom radius with saw cutter • Length 1 meter Saw: (ROBBJACK) • Machine with special profile gang cutter

  5. Possible Mfg Options • Extruding (Vendor ALMAG) • Slitting saw type cutter with profile to match groove form (Vendor ROBBJACK) • Electro Discharge Machining (EDM) • Casting • Press forming • Laser for reforming bottom groove • Roll forming/metal folding • Textured metal forming

  6. CERN Option • Use existing PEP II extrusion • Cut out existing grooves in extrusion (approx 34 mm wide) • Grooves are approx 3.7 mm deep • Overall depth approx. 7mm but can be reduced • Weld several sections together • Length as required

  7. Existing PEPII Extrusion

  8. Mfg Comments • Options limited due to very precise requirements • Roundness tolerances beyond normal mfg • 1 mm type groove depth/radii are very small

  9. Mfg Comments Extruding • Almost meets requirements • Can secondary operation reduce bottom groove radius ?

  10. Mfg Comments Slitting Saw Type Profile Cutter • Can very thin profile cutter be mfg & survive metal cutting ? • Gang cutter possible for multi-cut mf

  11. Mfg Comments EDM • Not a continuous mfg process • Short length (15 in max) • Sharp top & bottom groove radii yet to be proven • Relatively expensive

  12. Mfg Comments Roll Forming/Metal Folding • Similar to auto radiator cooling fin mfg • Very small pitch would be as issue • Very sharp corner radii would be an issue

  13. Mfg Comments Casting • Minimal radius may be an issue • Not a continuous mfg process • Limited length capability • Casting material may be an issue • Possible Vendor : Precision Cast Parts in Portland, OR

  14. Mfg Comments Press Forming • Very sharp corners are a problem • Length may be a problem - dependant on press platen size • Not a continuous mfg process

  15. Mfg Comments Textured Metal Forming • Can groove embossing provide adequate e-cloud profile ? • Would be inserted into chamber • Inexpensive

  16. Solution Planning • Saw Cutting : Rework extrusion or full machining with saw • Experiment with new saws • For long range approach : Cerro Will they license or develop their mfg process for larger bore sizes ? Who designed their extruder ? Contact them & arrange a visit (St Louis) Estimate cost

  17. Solution Planning Textured Metal Forming • How close can textured metal be formed to form grooves ? • Will a textures pattern perform the electrical requirements ? • Contact & visit a couple of textures metal manufacturers

  18. Solution Planning Chamber Coating • Microwave tube industry has experimented with many coatings – are any applicable to the EC Cloud problem ? • Are nanotubes applicable ?

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