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2D Structural Analysis of 2-in-1 11 T Options 2012-01-12 CERN Engineering Meeting

2D Structural Analysis of 2-in-1 11 T Options 2012-01-12 CERN Engineering Meeting. B. Auchmann, M. Karppinen (CERN) I. Novitski , A. Zlobin (FNAL). Overview / Material Data. Active design features of 1-in-1 and 2-in-1 integrated pole and pole-loading concepts

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2D Structural Analysis of 2-in-1 11 T Options 2012-01-12 CERN Engineering Meeting

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  1. 2D Structural Analysis of 2-in-1 11 T Options2012-01-12 CERN Engineering Meeting • B. Auchmann, M. Karppinen (CERN) • I. Novitski, A. Zlobin (FNAL)

  2. Overview / Material Data • Active design features of 1-in-1 and 2-in-1 integrated pole and pole-loading concepts • Comparison of integrated pole design and pole loading design for 2-in-1 magnet • Outlook January 12, 2012 B. Auchmann TE-MSC

  3. 1-in-1 Demonstrator @ FNAL • Design features: • Midplane Shims • Collar/Yoke Shimsaround midplane • Stopper shims • Shell & Al Clamp • Yoke gap remains openat all times • FEA was (re)done at CERNto validate modeling Al Clamp and SS shelltakes Lorentz forces 4. 3. Shims for interference Uniform MP Shims 1. 2. January 12, 2012 B. Auchmann TE-MSC

  4. 2-in-1 with Integrated Poles 6. • Proposed design by I. Novitski • Design features • Uniform midplane shim • Uniform coil/collar radial shim • Tapered collar/yoke shim around midplane • Stopper shims • Yoke gap closing at cryogenic temperatures • Stainless steel shell • 316L outer-layer pole and Ti inner-layer pole • (7) increases inner-layer preload at cryo.temp. by 15 MPa, also leads to unloadingof outer-layer pole at 12 T. • (3), (4), and (5) form a “triangle” in whichthree relative sizes (with contraction and friction) must be controlled. 5. 7. 1. 3. 2. 4. January 12, 2012 B. Auchmann TE-MSC

  5. 1-in-1 with Pole-Loading • Design features: • Pole shim • Collar/yoke shim • Pole adjustment shim • Gap closing @ room temperatureremaining closed to 12 T. • Stainless-steel shell • (3) is an optional knob. • (2) and (4) must be controlledin order to close gap at RT. 4. 3. 2. 1. January 12, 2012 B. Auchmann TE-MSC

  6. 2-in-1 with Pole-Loading • Design features: • Pole shim • Collar/yoke shim • Pole adjustment shim • Gap closing @ room temperatureremaining closed to 12 T. • Stainless-steel shell • (3) is an optional knob. • (2) and (4) must be controlledin order to close gap at RT. 5. 4. 3. 2. 1. January 12, 2012 B. Auchmann TE-MSC

  7. FEA Model Under the Collaring Press • Left: integrated pole concept, Right: Pole-loading concept January 12, 2012 B. Auchmann TE-MSC

  8. Press Displacement, Coil Stress • Shim thickness: • 0.1 mm on midplane • 0.05 mm radially • Press displacement: • – 0.025 mm • Peak stress under press: • 148 MPa • 0.21 mm on pole • 0.015 mm • 0.075 mm still ok • 110 MPa 110 MPa 65 MPa 148 MPa 95 MPa January 12, 2012 B. Auchmann TE-MSC

  9. Collared Coil - Spring Back • Collared-coil deformation: • Prestress after collaring 0.03 mm 0.09 mm default 0.2 mm 0.0 mm 0.4 mm 0.04 mm 0.11 mm 111 MPa 62 MPa 55 MPa 87 MPa January 12, 2012 B. Auchmann TE-MSC

  10. Coil Stress Evolution 1/2 -150 MPa Yoke assembly@ room temp. Cryogenic temp. 12 T January 12, 2012 B. Auchmann TE-MSC

  11. Coil Stress Evolution 2/2 • Minimal azimuthal coil stress: • FEA shows that both designs allow for +/- 0.05 mm adjustment of the collar size. -150 MPa P2 P1 M1 M2 January 12, 2012 B. Auchmann TE-MSC

  12. Azimutal stress vs. von Mises Stress • Coil stress after yoke assembly at room temperature, pole-loading concept. • Left: von Mises stress, Right: Azimutal stress January 12, 2012 B. Auchmann TE-MSC

  13. Sensitivity to Coil Material Data • Check sensitivity to coil material by using the overall coil strength (including wedges) instead of Nb3Sn estimate. 27/30 GPa 44/50 GPa January 12, 2012 B. Auchmann TE-MSC

  14. Impact of Over-Compression • Check impact of over-compression by additional 0.05 mm collar press displacement. -145 MPa -205 MPa Values for default displacement January 12, 2012 B. Auchmann TE-MSC

  15. Shape Evolution • Coil deformation • Pole loading, coil inner-contour ellipticityf = b/a • We may review the room-temperature beam separation of 2 x 97.194 mm. f = 1.002 f = 0.999 f = 0.994 Δx = 0.39 Δx = 0.3 b a January 12, 2012 B. Auchmann TE-MSC

  16. Shape Evolution • Coil deformation • Integrated pole, coil inner-contour ellipticityf = b/a • We may review the room-temperature beam separation of 2 x 97.194 mm. f = 1.006 f = 1.006 f = 1.001 b Δx = 0.11 Δx = 0.65 Δx = 0.57 a January 12, 2012 B. Auchmann TE-MSC

  17. Collar Stress Yoke assembly RT Cryogenic temp. Under press Collared Coil 12 T January 12, 2012 B. Auchmann TE-MSC

  18. Shell Stress, Yoke Gap Cryogenic temp. Room temp. 12 T shell thickness 10 mm shell thickness 10 mm weld shrinkage0.65 mm weld shrinkage0.4 mm January 12, 2012 B. Auchmann TE-MSC

  19. Conclusion/Outlook • The solutions differ in terms of • Peak stress under the press • Pre-stress after collaring • Coil deformation • Number of active design features • Sensitivity to coil modulus, press displacement • Next steps • Finish 3D analysis of pole-loading concept • Converge on a single FNAL/CERN concept • Perform sensitivity analysis • Complete detailed manufacturing design • Develop instrumentation January 12, 2012 B. Auchmann TE-MSC

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