2D Structural Analysis of 2-in-1 11 T Options 2012-01-12 CERN Engineering Meeting
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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)
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2January 12, 2012 B. Auchmann TE-MSC
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
Overview / Material Data
Structure Material Thermal contraction (300-2 K) mm/m
E modulusGpawarm
E modulusGpacold
Coil impregnated Nb3Sn
3.3/2.9(rad./azi.)
27 30
Wedge pole loading
Copper, Glidcop
3.3 130 130
Wedge inte- grated pole
316L 2.9 195 215
Central post Ti-6Al-4V 1.7 115 125
Collar YUS 130S 2.9 195 215
Keys Nitronic 40 2.64 190 210
Yoke Soft iron 2.05 210 225
Shell 304L/316L 2.9 195 215
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3January 12, 2012 B. Auchmann TE-MSC
Design features:1. Midplane Shims2. Collar/Yoke Shims
around midplane3. Stopper shims4. Shell & Al Clamp
Yoke gap remains openat all times
FEA was (re)done at CERNto validate modeling
1-in-1 Demonstrator @ FNAL
Al Clamp and SS shelltakes Lorentz forces
Uniform MP Shims
Shims forinterference
1.2.
3.
4.
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4January 12, 2012 B. Auchmann TE-MSC
Proposed design by I. Novitski Design features
1. Uniform midplane shim2. Uniform coil/collar radial shim3. Tapered collar/yoke shim
around midplane4. Stopper shims5. Yoke gap closing at
cryogenic temperatures6. Stainless steel shell7. 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.
2-in-1 with Integrated Poles
1.
2.
3.
4.
5.
6.
7.
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5January 12, 2012 B. Auchmann TE-MSC
Design features:1. Pole shim2. Collar/yoke shim3. Pole adjustment shim4. Gap closing @ room temperature
remaining closed to 12 T.5. Stainless-steel shell
(3) is an optional knob. (2) and (4) must be controlled
in order to close gap at RT.
1-in-1 with Pole-Loading
1. 2.3.
4.
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6January 12, 2012 B. Auchmann TE-MSC
Design features:1. Pole shim2. Collar/yoke shim3. Pole adjustment shim4. Gap closing @ room temperature
remaining closed to 12 T.5. Stainless-steel shell
(3) is an optional knob. (2) and (4) must be controlled
in order to close gap at RT.
2-in-1 with Pole-Loading
1. 2.
3.
4.
5.
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7January 12, 2012 B. Auchmann TE-MSC
FEA Model Under the Collaring Press Left: integrated pole concept, Right: Pole-loading
concept
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8January 12, 2012 B. Auchmann TE-MSC
Press Displacement, Coil Stress
148 MPa
110 MPa65 MPa
95 MPa
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9January 12, 2012 B. Auchmann TE-MSC
Collared Coil - Spring Back Collared-coil deformation:
Prestress after collaring
55 MPa 87 MPa
default 0.2 mm
111 MPa
0.4 mm
62 MPa
0.0 mm0.09 mm
0.04 mm
0.03 mm
0.11 mm
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10January 12, 2012 B. Auchmann TE-MSC
Coil Stress Evolution 1/2
Yoke assembly@ room temp.
Cryogenic temp.
12 T
-150 MPa
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11January 12, 2012 B. Auchmann TE-MSC
Coil Stress Evolution 2/2 Minimal azimuthal coil stress:
FEA shows that both designs allow for +/- 0.05 mm adjustment of the collar size.
Integrated pole Pole loading
P1 P2 M1 M2 P1 P2 M1 M2
Under press -65 -80 -148 -80 -110 -65 -95 -82
Spring-back -55 -55 -103 -55 -87 -45 -45 -73
Yoke assy. -102 -57 -70 -70 -137 -48 -60 -110
Cool down -129 -35 -70 -70 -111 -44 -55 -90
12 T -4 -14 -147 -100 -10 -37 -126 -139
-150 MPaP1P2
M1 M2
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12January 12, 2012 B. Auchmann TE-MSC
Azimutal stress vs. von Mises Stress Coil stress after yoke assembly at room temperature,
pole-loading concept. Left: von Mises stress, Right: Azimutal stress
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Check sensitivity to coil material by using the overall coil strength (including wedges) instead of Nb3Sn estimate.
13January 12, 2012 B. Auchmann TE-MSC
Sensitivity to Coil Material Data
Structure Material Thermal contraction (300-2 K) mm/m
E modulusGpawarm
E modulusGpacold
Coil approx. impregnated Nb3Sn
3.3/2.9(rad/azi)
27 30
Coil incl. wedge
impregnated Nb3Sn, SS
3.3/2.9 44 50
Integrated pole Pole loading
P1 P2 M1 P1 P2 M1 M2
Under press -65 -90 -206 -122 -80 -145 -95
Spring-back -60 -65 -121 -99 -47 -40 -85
Yoke assy. -115 -70 -70 -162 -70 -66 -124
Cool down -148 -36 -70 -133 -65 -60 -105
12 T -22 -2 -172 -24 -6 -130 -156
27/30 GPa 44/50 GPaIntegrated pole Pole loading
P1 P2 M1 P1 P2 M1 M2
Under press -65 -80 -148 -110 -65 -95 -82
Spring-back -55 -55 -103 -87 -45 -45 -73
Yoke assy. -102 -57 -70 -137 -48 -60 -110
Cool down -129 -35 -70 -111 -44 -55 -90
12 T -4 -14 -147 -10 -37 -126 -139
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Check impact of over-compression by additional 0.05 mm collar press displacement.
14January 12, 2012 B. Auchmann TE-MSC
Impact of Over-Compression
Values for default displacementIntegrated pole Pole loading
P1 P2 M1 P1 P2 M1 M2
Under press -65 -80 -148 -110 -65 -95 -82
-205 MPa
-145 MPa
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15January 12, 2012 B. Auchmann TE-MSC
Shape Evolution Coil deformation
Pole loading, coil inner-contour ellipticity f = b/a
We may review the room-temperature beam separation of 2 x 97.194 mm.
Coil ellipticity Coil center shift
Integrated pole
Pole loading
Integrated pole
Pole loading
Yoke assy. 0.6% vert. 0.2% vert. -0.11 mm 0.02 mm
Cool down 0.6% vert. 0.1% hor. -0.65 mm -0.39 mm
12 T 0.1% vert. 0.6% hor. -0.57 mm -0.3 mm
f = 1.002 f = 0.999 f = 0.994
Δx = 0.39 Δx = 0.3
b
a
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Coil deformation
Integrated pole, coil inner-contour ellipticity f = b/a
We may review the room-temperature beam separation of 2 x 97.194 mm.
16January 12, 2012 B. Auchmann TE-MSC
Shape Evolution
Coil ellipticity Coil center shift
Integrated pole
Pole loading
Integrated pole
Pole loading
Yoke assy. 0.6% vert. 0.2% vert. -0.11 mm 0.02 mm
Cool down 0.6% vert. 0.1% hor. -0.65 mm -0.39 mm
12 T 0.1% vert. 0.6% hor. -0.57 mm -0.3 mm
f = 1.006 f = 1.006 f = 1.001
Δx = 0.65 Δx = 0.57b
a
Δx = 0.11
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17January 12, 2012 B. Auchmann TE-MSC
Collar Stress
Under pressYoke assembly RT12 TCollared CoilCryogenic temp.
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18January 12, 2012 B. Auchmann TE-MSC
Shell Stress, Yoke Gap
Room temp.
weld shrinkage0.65 mm
weld shrinkage0.4 mm
shell thickness 10 mm shell thickness 10 mm
Cryogenic temp.12 T
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19January 12, 2012 B. Auchmann TE-MSC
Conclusion/Outlook The solutions differ in terms of
o Peak stress under the presso Pre-stress after collaringo Coil deformationo Number of active design featureso Sensitivity to coil modulus, press displacement
Next stepso Finish 3D analysis of pole-loading concepto Converge on a single FNAL/CERN concepto Perform sensitivity analysiso Complete detailed manufacturing designo Develop instrumentation