Co-op Update #1

Co-op Recap

Matt Sterling

June 8th, 2017

Outline

• Focus on two recent Projects

– Nanofiber Sample Tensile Grip

– Vacuum Lifting Fixture Engineering Note

• Additional Projects This Term

• Projects From Previous Term

6/8/20172

Nanofiber Sample Tensile Grip (Background)

• Sujit Bidhar (of TSD) is using a

process called electrospinning to

create samples of webbed nanofibers

• The nanofibers are made out of a gel-

like polymer mixed with various types

of powdered metals (titanium,

tungsten, etc.)

• Sujit’s goal is to bake out the polymer

and be left with a sample of metallic

nanofibers

• A mesh of metallic nanofibers would

cool more easily than a solid body of

material, therefore is an ideal target

material for future high intensity beams

6/8/20173

Nanofiber Sample Tensile Grip (Background)

• A tensile testing machine, along with a

2N load cell was purchased in order to

test the mechanical properties of these

samples

• The stock grips are too heavy for the 2N

loadcell

• My task was to design a lightweight grip

to hold the nanofiber samples

6/8/20174

Nanofiber Sample Tensile Grip

• Design Requirements:

– Attaches to purchased tensile

tester

– Weighs less than 50 grams

– Can hold samples with variable

tightness

– Holds sample of dimensions

roughly 5mm wide, 50 mm long,

and 1mm thick

6/8/20175


• After initial hand drawing, created model in NX

• Material choice for body/holding plate was PEEK due to its

low density and high strength

• Found applicable hardware on McMaster

• Made spreadsheet to calculate weight and price of current

design in order to make accurate design decisions

• After going over initial design with Sujit, a vertical layout

was preferred in order to save weight (35g 30g)

• Removable dowel pin was added in order to keep holding

plate aligned as best as possible

6/8/20176


6/8/20177


• After checking this final design with Sujit, I began making

drawings with the help of Dirk from drafting

6/8/20178


6/8/20179

• Status:

– Need to create an assembly drawing to aide in the

manufacturing process

• Grand Scheme:

– Sujit would like to use this grip to test the material properties of

his samples

– Use laser microscopy to evaluate the cross-section of samples

(for stress-strain curves)

– Ultimately test the entirely metallic samples if all goes to plan

Vacuum Lifting Fixture Engineering Note (Background)

• Vacuum cup lifting fixture originally built at Argonne and used

at Fermilab for several years is now at the University of

Virigina for use by collaborators who need it to move modules

for Cosmic Ray Veto (CRV)

• An engineering note was written previously to certify the

fixture for a 1500lb load

• Now, the group at UVA would like to use the fixture for a load

capacity of 2500lb

• Our job was to determine whether the lifting fixture could

sustain the new load and update the Engineering Note

accordingly

• Dave Pushka (of TSD) was my supervisor on this project

6/8/201710

Vacuum Lifting Fixture Engineering Note

• At first, I went through the original EN to

get an idea of what was required and to

become familiar with ASME BTH

• As I became familiar with the

calculations I began to re-do them with

the new load of 2500lb to see whether

any major modifications would need to

be made to the lifter

• I contacted the collaborator at UVA to

get a better understanding of the current

state of the lifter (as modifications had

been made) and what vacuum cups

were available to them

6/8/201711


• At UVA, they had twenty 7”

diameter vacuum cups, with a load

rating of 160 lbs each (already

rated with safety factor)

• The lifter would need a minimum of

16 cups to meet the 2500lb

capacity

• The use of all 20 cups was agreed

upon as the safest and most

practical application, therefore the

Engineering Note was updated

with all 20 cups in mind

6/8/201712


• Updated calculations

included

– Bending of the main box

section

– Bending of the “arms”

– Torsion on the “arms” due to

offset vacuum cups

– Capacity of the cups

themselves

– Shear on bolts that attach

vacuum pack

– Weld strength connecting

“arms”

– Strength of the center lug

6/8/201713


• An additional analysis was done in ANSYS to determine

whether the deformation of the module (to be lifted) under

self weight was more than the cups could swivel

• Conservative estimates gave a deformation of less than ¼”

which was determined to be safe.

6/8/201714


• Status:

– The Engineering Note has been completed and is currently in

the TeamCenter review process

• Grand Scheme:

– Make any needed edits upon review and get it checked off

6/8/201715

Additional Projects This Term

• Mu2e Septa Fluorinert Circulation System

• MEBT Emittance Scanner Motion Study

• CMTS Waveguide Lifting Fixture

6/8/201716

Mu2e Septa Fluorinert Circulation System

• FC-40 was to act as an electrical isolator for the high voltage

feedthroughs of the Mu2e Septa

• I was asked by Dez to begin setting parameters and

ultimately design a piping system to circulate this Fluroinert

because it would otherwise dissociate due to the high

radiation environment

• I began to determine system requirements and calculate

theoretical head losses but the project was put on hold

6/8/201717

MEBT Emittance Scanner Motion Study

• One day project at PIP-II to help

determine whether the MEBT

Emittance Scanner’s encoder was

locating correctly

• Set up dial indicator to cross-reference

inputted position

• Took several measurements both

lowering and raising the Emittance

Scanner

• Entered data into excel and made

error and hysteresis plots

• Wrote short write-up describing my

procedure and data

6/8/201718

CMTS Waveguide Lifting Fixture

• Currently the waveguides at CMTS

are moved using a combination of

slings and human power

• Brian Hartsell asked me to design a

custom lifting fixture which could be

attached to these waveguides and

used for more secure maneuverability

• I took measurements at CMTS, found

the CoG, and after a few iterations

have come up with a design that

seems feasible

• This design still needs to be assessed

and will most likely be passed on to

the next co-op

6/8/201719

Projects From Previous Term

• LBNF Window Module

• AP0 Structural Analysis

• CMTF Powerline Road Dust Mitigation

• SEM Engineering Support and Stand Design

• NuMI Shielding Fixture Cart

6/8/201720

LBNF Window Module

• Window leading into helium decay

pipe in the LBNF Target Chase was

originally designed for a 1 meter

diameter

• I was asked to upgrade the window

module to a 1.5 meter diameter

along with making several

adjustments per Dave Pushka’s

request

– Added airflow channel and supports

– Widened and added height to

module

6/8/201721

AP0 Structural Analysis

• Old Tevatron beam dump was

going to be placed into a coffin in

A0 over an empty pit

• Ryan Shultz had found I-beams

that could be used to support

concrete blocks and create a

surface to place the coffin and

ultimately the beam dump

• Did several calculations to

determine the max stress and

safety factors on the 6 different I-

beams in 3 possible loading

situations

6/8/201722

CMTF Powerline Road Dust Mitigation

• The unpaved road just west of

CMTF was causing dust to clog

filters and made it more difficult to

maintain clean rooms

• I researched several dust

mitigation options to determine

cheapest and safest way to

reduce the impact

• Found a company that is used in

the Village and other areas of the

lab, contacted them, and got a

quote for calcium chloride which

is now being applied 1-2 times a

summer

6/8/201723

SEM Engineering Support and Stand Design

• A Secondary Emission Monitor is a

device used to measure beam flux

• Matt Alvarez designed and

procured this SEM

• My job was to take inventory and

assemble the SEM at the NWA

cleanroom

– I also wrote a paper to help

optimize assembly procedure

in future

• Helped Matt with Engineering Note

for vacuum windows

• Designed a stand to hold the SEM

in the beamline (did not end up

being used)

6/8/201724

NuMI Shielding Fixture Cart

• A moveable, liftable, lockable

cart needed to be designed to

transport 3 shielding base rails

throughout the NuMI Target

Hall Chase

• I drew up a concept and

worked with Steiner Electric to

end up with a bill of materials

• Adjusted the order to cut costs

by 35%

• Once everything came in,

worked with Zac (previous

intern) at MI-8 to build it

6/8/201725

Thank You!

• Co-op Supervisors

– Kavin Ammigan

– Matt Alvarez

– Maurice Ball (last term)

• Project Supervisors

– Dave Pushka

– Ryan Shultz

– Jerry Leibfritz

– Cory Crowley

– Sujit Bidhar

– Abhishek Deshpande (Dez)

– Brian Hartsell

• Anyone else I’ve worked with! (Techs, Physicists, Engineers, etc.)

6/8/201726

Co-op Update #1

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