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STAVE INTEGRATION PROPOSAL to avoid machining of existing stave

STAVE INTEGRATION PROPOSAL to avoid machining of existing stave. 04 March 2013. OVERVIEW. 14 x Threaded insert. SIDE C. SIDE A. 14x standard holes Ø3 H7. 14x Slotted holes: +-0.5 mm. 14 x Threaded insert. SIDE C: FIX. BONDING INSERT (TITANIUM). 14x threaded insert M1.6. IPT (CFRP).

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STAVE INTEGRATION PROPOSAL to avoid machining of existing stave

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  1. STAVE INTEGRATION PROPOSALto avoid machining of existing stave 04 March 2013

  2. OVERVIEW 14 x Threaded insert SIDE C SIDE A 14x standard holes Ø3 H7 14x Slotted holes: +-0.5 mm 14 x Threaded insert

  3. SIDE C: FIX BONDING INSERT (TITANIUM) 14x threaded insert M1.6 IPT (CFRP) EoS RING (CFRP) Precise positioning Ø2.2 MUSROOM HEAD EoS (PEEK CF30) Ø3.4 Ø4 PIN (TITANIUM) Ø3 H7 g6 MUSHROOM FOOT (TITANIUM) MUSHROOM HEAD (PEEK) VIEW A-A CF CLIP IPT

  4. SIDE A: «SLIDING» 14x threaded insert M1.6 BONDING INSERT (TITANIUM) IPT (CFRP) Slotted hole +- 0.5 mm SLOTTED HOLE +- 0.5 mm EoS RING (CFRP) EoS (PEEK CF30) PIN (TITANIUM) Ø3 H7 g6 MUSHROOM FOOT (TITANIUM) MUSHROOM HEAD (PEEK) VIEW B-B CF CLIP IPT

  5. KEY POINTS • What is the precision of the counterbored hole ? Iso 2768 fK (should be )

  6. EoSRing IPT • Assuming: • +/- 0.05mm for relative tapped holes positioning on each ring (dedicated jig for insert gluing) • 724mm with +-0.05mm tolerance using a jig in CFRP (to get rid of temperature effect) • Then, the maximum length variation is: 724mm +/-0.15mm

  7. Variation of length on Stave: • Based on FEA, the CTE has been homogenized at 1.1 ppm/°C (0.8 ppm/°C INFN) • Then, at -40°C, the overall shrink is at the order of 0.05mm (0.035 mm)… • So, in Nominal case (Integration at SR1) • Min length: 723.95 mm • Max length: 724.05 mm

  8. COLD CASE at -40°C • Single thin (5 plies) IPT: extension of 17 µm (-4 e-07 .°K-1) • Single stave: contraction of 50 µm (1.1 e-06.°K-1) Sliding Sliding Fix in COLD case: Stave min length: 723.95 - 0.05mm = 723.9mm Stave max length: 724.05 -0.05mm = 724mm IPT min length: 723.85 + 0.017mm = 723.867mm IPT max length: 724.15 + 0.017mm = 724.167mm Fix 5 plies composite pro (thanks to Seattle) ΔL= 267µm

  9. BAKE OUT CASE • Single thin (5 plies) IPT: contraction of 15 µm • Single stave: contraction of 35 µm Sliding Sliding Fix in COLD case: Stave min length: 723.95 - 0.035mm = 723.915mm Stave max length: 724.05 -0.035mm = 724.015mm IPT min length: 723.85 - 0.015mm = 723.835mm IPT max length: 724.15 - 0.015mm = 724.135mm ΔL= 220µm

  10. KEY POINTS • Need to redrill Ø2.2 counterbored holes in all EoSside A • Mushroom need to be tighten at the correct torque (H head) to position and fix the stave • Need to test bonding of M1.6 inserts • Temporary screws after stave integration to fix the stave before mushroom (x7) • Pins need to be secured on stave

  11. KEY POINTS • Accept overall variation of length +- 300 microns • Bonding of EoS slotted ring more difficult with bonding tool: additional holes ?

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