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FRESCA2 Update on the dipole design and new calculations

FRESCA2 Update on the dipole design and new calculations. EUCARD - WP7- HFM Collaboration Meeting LASA Milano Jorge Enrique MUÑOZ GARCIA. outline. Introduction : related projects & magnet overview Dummy-coils : replacement of superconducting coils Instrumentation : strain gauges

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FRESCA2 Update on the dipole design and new calculations

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  1. FRESCA2Update on the dipole design and new calculations EUCARD - WP7- HFM Collaboration Meeting LASA Milano Jorge Enrique MUÑOZ GARCIA EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  2. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  3. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  4. Introduction: related projects FRESCA2 RMC SMC Short Model Coil 12.5 T peak field on the coil @ 1.9K Weight: 2 double pancake racetrack coils mounted in a bolted steel structure composed of 2 horizontal and 2 vertical pads, to obtain a “coil pack” Fe yoke / Al shell: 20 mm thick Race-track Model Coil 16 T peak field / 18.3kA Weight: 2 double pancake racetrack coils mounted in a bolted steel structure composed of 2 horizontal and 2 vertical pads, to obtain a “coil pack” Fe yoke / Al shell Øout = 0.570m Facility for the REception of Superconducting CAbles 13 T bore field / 10.8kA @ Ø100mm aperture Weight: 10 t Block-type coil design with flared ends: 4 double-pancakes, Bladder-and-key type of structure Fe yoke / Al shell: 65 mm thick, Øout = 1.030m Magnet length: 2.255 m EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

  5. Introduction: magnet overview FRESCA2 Cross-section • Target: 13 T / Ø100 mm bore • Ø1.030 m; length: 2.255 m • Al shell, 65 mm thick, 1.6 m long • Iron yoke • Holes for 4 Al-axial rods • Horizontal stainless steel pad • 3 bladders • 2 load keys (1horizontal, 1vertical) • Iron / Ti central post • Vertical iron pad • 2 bladders, • 2 load keys • Auxiliary bladders between yokes • 4 double-layer coils

  6. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  7. Dummy coils: replacements of coils FRESCA2 Cross-section Al block • Replacement of coils & pole by 2 Al-blocks • dummy-coils • Mechanical test of the structure: • at room temperature (warm) • at cryogenic temperature (cold) • Instrumentation (strain gauges): • Aperture (dummy-coils) • Shell • Rod • Qualification of the structure • Validation of the assembly process • Validation of the FEM model Al block EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  8. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  9. Instrumentation: strain gauges FRESCA2 Rods Shell Dummy-coil EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  10. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  11. FRESCA2 dummy-coil: FEM model components Rod [Aluminum] Shell [Aluminum] Yoke [Iron] Pad-h [stainless steel] Key-v [stainless steel] Key-h [stainless steel] Yoke[stainless steel] Pad-v [Iron] Shim-in [G10] Pad-v [stainless steel] Shim-mid [G10] Dummy [Aluminum] End-plate [Nitronic] solid95 3D 20-node structural solid element (brick) conta174 3D 8-node surface-to-surface contact targe170 3D target segment friction = 0.2 everywhere that components come into contact with each other EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  12. FEM model: assembly process Expected stresses: FRESCA2 2D dummy-coils Outside shell 90° Outside shell 45° Outside shell 0° Cross-section at the middle of FRESCA2 dummy aperture • Comparison of stress during assembly & cool-down: FEM simulation vs. strain gauges measurements EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  13. FEM model: assembly process Expected stresses: FRESCA2 2D dummy-coils • Comparison of stress during h-bladder operation: Peak stress outside the shell: 50MPa Peak compression in the dummy-aperture: 120MPa Outside shell FRESCA2 dummy 2D model Cross-section at the middle of FRESCA2 dummy aperture EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  14. FEM model: assembly process Expected stresses: FRESCA2 2D dummy-coils • Comparison of stress during v-bladder operation: Peak stress outside the shell : 25MPa Peak compression in the dummy-aperture : 30MPa Outside shell FRESCA2 dummy 2D model Cross-section at the middle of FRESCA2 dummy aperture EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  15. FEM model: assembly process Expected stresses: FRESCA2 2D dummy-coils • Comparison of stress during key operation: Peak stress outside the shell : 30MPa Peak compression in the dummy-aperture : 75MPa Outside shell FRESCA2 dummy 2D model Cross-section at the middle of FRESCA2 dummy aperture EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  16. FEM model: assembly process Expected stresses: FRESCA2 2D dummy-coils • Comparison of stress during cool-down: Peak stress outside the shell : 120MPa Peak compression in the dummy-aperture : 200MPa Outside shell FRESCA2 dummy 2D model Cross-section at the middle of FRESCA2 dummy aperture EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  17. FEM model: assembly process Expected stresses: FRESCA2 3D dummy-coils • Comparison of stress during key operation: Peak stress outside the shell : 30MPa Dummy peak compression: 75MPa shell FRESCA2 dummy 3D model dummy Key operation EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  18. FEM model: assembly process Expected stresses: FRESCA2 3D dummy-coils • Comparison of stress during rod pre-tension: Peak stress inside the shell @90° Dummy stress concentration at the straight section shell FRESCA2 dummy 3D model dummy Rod pre-tension EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  19. FEM model: assembly process Expected stresses: FRESCA2 3D dummy-coils • Comparison of stress during cool-down: Peak stress inside the shell @0° Dummy stress concentration at the straight section shell FRESCA2 dummy 3D model dummy Cool-down Longitudinal location of strain gauges EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  20. FEM model: assembly process Expected stresses: FRESCA2 3D dummy-coils vs. superconducting coils coil pack • Comparison of stress during cool-down: Peak stress outside the shell @0° Dummy stress concentration at the straight section end shoes rails coils coils Vs. dummy pole wedge dummy Cool-down Rod pre-tension EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  21. FEM model: assembly process Expected stresses during the assembly process • Stress in the compression system: Aluminum rod longitudinal average stress: 160MPa @RT 225MPa @cryogenic End-plate stress within yield stress limits* * EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  22. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  23. Cases of study • FRESCA2 dummy-coils • Coils replaced by a block (this presentation) • Validation of the assembly process • Validation of the model: comparison with the strain gauges measurements • FRESCA2 superconducting coils • FRESCA2 mech • FRESCA2 wedge (contact), overall friction • FRESCA2 wedge (no contact), overall friction • FRESCA2 wedge (glued, no contact) • FRESCA2 wedge (glued, contact) EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  24. outline • Introduction: related projects & magnet overview • Dummy-coils: replacement of superconducting coils • Instrumentation: strain gauges • FEM model: expected stresses during the assembly, pre-load, and cool-down • FEM model: cases of study • Work in progress EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  25. Work in progress • 3D FEM model: • Updating of geometries: • Update Ørod in the dummy-coil model • Wedge geometries • Analysis & comparison of the results • Different cases of study • Instrumentation of the structure: • Strain gauges on dummy aperture at 90°, 45° • Strain gauges on rods EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  26. Thank you EUCARD - WP7- HFM Collaboration Meeting LASA Milano

  27. Assembly process: rotating device @ 927 ½ yoke weight ≈ 2400 kg Shell weight ≈ 860 kg EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

  28. Assembly process: table @ 927 Yoke and shell will be transported to an assembly table The assembled parts will be rotated to horizontal position bearing rollers will be used to slide the coil-pack into the yoke aperture The Al-block will be transported to the assembly table (Coil-pack weight ≈ 2000 kg) EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

  29. Assembly process: ½ Yokes centring @ 927 Two bladders will be used to push the ½ yokes towards the shell inner radius to allow gap keys insertion Insertion of the keys in between the ½ yokes EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

  30. Assembly process: table @ 927 3 vertical bladders will be used to lift the coil-pack and remove the rollers Temporary keys will be inserted to center the coil –pack into the yoke aperture EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

  31. Assembly process: horizontal bladder operation @ 927 Pumping horizontal bladders & insertion of horizontal keys Horizontal bladders insertion EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

  32. Assembly process: vertical bladder operation @ 927 Pumping vertical bladders & insertion of vertical keys Final configuration after loading operation • Mechanical test • Room temperature • Cold-down EUCARD - WP7- HFM Collaboration Meeting LASA Milano • Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting

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