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T he design study of the vacuum system elements ( KOPIO experiment )

T he design study of the vacuum system elements ( KOPIO experiment ). A. Ryabov, A. Soldatov, S.Chernichenko ( IHEP, Protvino ) V.Demitchev, A.Timofeev ( RDP Corp. KOMPOZIT, Korolev ). Geometry. General View. Pipe. Lid. Ribs. FE-Analysis Models. GA – connection. GB – connection.

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T he design study of the vacuum system elements ( KOPIO experiment )

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  1. The design studyof the vacuum system elements(KOPIO experiment) A. Ryabov, A. Soldatov, S.Chernichenko (IHEP, Protvino) V.Demitchev, A.Timofeev (RDP Corp. KOMPOZIT, Korolev)

  2. Geometry. General View Pipe Lid Ribs

  3. FE-Analysis Models GA – connection GB – connection GC – connection • Three geometry models of the pipe-lid connection have been used in the Finite Element Structural Analysis (FE-Analysis): GA - the joint without any additional intermediate element; GB - the joint thru an intermediate conic surface; GC - the joint thru an intermediate “horn” surface. • Three sets of thickness for the lid, pipe and ribs have been considered. Values of these thickness (TS1, TS2 and TS3) are shown intable on next slide.

  4. The basic parameters of models

  5. FE-Analysis (the stress distribution) Two versions of FE-Analysis have been done for each combination of the geometry model and thickness: first one for a free pipe end (V1), the second one for a fixed pipe end (V2). A typical example of a stress distribution with two critical zones Critical zone P1 Critical zone P2 V1: Von Mises Stress [MPa] SEQV_max = 330 MPa V2: Von Mises Stress [MPa] SEQV_max = 154 MPa

  6. FE-Analysis (displacements) A typical example of a maximum displacement (GA, TS1) V1: USUM_max = 2.17 mm V2: USUM_max = 1.91 mm

  7. FE-Analysis (the pipe displacements) V1 V2 Uz = -1.23 Uz = -0.05 Longitudinal displacements UZ [mm] V1 V2 Uy = ± 1.31 Uy = ±1.34 Vertical (Flexure) displacements UY [mm]

  8. Summary Results of FE-Analysis TS1: t_cover = 1/2, t_pipe = 1/4, t_ribs = 3/8 inch TS2: t_cover = 1/4, t_pipe = 1/4, t_ribs = 3/8 inch TS3: t_cover = 1/3, t_pipe = 1/3, t_ribs = 1/3 inch

  9. Conclusions • For all design variants of the lid-pipe system, the fixed end of a pipe allows to decrease the maximum displacements of pipe and to reduce also the stress of lid in critical zones (P1, P2) up to acceptable values. • The base variant of the lid-pipe design of the vacuum system (Beryllium alloy with thickness of 1/2”) can’t be made due to technological reasons - the today technology and the equipment allow to weld sheets of Beryllium alloy with the thickness up to 1/4”.

  10. Conclusions • The variant of the lid-pipe design with Beryllium alloy of the thickness of 6 mm and with the conic joint of lid-pipe can be made on the modernized technological equipment. The estimated cost of this variant will be more than $2M, period of manufacturing will be 3 years. But, two comments have to be done for this version: - Even for this thickness of Beryllium alloy, ribs on the beam pipe will be soldered by silver, but not welded, because the existing technology allows to weld only an end-to-end shape, but not T-shape. - Opportunity of appearance of micro-cracks in the welded seams because of cyclic loading (vacuum - atmosphere). It will demand an additional polymeric covering on the product surfaces.

  11. Conclusions • However, the today technology allows to produce the alternative variant of the lid-pipe design with a carbon-plastic composite of the thickness of 1/3” and with the conic joint of lid-pipe, which provides a safety factor almost 7 and the radiation thickness of  0.05X0. The estimated cost of this variant will be ~ $600K, period of manufacturing will be 2-3 years.

  12. Schedule and the cost estimation for production of the composite version

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