FRESCA2 Update on the dipole design and new calculations EUCARD - WP7- HFM Collaboration Meeting LASA Milano Jorge Enrique MUÑOZ GARCIA September 18th, 2012 EUCARD - WP7- HFM Collaboration Meeting LASA Milano

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

Introduction: related projects SMC RMC FRESCA2 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 Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting EUCARD - WP7- HFM Collaboration Meeting LASA Milano

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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

FRESCA2 dummy-coil: FEM model components Rod [Aluminum] Shell [Aluminum] Yoke [Iron] Key-v [stainless steel] Pad-h [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

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

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

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

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

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

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

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

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

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

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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

EUCARD - WP7- HFM Collaboration Meeting LASA Milano 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

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

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

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) Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting EUCARD - WP7- HFM Collaboration Meeting LASA Milano

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 Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting EUCARD - WP7- HFM Collaboration Meeting LASA Milano

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 Juan Carlos Perez “Fresca2 construction status, assembly procedures, tooling and test facilities” EuCard-WP7-HFM 9th Collaboration Meeting EUCARD - WP7- HFM Collaboration Meeting LASA Milano

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

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