Ottó Bede TBM Consortium Meeting, Brasimone WP5 - FEM analyses ITER PPE training session 7 December – 11 December 2009, Cadarache, France József NÉMETH Association EURATOM-HAS KFKI Research Institute for Particle and Nuclear Physics

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 2 WP5 - FEM analyses CONTENTS ○ Introductory structural analysis task ○ Introductory thermomechanical analysis task ○ Workpackage overview ○ Complex structural analysis task ○ Workpackage overview

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 3 WP5 - FEM analyses Workpackage overview WP 5: Thermomechanical Engineering of In-Vessel Components Starting date: Objective : To become a thermomechanical analyst expert for the further fusion research. Tools : ANSYS Multiphysics and ANSYS Workbench Short term aim: To achieve the assured knowledge and routine on using the tools. Implementation: FEM tasks from simple to more complex under mentoring by Gábor Grunda

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 4 WP5 - FEM analyses CONTENTS ○ Introductory structural analysis task ○ Introductory thermomechanical analysis task ○ Workpackage overview ○ Complex structural analysis task

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 5 WP5 - FEM analyses COMPASS ion beam vacuum vessel The challenge: - An ion beam is developed for the COMPASS in our institute. - We would like to know what is the stress field of the following part of the appliance. - The structure has only static loads. Pressure, force and weight. The task: -Check the strength of the vacuum vessel and the bolts of the flange -Used tool: ANSYS Workbench

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 6 WP5 - FEM analyses The FEM model I. Geometry of the examined part: - Simple cylindrical part with bolts. Materials: - vacuum vessel: aluminium alloy: AlMgSi 0,5 - bolts: steel flange: PVC

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 7 WP5 - FEM analyses The FEM model II. The mesh: - Fine tetra mesh has been chosen. Loads and supports: - 0,3 [MPa] inner pressure - forces on the bolts - gravitational field - fix support

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 8 WP5 - FEM analyses Results The main stress in the vessel is 11 [MPa]. The maximal stress is 150 [MPa]. The yield strenght is 160 [MPa].

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 9 WP5 - FEM analyses Results The maximal stress is 260 [MPa] in the bolts. The yield strenght is 640 [MPa]. The structure is adequate.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 10 WP5 - FEM analyses CONTENTS ○ Introductory structural analysis task ○ Introductory thermomechanical analysis task ○ Workpackage overview ○ Complex structural analysis task

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 11 WP5 - FEM analyses AEU frame structure The challenge: - For the functioning of the ITER TBS we need a removable unit (AEU) which contains some sub-systems of TBS. - The frame structure was a design concept for preliminary layout. - To minimize the weight of the frame structure, so this is an optimizing task. - To check the necessity of side frame structure. - The frame structure has only static loads.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 12 WP5 - FEM analyses Dimensions of frame structure The outer dimensions are equal to the EQ Transfer Cask. Width of longitudinal beams is given by the space next to ATS.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 13 WP5 - FEM analyses Loads of frame structure Weight of sub-systems: Helium Cooling System (HCS): 359,5[kg] PbLi loop:20000[kg] Tritium Extraction System (TES):927[kg] Diagnostics:7000[kg] Maintenance Equipment:1162[kg] Layout of sub-systems: DiagnostiscHCSTESMaintenance EquipmentPbLi loop

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 14 WP5 - FEM analyses The FEM model Rough FEM models have been made in the first steps and these have been specified in the next phases. Solid model has been made and hexa mesh has been used. The mesh size has been fined during the development procedure. The raw material is a good weldable structural steel S235JR (standard MSZ EN ). The numerical designation of material is MPa maximal stress had aimed during the optimization. First the correct value of the standard stress has been aimed during the procedure of optimizing then the smaller stress maximums had corrected.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 15 WP5 - FEM analyses The first analysis Conception:- standard I beams and rectangular tube - frame structure without side beams Mesh:- rough tetra mesh Loads and supports:- one common pressure, gravity, fix support Weight: 3840 [kg]

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 16 WP5 - FEM analyses Result of the first analysis The calculation confirmed frame structure without side beams is possible. The main stresses are nearby 30 [MPa]. The maximal stress is 90[MPa].

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 17 WP5 - FEM analyses The first phase Conception:- standard I 120 cross beams IPE series - uniquely welded longitudinal beam Mesh:- rough tetra mesh Loads and supports:- pressures on the location of sub-systems, gravity, fix support Weight: 1855 [kg]

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 18 WP5 - FEM analyses Result of the first phase The stresses in the cross beams are nearby 150[Mpa] but some cross beam is under sized. The longitudinal beam is over sized. The maximal stress is 347[MPa].

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 19 WP5 - FEM analyses The second phase Conception:- standard I 120 cross beams IPE and HEB series - uniquely welded longitudinal beam with holed ridge Mesh:- fine tetra mesh Loads and supports:- pressures on the correct location of sub-systems, gravity, one bonded DOF Weight: 1959 [kg]

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 20 WP5 - FEM analyses Result of the second phase The HEB I beams are proper, IPE beams are over sized. Local stress maximums are by the welded joints. The longitudinal beam is adequate.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 21 WP5 - FEM analyses The last phase Conception:- the IPE beams have been exchanged to rectangular tubes - ribs and node plates with large fillet have been used Mesh:- fine tetra mesh Loads and supports:- pressures on the correct location of sub-systems, gravity, one bonded DOF Weight: 1762 [kg]

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 22 WP5 - FEM analyses Result of the last phase The stress is correct everywhere in the structure. Due to the ribs the stiffness is better. The maximal stress is 170 [MPa]. Calculations with non flat seat.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 23 WP5 - FEM analyses CONTENTS ○ Introductory structural analysis task ○ Introductory thermomechanical analysis task ○ Workpackage overview ○ Complex structural analysis task

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 24 WP5 - FEM analyses MAST diagnostics The challenge: Thermal analysis for MAST Beam Emission Spectroscopy In-vessel Optics - the optics has to operate on 150 ° C in vacuum environment - it is important to know what heater must be use and how long the heating going to last - to check the 750 W electric heater and thermal insulation The model of diagnostics - cylindrical vacuum vessel and mirror and lens support elements

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 25 WP5 - FEM analyses The FEM model I. Geometry: - Vacuum vessel + heater + thermal insulation Materials: - vacumm vessel: A300 stainless steel: thermal conductivity: 15 W/mK specific heat: 500 J/kgK - thermal insulation: fiberglass:thermal conductivity: 0,032 W/mK specific heat: 670 J/kgK

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 26 WP5 - FEM analyses The FEM model II. Mesh: - solid model has been built - tetra mesh has been applied

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 27 WP5 - FEM analyses Steady state analysis Heat and convection: - Internal heat generation in the heater: 750W - Convection on the outer surface of thermal insulation

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 28 WP5 - FEM analyses Calculation of convection - thermal conductance of the environment (air): λ - acceleration due to gravity: g - thermal expansion of the environment (air): β Convection depends on: - temperature difference: Δt - kinematic viscosity : ν - thermal diffusivity: a

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 29 WP5 - FEM analyses Results of steady state calculation The maximum temperature is 436 ° C on the cylindrical surface of the vacuum vessel. The temperature of support elements of mirrors is nearby 370 ° C. The heater with 750 W power is enough but this simulation doesn’t give answer for the transient processions.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 30 WP5 - FEM analyses Transient analysis Heat, convection and radiation: - internal heat generation in the heater: 2x750W (double heater) - convection on the outer surface of thermal insulation - radiation between the surfaces Radiaton depends on: - surfaces: F - emission factor: ε - temperatures: T - Stefan-Boltzmann ratio: σ Relative emission factor: Heat flow:

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 31 WP5 - FEM analyses Results of transient calculation After sec the temperature of support elements of mirrors is nearby 150 °C. The heating time is too long with 750 W heating power. Two heaters must be used. This analysis was based some estimations, so the real laboratory test will give important feed-back about the validation.

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 32 WP5 - FEM analyses Results of transient calculation Thank you!