LHQ Curing Mold Miao Yu Fermilab 07/26/2011

HQ and LQ Curing HQ coil curing (LBNL) 2 LQ coil curing For HQ, the pressure of the mandrel cylinder is set at 500 psi The pressure of the main cylinder is 2,500 psi and the cavity is closed. Hold the platen position during curing. The pressure of the main cylinder increases to 3,500 psi. For LQ, the pressure of the mandrel cylinder is set at 600 psi The pressure of the main cylinder is 750 psi and the cavity is closed. Keep the pressure in both the mandrel cylinder and the main cylinder during curing. Adjust the platen position.

LHQ Curing Mold Modification on the HQ curing mold cross-section [234.95] [69.85] Die spring 1” OD * 1.25” Length Max. load: 321 lbs (Mcmaster) [254.0]

LQ Mold Deflection µm 4.3 µm

HQ Mold Deflection µm 8.3 µm

LHQ Mold Deflection µm 8.8 µm

Curing Pressure Mandrel Cylinder (pump psi) Main Cylinder (pump psi) Mandrel Support (MPa) Coil (MPa) TQ LQ HQ (3500) (27.3) LHQ Note: the cylinder pressure is converted to the effective load TQ Press: Mandrel cylinder (6), 10,000 pump psi ~ 10 tons Main cylinder (7), 10,000 pump psi ~ 60 tons LQ & LHQ Press: Mandrel cylinder (24), 10,000 pump psi ~ 15 tons Main cylinder (28), 10,000 pump psi ~ 200 tons HQ Press: Mandrel cylinder (7), 10,000 pump psi ~ 10 tons Main cylinder (10 + 4), 10,000 pump psi ~ 55.2 tons tons

EDM Block or Lamination ’’ long 2” EDM block 168 ’’ long 1/16” Lamination 348 ’’ long 1/16” lamination The short assembly requires the steel cylinders as the spacers put in between the top and bottom platens. 40 transport systems (wheel assembly) Max. load: 321*40 = 12,840 lbs 348” mold cavity weight: ~6600 lbs 160” coil envelop weight < 1700 lbs (SS) 348” coil envelop weight < 3700 lbs (SS) Rods+heaters+tie bars+… : ~500 lbs

Comparison of Cost Estimation 9 Method/CategoryM & STech LaborEDIATotal 348” EDM$217 k$23 k$52 k $291 k ± 58 k 168” EDM$109 k$15 k$52 k $176 k ± 35 k 348” Lamination$91 k$24 k$52 k $167 k ± 33 k 168” lamination$71 k$15 k$52 k $138 k ± 28 k * Note: the cost of the cylinders for the168’’ long mold was not included.

Cost Estimation for Lamination 10 LHQ 348" Curing Mold Assembly Variation20% $ 33,000 Sub-total $ 167,000 M & S $ 91,072 Toolingunitamount$/unit $ 42,440 Lamination stamping dieea1 $ 30, $ 30,000Final stamping profile, Note 1 Pre-notch dieea1 $ 10, $ 10,000Pre-stamp for stress-relief, Note 1 Short-stack toolingea1 $ $ 600Stacking 2' stacks Stacking toolingea1 $ 1, $ 1,200~7' stack on inclined table Mandrel for emery clothea2 $ $ 640Polishing profile interior Mold partsunitamount $/unit $ 48, Sphero Annealed Steellbs11200 $ 1.60 $ 17,920Note 1 Stampingea5600 $ 1.02 $ 5,712Note 1 Tie bars (staggered pieces)set6 $ $ 720 Tie rods (welded at FNAL)ea6 $ $ 2,880 Wheel assembliesassy40 $ $ 16,800 Top shim platesea8 $ $ 4,400Hardened, counterbored Hardware, misclot1 $ $ 200 Total Labor $ 76,216 Technician /hr$100techshrs/techqty parts $ 24,376 Clean 5600 laminations2161 $ 3,200 Inspect 10% to verify crown141 $ 400 Stack short stacks2115 $ 3,000 Weld short stacks $112/hr1115 $ 1,680 Attach wheel assemblies2140 $ 8,000 Align on transfer table281 $ 1,600 Weld tie rods (set of 6) $112/hr181 $ 896 Dress welded tie rods (set of 6)141 $ 400 Assemble with tie bars281 $ 1,600 Polish contour with emery cloth2161 $ 3,200 Inspect assembly141 $ 400 EDIAnum.wkspay rate/hr $ 51,840~ 0.25 FTE Engineer16108 $ 25,920 Designer13108 $ 12,960 Drafter12108 $ 8,640 QA11108 $ 4,320 Notes: 1) The above utilizes material values supplied by TD's Q&M Material Control Group. 2) Machining of short stacked packs can be more cost effective by mounting multiple stacks on the mill to make the cuts. 3) Heating element are excluded from this estimate. 4) EDIA: Engineering, Design, Inspection and Administration. 5)Sharpen the die after 3,000 pieces of lamination.

Conclusion The HQ curing mold cross-section can be modified to fit in the curing press. The deflection of the LHQ cavity is simulated and compared with the other curing cavities. The LHQ coil deflection in x-direction (open) during curing process is less than 8.6 µm. The cost of mold assembly using 2”EDM block and 1/16” lamination is estimated and compared. The long mold lamination assembly is preferred, and the total cost is estimated. 11