FNAL QXF Curing Mold Miao Yu, FNAL 05/07/2013

FNAL Short Curing Press 2 2 meter long Capacity (pump psi) Max. force/cylinder kN (ton) Spacing cm(inch) Unit force kN/m-pump psi (lb/in-pump psi) Main Cylinders (60)15 (6)0.356 (2) Mandrel Cylinders (10)15 (6)0.06 (0.34)

FNAL Long Curing Press Capacity (pump psi) Max. force/cylinder kN (ton) Spacing cm(inch) Unit force kN/m-pump psi (lb/in-pump psi) Main Cylinders (200)30 (12)0.6 (3.34) Mandrel Cylinders (15)15 (6)0.09 (0.5) m long

Curing Mold Analysis 1.2 MPa 22 MPa 5 MPa Unit: mm ComponentMaterial CoilNb 3 Sn Mold1050 steel MandrelSS 304 Sector pusherSS 304 Stop barA2 Steel Cylinder Load (kN/m) Short Press (pump psi) Long Press (pump psi) Main Cylinder Mandrel Cylinder Assume the coil az. pressure 22 MPa, and the mold is just closed. 4 Main Press = (Load/Unit force) x (Coil length/Mold length)

Normal Operation P mandrel =1.2 MPa P coil =22 MPa P mandrel =1.2 MPa P coil =22 MPa P mold =5 MPa Stress (MPa) Deflection (µm) in x,y Stress (MPa) Deflection (µm) x, y Stress (MPa) Deflection (µm) x, y Coil (MPa) Mold (MPa) 6.13, , , 21 5

Disassembly Mold Disassemble IR Quad short inner coil mold and LHQ curing mold Reuse most of the tooling (tie rods, wheels, keys, bars, etc) 6

Curing Mold Assembly 7

SQXF and LQXF Molds SQXF Mold: ~$56k –2.08 m (78”) long, one stacking section. –Procure two end blocks ($5,600) –1250 pieces of laminations ($38,000 + $10,000) –one wheel assembly, one heater outlet box and one alignment cylinder. ($2,000) LQXF Mold: ~$52k –8.84 m (348”) long, 5 stacking sections –Procure two end blocks ($5,600) –5600 pieces of laminations ($45,000) –Two heater outlet boxes (power at both ends) ($1,000) 8

Post Curing Mold Review Miao Yu 05/14/2013

Review note 1: D. & Proc. Procurement of LQXF formblock laminations should be delayed until design develops for SQXF. In the event that conductor width or other changes are incorporated, revisions to the stamping die may be implemented before LQXF laminations are stamped. – Mike 2 step procurement process, short tooling now, long tooling later. - Fred 10

Action1: Design &Procurement FY13: SQXF curing mold FY14: LQXF curing mold Keep the same cross-section design on both SQXF and LQXF curing mold. Keep the 60 mil thick curing retainer. Adjust the shim in between the retainer and the coil to compensate the difference in final cable dimension. (current design has 20 mil shim) 11 Procurement LQXF die

Review note 2: Curing Press Values of applied load to coils for given hydraulic pressure assumed that cylinders beyond the length of the coil contributed to the coil pressure. This should be revised to reflect that only cylinders directly loading coils contribute to applied load. – Mike Applied pressure of 22 MPa on coils during curing was considered to be high. However, planning for unexpectedly high loads is a conservative measure. Furthermore, this is a tooling review, not a coil curing procedural review, and so extra safety margin in the tooling design is appropriate. – Mike Adjust formula on page 4, load per unit length on coil only. - Fred 12

Action 2: Curing Press 13 Cylinder Load (kN/m) Short Press (pump psi) Long Press (pump psi) Main Cylinder Mandrel Cylinder Capacity (pump psi) Max. force/cylinder kN (ton) Spacing cm(inch) Unit force kN/m-pump psi (lb/in-pump psi) Main Cylinders (60)15 (6)0.356 (2) Mandrel Cylinders (10)15 (6)0.06 (0.34) 2 meter Press Capacity (pump psi) Max. force/cylinder kN (ton) Spacing cm(inch) Unit force kN/m-pump psi (lb/in-pump psi) Main Cylinders (200)30 (12)0.6 (3.34) Mandrel Cylinders (15)15 (6)0.09 (0.5) 8.8 meter Press Under these load, ~22 MPa will go to the coil azimuthally. The pressure starts low Main pressure: 700 psi Mandrel pressure: 500 psi 5 loading steps up to the limit pressure, each step we measure the mold gap Upper limit

Review note 3: Heat transfer Mandrels do not include holes for electric heaters. LHQ mandrel temperatures will be monitored to determine if coil reaches proper temperature at all locations along inner radius during cure. Thermal analysis of the QXF curing assembly (mandrel, pushers, coil and formblock installed in press) should also be completed to validate the experimental results. Note that if results are unsatisfactory, in this respect also carbon steel mandrel material may be advantageous due to superior thermal conductivity as compared to stainless steel. Analysis should also include the effect of candidate steel versus mylar spacers between coil and liner during cure. - Mike Analyze heat transfer in coil during curing. Use coil LHQ02 to measure mandrel & coil shell temperature during curing with Mylar radial spacer. Compare the time to heat the coil shell temperature with LQH01. Apply results to FQX curing tooling. - Fred 14

Action 3: Heat transfer In LHQ coil 02, coil mandrel temperature will be monitored, at two locations close to the end of the coil, to determine if the coil reaches the proper temperature. (Mylar shim will be used in between the retainer and this coil) Thermal analysis of QXF. 15

Review note 4: Coil End Load Coils are cured without end pressure. Instead set screws on pusher blocks attached to the mandrel apply an initial load to the coil end shoe after winding. This load is applied before azimuthal pressure is applied to put conductors in proper azimuthal position, i.e., before the end shoes are fully seated, and therefore remains a concern. Use of Belleville washers or some other means to be able to complete the seating of the coil end shoe after the azimuthal pressure is applied should be considered. - Mike 16

Action 4: Coil End Load Belleville washers will be used in LHQ coil 02 between the screw and the coil end pusher, which will help the coil saddle sit better after coil compressed azimuthally. 17

Review note 5: Material 304 stainless steel is planned for mandrel and pushers (apparently this is being considered for use at CERN as well). Carbon steel should be considered for relatively lower material and machining costs. – Mike Material selection or the tooling is acceptable. - Fred 18

Action 5: Material 19 ComponentQXF Mandrel support4140 H.T steel MandrelSS 420 Curing SpacerSS 420 Sector pusherSS 420 Side pusherA2 steel Retainer1074 spring steel SQXF/LQXF Mandrel Mandrel support block Sector pusher Side pusher Coil Retainer Curing Spacer during IL curing The price for SS 420 is roughly 4 time more than the low carbon steel Using steel will save us ~$30k, however there may be high risk to do so.

Review note 6: Model compare FNAL and CERN curing tooling drawings should be compared. -Mike 20

Action 6: Model Status at FNAL We are still working on the winding and curing tooling. (1~2 month) Try to fit all the other existing tooling, such as winding table and rotation table. Waiting for the final cross-section and coil design for the curing spacer at layer jump area. 21