1. PROTOTYPE January, 27 th 2016 Valery AKHNAZAROV Diego ALVAREZ Christophe BAULT Andrea CATINACCIO Daniel DOBOS Heinz PERNEGGER Danilo GIUGNI Eric VIGEOLAS Didier LAPORTE Bart VERLAAT Collaboration of: SLIM SLIM project: A Stiff Longeron for ITK Modules Franck CADOUX Noemi CALACE Yannick FAVRE Didier FERRERE Sergio GONZALEZ SEVILLA Giuseppe IACOBUCCI Sébastien MICHAL Maarten WEBER

2. Slide 2 January, 27 th 2016 Sébastien MICHAL LONGERON PROTOTYPES Shell design: ▫ Minimum number of structural component ▫ Can follow highly complex shape design ▫ Easily manufacturable Base block Longeron

3. Slide 3 January, 27 th 2016 Sébastien MICHAL LONGERON PROTOTYPES Outer molds: ▫ Precision on outer surface for precise block positioning Three prototypes with several combination of fibers have been manufactured

4. Slide 4 January, 27 th 2016 Sébastien MICHAL SHELL LONGERON DEFLECTION Information about composite plies from test and manufacturer information T300/epoxyM55J/epoxyK13C/epoxy 453635 556465 176019102200 1200 145415741703 54.652.849.7 45.447.250.3 T300/epoxyM55J/epoxyK13C/epoxy K13C/epoxy (measured) 106.5286454417 6.95.69.64.6 0.280.260.275 0.2 0.144 0.280.260.275 3.54.25.33.89 2.82.14.2 3.1 Based on calculation From manufacturer From analytical calculation From tensile test (LAPP) From ESAComp

5. Slide 5 January, 27 th 2016 Sébastien MICHAL EXPERIMENTAL MEASUREMENTS Fiber typeYoung modulus (GPa) T300107Skin HM M55J286Skin / inserts HM K13C417Inserts Skin Stiffening Inserts K13 cannot be used for skin because of limitation of bending radius

6. Slide 6 January, 27 th 2016 Sébastien MICHAL LONGERON PROTOTYPE Support frame: ▫ Load tests ▫ Modal analysis ▫ Metrology... Axis for simply support

7. Slide 7 January, 27 th 2016 Sébastien MICHAL LONGERON PROTOTYPE Simply supported load test: compare experimental measurements with FEA results: ▫ Find sources of discrepancies (material prop., geometry, contact…) Point of measure Masses Clamp (avoid local deformation) Cylindrical support

8. Slide 8 January, 27 th 2016 Sébastien MICHAL Simply supported MASS (gr)Proto1 T300-K13 mesProto1 T300-K13 FEAProto2 T300-M55 mesProto2 T300-M55 FEAProto3 M55-K13 mesProto3 M55-K13 FEA 500-0.15-0.145-0.175-0.172-0.06-0.062 1000-0.3-0.29-0.35-0.344-0.115-0.124 1500-0.45-0.435-0.52-0.516-0.18-0.186 2000-0.59-0.58-0.68-0.688-0.24-0.248 2500-0.75-0.725-0.84-0.86-0.3-0.31

9. Slide 9 January, 27 th 2016 Sébastien MICHAL Simply supported MASS (gr)Proto1 T300-K13 mesProto1 T300-K13 FEA Proto2 T300-M55 mes Proto2 T300-M55 FEAProto3 M55-K13 mesProto3 M55-K13 FEA 500-0.16-0.164-0.185-0.184-0.05-0.058 1000-0.32-0.328-0.38-0.368-0.11-0.116 1500-0.49-0.492-0.56-0.552-0.16-0.174 2000-0.65-0.656-0.75-0.736-0.215-0.232 2500 -0.27-0.29

10. Slide 10 January, 27 th 2016 Sébastien MICHAL LONGERON PROTOTYPE Lateral load test: no rotation of the flanges (fix boundary condition) ▫ First try with support frame rotated was not performing well: design of new brackets Point of measure Masses Maarten WEBER

11. Slide 11 January, 27 th 2016 Sébastien MICHAL Lateral deflection MASS (gr) Proto1 T300-K13 lat mesProto1 T300-K13 lat FEAProto3 M55-K13 LAT mesProto3 M55-K13 LAT FEA 500-0.06-0.058-0.03-0.0296 1000-0.13-0.116-0.05-0.0592 1500-0.195-0.174-0.08-0.0888 2000-0.26-0.232-0.11-0.1184 2500-0.335-0.29-0.145-0.148

12. Slide 12 January, 27 th 2016 Sébastien MICHAL Lateral deflection MASS (gr)Proto1 T300-K13 lat mesProto1 T300-K13 lat FEAProto3 M55-K13 LAT mesProto3 M55-K13 LAT FEA 500-0.07-0.058-0.03-0.032 1000-0.15-0.116-0.07-0.064 1500-0.235-0.174-0.105-0.096 2000-0.32-0.232-0.125-0.128 2500-0.4-0.29-0.16 Load to high (Buckling)

13. Slide 13 January, 27 th 2016 Sébastien MICHAL Mechanical performances FEA model of the prototype longeron is compliant with the experimental measurements performed at UNIGE ▫ Results will be cross checked / validated with modal analysis Last longeron design of 1.6 m long for layer 2-3 is performing:  460 µm simply supported  58 µm fix  200 µm lateral simply supported  36 µm lateral fix Full mass under gravity sag Worst TFM for layer 2-3 -177 grams per top cooling line -157 grams per bottom cooling line -220 grams of longeron + Cooling pipe TFM 15 Al-Cf TFM 12 Al-diamond

14. Slide 14 January, 27 th 2016 Sébastien MICHAL NEXT OPTIMIZATION STEP Considering simply supported staves of 1.6 m long for L23 fully loaded. M55J longeron [90,30,-30] (no K13 inserts) Coupling of longerons using brackets  62 % stability improvement (from 0.8 mm down to 0.3 mm) Brackets

15. Slide 15 January, 27 th 2016 Sébastien MICHAL NEXT OPTIMIZATION STEP Skin Layout [90,30,-30] to [-60,0(K13),60] ▫ 20 % bending reduction  Simply supported: 460 µm down to 370 µm  Fully constrained: 58 µm down to 47 µm

16. Slide 16 January, 27 th 2016 Sébastien MICHAL THERMAL PROTOTYPES: TFM validation Two prototypes of 30 cm long for barrel and tilted parts are being assembled. ▫ Two types of blocks:  Al-Cf  Graphite ▫ Standard or Bi-phase interface ▫ Various flavor of glue

17. Slide 17 January, 27 th 2016 Sébastien MICHAL