1. SCT End-Cap FDR1/11/01 C.J.Nelson 1 Inner Detector SCT End-Cap FDR Summary of Prototyping and FE Analysis C.J.Nelson Rutherford Appleton Laboratory, CLRC Summary of documents; ATL-IS-EA-0001 ATL-IS-ER-0041 ATL-IS-TR-0011 ATL-IS-TR-0003 ATL-IS-EA-0002 ATL-IS-EA-0001

2. SCT End-Cap FDR1/11/01 C.J.Nelson 2 l Skin laminate: Tensile Good result E=112 Gpa Strength = 400 MPa l SandwichFWT Good result 2.5 - 3.9 MPa l 4 Point Bend : Good correlation Prototyping and FE Analysis Sample tests

3. SCT End-Cap FDR1/11/01 C.J.Nelson 3 Inspection of wingFrq test: Expt. Set-up Prototyping and FE Analysis Prototype Wing

4. SCT End-Cap FDR1/11/01 C.J.Nelson 4 Prototyping and FE Analysis Prototype Wing/ Modal Correlation

5. SCT End-Cap FDR1/11/01 C.J.Nelson 5 Prototyping and FE Analysis Structure FE Modelling ANSYS FEA -Shell 91 composite elements, 3 layers, thick sandwich Early Model ~2500 elements -Coarse mesh -discs attached to cylinder -mass only 100 kg Max defl ~0.12mm Nat freq ~8 Hz

6. SCT End-Cap FDR1/11/01 C.J.Nelson 6 Detailed Model ~37 000 elements -Fine mesh where reqd. -accurate apertures -cylinder flanges -12 point disc attachment -Mass 168 kg Max defl ~0.5 mm Nat freq ~6.4 Hz Prototyping and FE Analysis FEA :Detailed model

7. SCT End-Cap FDR1/11/01 C.J.Nelson 7 Detail of mesh at disc mounting positions Prototyping and FE Analysis FEA :Detailed model

8. SCT End-Cap FDR1/11/01 C.J.Nelson 8 Model showing constraints under wing tips Fixed (spatially as per plot) Front Wing: Y, Z-rotation Front Wing: X, Y, Z-rotation Rear wing: Z,Y, X-rotation Y-rotation and Z-rotation Rear wing: all 6 dofs Prototyping and FE Analysis Model constraints

9. SCT End-Cap FDR1/11/01 C.J.Nelson 9 Vertical deflections (mm) under gravity and operating temperatures Predicted vector deflections (mm) Prototyping and FE Analysis Load Case 1: Initial conditions -Deflection

10. SCT End-Cap FDR1/11/01 C.J.Nelson 10 Prototyping and FE Analysis Load Case 1: Initial conditions -Stresses

11. SCT End-Cap FDR1/11/01 C.J.Nelson 11 Prototyping and FE Analysis Load Case 2: Initial conditions including worst case CME;

12. SCT End-Cap FDR1/11/01 C.J.Nelson 12 Prototyping and FE Analysis Load Case 3: Temperature Variation Conditions Upper half of cylinder : 5 deg above expected All discs : 5 deg above expected Results

13. SCT End-Cap FDR1/11/01 C.J.Nelson 13 Prototyping and FE Analysis Modal Analysis Very similar modes to early model, but with extra mode for ITE

14. SCT End-Cap FDR1/11/01 C.J.Nelson 14 Prototyping and FE Analysis Random Analysis Results from psd analysis of early model

15. SCT End-Cap FDR1/11/01 C.J.Nelson 15 l Tests have been done to confirm material properties and modelling l Prototyping has proved manufacturability of proposed sandwich with Korex l Detailed model confirmed early results l Predicted deflections, stresses are acceptable l Structure is fit for purpose! Prototyping and FE Analysis Conclusions