1. TMM of the CLIC Two-Beam Module T0 in the LAB – Proceedings to structural FEA Riku Raatikainen 22.8.2011

2.  Introduction -TMM geometry -Load condition -Cooling concept  Model description  Results  Discussion  Introduction -TMM geometry -Load condition -Cooling concept  Model description  Results  Discussion INDEX

3.  TMM was implemented to the CLIC Two-Beam module to be tested in the lab (Type 0)  As a first step, the FEM TMM had to be re-assembled to correspond current layout (including significant geometrical simplification to the 3D design, ST0312798_01)  After the simplification, the geometry was imported to ANSYS  Fluid network generation was done in parallel with CATIA and ANSYS Overview 3D model of the CLIC Test module in the lab (Type 0 – Type 0) - Courtesy of D.Gudkov

4. Waveguide DB QP PETS Vacuum reservoir PETS support DB cradle and movers; DB girder MB cradle and movers; MB girder AS support AS Load CMF DB side MB side TMM geometry

5. DB Q 410 W 110 W 150 W EDMS 1097388 Loading condition  In the lab no cooling is applied to the DB QP → shown thermal dissipation is suggestive and to be used only to heat up the magnets  In the lab the aim is to create an environment close to the unloaded operation of the CLIC module. Thus, for example, the PETS are heated up to 110 W (maximum reservation)

6. MB DB PETS SAS WG DB QP  Steady temperature variation of 5°C for the mock-up magnet was considered (based on the current reference value) – Courtesy of A. Bartalesi Thermal dissipations in TMM (LAB) 110 W 820 W

7. CLIC Test Modules - Meeting #44 Cooling concept (LAB) ItemDescriptionValue MB input flowmass flow68.6 kg/h PETS+WGmass flow37.4 kg/h HTC MBConvection to water5079 W/(m 2 ·K) HTC PETS+WGConvection to water1407 W/(m 2 ·K) HTC airConvection to air4 W/(m 2 ·K) Cooling boundary conditions; HTC: heat transfer coefficient.

8. BOOSTEC MC Master Slave Master  Adjacent girders will be interlinked with their extremities (so called cradle), allowing a movement in the transverse girder interlink plane within 3 degrees of freedom (X, Y, roll)  The ANSYS modeling was done to the level of the mounting surface of the actuator lower ends → As a results the estimated vertical and lateral stiffness of the actuator support was taken into account – both master and slave cradle end design were introduced to the model (Thanks to M. Sosin) Modeling Highlights - Supports Actuator stiffness was reduced to equal stiffness linear and torsional springs Master and slave supporting system in the lab (Type 0)

9. Modeling Highlights – Contact modeling  Contact and joint modeling includes flexible joint and standard ANSYS component bonded connections. Flexible joints can be defined analytically as a stiffness matrices. All the module subsystems are thermally coupled (perfect thermal conductance)  All contact modeling aimed at the lightest possible computation because of overall contact and joint number is in the magnitude of several hundred Contact and joint modeling illustration Stiffness matrix definition for the contacts. Note that ANSYS allows also damping coefficients as a direct input

10. Modeling Highlights – Meshing options  The ANSYS meshing had to be adjusted and optimized and several different configurations were implemented  The current mesh includes hexa and tetrahedral methods, element size control settings, Sweep, contact sizing etc. in order to achieve fine and appropriate mesh for the coupled field simulation. The mesh is highly relevant between the contact surfaces and interconnection areas where the fluid flow interacts with the solid structure (convectional area)  At the moment the model includes approximately 4.9 million nodes. The coupled FLUID116 element is the driving parameter to the fluid-thermal results  Solution time for the whole model takes > 10 h minimum with a virtual remote Engineering PC Created mesh for the lab module in ANSYS Workbench 13.0

11. Results Temperature distribution within the module. The highest surface temperatures are in magnitude of 42 °C; on the internal beam surfaces the temperature could rise up to 44 °C

12. Results The water temperature rise is approximately 10 °C as shown.

13. Total deformation of the module. The maximum deformation exceeds 500 µm. Results

14. Deformation of the MB under applied loading. The maximum deformation is 480 µm. ItemValue Max temp. of medium42 ˚C Water output temp MB35.0 ˚C Water output temp DB35.0 ˚C Heat to water / air3600/ 120 W Max. def. at MB line G41 µm Max. def. at DB line G30 µm Max. def. at MB line G, RF 480 µm Max. def. at DB line G, RF 340 µm Summary of the TMM results. G; gravity, RF; thermal dissipation.

15. Conclusion  The TMM has been successfully built to correspond the current complex.  The thermal results show that during the heating ramp up the temperature of the module rises over 40 °C. The highest temperature variations occur on the inner beam surfaces where the heaters are located.  The water temperature rise is 10 °C and the variation to the heat balance is less than 1 %. Though the thermal results can be considered reliable. Unlike with PETS average dissipation of 39 W, the 110 W thermal dissipation will drive the PETS and AS temperature closer to each other.  Structural analysis indicates deformation of several hundred micrometers during loading ramp-up. Note that the location of the maximum depends on which side the girder end a longitudinal fixed support is applied. From the fixed point MB side, for example, expands as a whole as a result of temperature variation.  The effect of gravity is naturally compensated in reality.  As a upcoming actions the TMM is applied to the CLIC module Type 0 with a both operation modes – unloaded and loaded – included. On basis of the new TMM geometry created for the lab module, different modules can be analyzed by modifying the current lab TMM module.