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EuCARD-WP7-HFMESAC Review of the dipole design

Engineering Design

Pierre MANILCEA/iRFU/SIS

January 20, 2011 @ Saclay

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Contents

• Inputs

• Magnet detailed geometry► Overview► Ends► Layer jump► Cable needs

• Structure detailed geometry► Overview► Focus► Masses

• Detailed engineering► Materials choice► Tolerances and machining

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• Magnetic inputs [1]► Cable properties► 2D magnetic layout

• Mechanical inputs [1]► 2D stress analyze► 3D conceptual study

• Constraints [2]► Specified straight section > 700 mm

Source: FRESCA2 test station requirements► Overall magnet length = 1500 mm

Source: EuCARD contract► Specified aperture = Φ100 mm

Source: EuCARD contract► Reaction furnace section = 350 x 200 mm

Inputs

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Magnet detailed geometry

[Draftsman: Jean-François Millot]

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Overview

• 1.5 m – long• Straight section length > 700 mm

✓

✓

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Preliminary test

• HW-bend is OK with this cable [3]• Ramp angle up to 25° possible• HW ‘safe radius’ ~ 500 mm• Circular end is OK• See Françoise’s talk

~R500

• Bare copper cable, HFM dimensions • Variable ramp angle• Versatile HW-bend geometry• 3 options for the end

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4 • Geometrical definition of the ends [2]► R > 500 mm (test)► Lss > 700 mm► Los > 0► htot < 200 mm► aperture 61 mm

Ends

α = 17°, R varies R = 700 mm, α varies

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• 17° ramp, R = 700 mm => Los = 24 mm, Lss = 730 mm (layer jump included) • Can be compared to HD2 [4]: 10° ramp, R ~ 350 mm• Slight differences between lead/return end

Ends details

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4 • Several options have been considered [5]

• ‘HW soft’ is selected

Layer jump

42423636

42423636

43423635(flat)

✓

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Layer jump details

Straight section(= 700 mm)

‘Chicane’in the top layer(over 28 mm)

HW-bend connection(in a plane)

to the bottom layer

Layer jump 3-4 [CATIA drawing]

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24 • ~ 1 km of cable for the dipole• ~ 50 km of strand

Cable needs

CABLE NEEDS

Sub-elementTheoretical

cable length (m)

+ 3% margin  

Double-pancake 1-2 223 230  

Double-pancake 3-4 253 260  

1 POLE 476 490  

FULL DIPOLE 952 981

in onepiece

4 pieces of cable

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• Shell-based structure principle from Berkeley [6]• Additional calculations are still needed• Connections (out of the structure) to be designed• Assembly process in Maria’s talk

Structure detailed geometry

[Draftsman: Pascal Labrune]

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Overview

Iron yoke

70 mm-thick aluminum shell

Axialpre-stress

system

COIL PACK

Coils 100 mm aperture(no bore tube)

Bladders and shims

Material colors:Coil Steel Aluminum Iron Titanium Aluminum-Bronze Insulation (Tooling)

1600 mm

2066 mm

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Focus: coil pack

Flexible insulation (~1 mm)

Vertical Pad171 iron laminations:MAGNETIL (LHC iron)

5.8 mm-thick

Horizontal Padin one steel piece

5 mm-thicksteel plates

No bore tubeRails, pole and

horseshoes potted with the coil

Steel wedges

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Focus: poles

Contactover 6 mm

Groove for midplane

shims

Layer jump template

Longitudinal positioning

notch

Vertical contacthere

Axial stop for midplane shim

500 MPaσeq peak@ 13 T

[1]

Titanium pole

Soft iron pole

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Focus: yoke

Notcheson both sides

for bladder positionning

Rod holes

Longitudinal Weld

Pinning holes x3

Yoke half250 iron laminations:MAGNETIL (LHC iron)

5.8 mm-thick

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Focus: axial compression system

Φ~30 mmaluminum rodsSteel end plates

(~100 mm)TO BE DIMENSIONNED

Hydraulic pre-stress tooling

of the SMC system [7]

Clearance for key insertion

Coil/Plate contact offsetwith grub screws

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Focus: bladders

• 14 bladders allowed [6]• 1.6 m-long (or 2 x 0.8 m-long)• Target pressure ~100 bars

Conical lock(700 bars)

Removable insertion shim

2 steel sheets (0.3 mm-thick)

Waterarrival

Laser-weld all along

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Focus: keys

• 6 keys• 1.6 m-long (or 2 x 0.8 m-long)• Versatile thickness (stack of shims)

Pin

Round chamfer all along

for insertion

Stack of shims(0 to 1000 μm)

Nominalsteel keys ‘sandwich’

(3+3 mm)

Handling hole

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24 • Magnet ~ 300 kg (copper density)• Structure ~ 10 300 kg (without magnet)

Masses

Sub-element Material Quantity Total mass (kg)  

Double-pancake 1-2 Insulated Nb3Sn* 2 138  

Double-pancake 3-4 Insulated Nb3Sn* 2 156  

Lower pole Titanium 2 38  

Upper pole Iron 2 57  

Horseshoes Steel 4 36

Rails Al Bronze 4 94

Midplane shim Steel 2 21

Horizontal Pad Steel 2 640

Vertical Pad Iron + Steel 2 1047

Wedge Steel 2 152

Yoke Iron + Steel 2 6 950

Shell Aluminum 1 1 020

Axial rods Aluminum 4 21

End plates Steel 2 200

Keys Steel 6 27

TOTAL 10 597

Pottedpoles:519 kg Coil pack:

2 379 kg

* See Philippe’s talk

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Materials choice

Material Parts 2D peakstress R Properties [8]

MPa MPa

Nb3Sn with NED insulation Coil 142 [150]

Magnetic steel Top pole 345* > 600

MAGNETIL iron laminations Yoke / Y-Pad 410* > 600 5,8 mm-thick sheets available at CERN

Steel AISI 316L X-Pad / Y-Pad 315 490-690 Solderable, amagnetic,resistant to corrosion

Titanium Ti-6-Al-4V Bottom pole 500 900

Al 2014 T651 (A-U4 SG)Shell 205

435 Solderable, machinable,limited resistance to corrosion

Al 7075 T651 (A-Z5GU) 485 Machinable, limited resistance to corrosion,limited solderability

• 2D stresses are supported• 3D stresses to be checked

Peak stress values from Attilio Milanese [1]* = corner value

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24 • Mostly conventional shape tolerances• Refined tolerances on key insertion planes and

bladder notches

• Lamination machining process• Outer shell:

► Outer diameter φ1140 mm► Overall length = 1600 mm, can be divided in several parts► Influence of the cylindrical tolerance between shell and yoke?► Can we allow roll welding?

Tolerances and machining

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Thank you

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References

[1] Fresca2 conceptual designA. Milanesetalk given this morning

[2] EuCARD-HFM dipole specification and baseline parametersMPWGEuCARD-HFM internal note, January 2011

[3] EuCARD-HFM : Rapport sur les essais de cintrage des têtes de bobine en configuration blocF.Rondeaux, A. Przybylski, P.ManilCEA report, ref. SAFIRS 00152 A, June 2010

[4] Design of HD2: a 15 Tesla Nb3Sn Dipole with a 35 mm BoreG. Sabbi et al.IEEE Trans. Appl. Supercond., 2005

[5] 21-10-10 - Status of the turns-by-turns modelP. Manil, J.-F. MillotEuCARD-HFM internal note, October 2010

[6] The use of pressurized bladders for stress control of superconducting magnetsS. CaspiIEEE Trans. Applied Superconductivity, vol. 16, Part 2, pp. 358–361, June 2006

[7] Mechanical Design of the SMC (Short Model Coil) Dipole MagnetF. Regis et al.IEEE Trans. Appl. Supercond., Vol. 20, 2010

[8] NF E 01-000 and NF A 50-451