kdemo structural analysis p. titus june 26 2013. ! kdemo coil axisymmetric analysis pfcb 21 1,...

KDEMO Structural Analysis P. Titus June 26 2013

! KDEMO coil axisymmetric analysispfcb211, 1.52,0.70,.9,1.3,8,10 !CS12, 1.52,2.10,.9,1.3,8,10 !CS23, 1.52,3.50,.9,1.3,8,10 !CS34, 1.52,4.90,.9,1.3,8,10 !CS45, 2.98,8.31,.60,1.25,8,10 !PF16, 3.66,8.31,.60,1.25,8,10 !PF27, 4.34,8.59,.60,1.25,8,10 !PF38, 5.02,8.75,.60,1.25,8,10 !PF49, 12.96,7.50,.849,1.5 ,8,10 !PF510, 14.88,2.95,.4,.5 ,8,10 !PF611, 14.88,-2.95,.4,.5,8,10 !PF612, 12.96,-7.50,.849,1.5,8,10 !PF513, 5.02,-8.75,.60,1.25,8,10 !PF414, 4.34,-8.59,.60,1.25,8,10 !PF315, 3.66,-8.31,.60,1.25,8,10 !PF216, 2.98,-8.31,.60,1.25,8,10 !PF117, 1.52,-4.90,.9,1.3,8,10 !CS418, 1.52,-3.50,.9,1.3,8,10 !CS319, 1.52,-2.10,.9,1.3,8,10 !CS2L20, 1.52,-0.70,.9,1.3,8,10 !CS1L21, 6.1,0,2.1,4.2,8,10 !Plasma

pfcu21,3,1,1.01,7.68,3.11,-1.552,7.68,3.11,-1.553,9.65,3.25,-2.254,9.65,3.25,-2.255,2.323,4.506,5.7156,3.171,6.235,7.9097,3.475,6.169,7.8978,3.663,5.286,6.9149,0.021,-13.70,-15.9510,0.184,0.135,-0.22311,0.184,0.135,-0.22312,0.021,-13.70,-15.9513,3.663,5.286,6.91414,3.475,6.169,7.89715,3.171,6.235,7.90916,2.323,4.506,5.71517,9.65,3.25,-2.2518,9.65,3.25,-2.2519,7.68,3.11,-1.5520,7.68,3.11,-1.5521,0,13,13

KDEMO Poloidal Coil Analysis

Poloidal Field Vectors

Kdm1.dat

Kdm2.dat

Kdm3.datNot 11 Tesla

Nodal ForceVectors

Kdm1.dat

Kdm3.dat

Kdm3.dat

DEMO CS CICC Parameter (Corner Channel)• Cable Pattern: (2SC+1Cu)x3x4x4x6 [576 SC Strand + 288 Cu Strand]• Void Fraction : 35.85%• Strand :

– ITER Type (Jc ~ 1000A/mm2) Nb3Sn Strand– Cu/Non-Cu = 1.0

• NO COOLING SPIRAL Corner Channel• Jacket Thickness : 5 mm• Insulation : 2.0 mm (with Voltage Tap)

– 0.1 mm Kapton 400% – 0.4 mm S-glass 400%

• Twist Pitch– 1st Stage 20 ± 5 mm– 2nd Stage 45 ± 10 mm– 3rd Stage 85 ± 10 mm– 4th Stage 150 ± 15 mm– 5th Stage 355 ± 20 mm

• Wrapping Tape Thickness – Sub-cable : 0.08 mm 40%– Sub-cable wrap width : 15 mm– Cable : 0.5 mm 60% – Final wrap width : 7 mm

DEMO CS CICC Cross-section

54

34

20

40

R 32 5

50

30

Insulation

Jacket

Hoop Multiplier = 459/173.7 = 2.64

Initial MagnetizationKdm1.txt, kdem1.datBased on the hoop multiplier76.1*2.64 = 200 MPa

Starts at 662 then propagates into region that is about 200 MPa

ITER CS Conductor near Butt Weld ITER CS He Penetration

Starts at 356 then propagates into region that is about 325 MPa

Average Hoop Stress =5.327e7/1.17/1e6=45.5MPa

Initial Magnetization Check of Average Hoop Stress

Based on the CS hoop multiplierApplied to PF590.6*2.64 = 240 MPa

Based on the CS hoop multiplierApplied to PF5126*2.64 = 332 MPa

TF Case 2/3* yield = 666 MPa½ Ultimate = 750 Mpa1/3 Ultimate = 500 MPa

Sm, Primary Membrane Allowable = 666 MpaAccording to ITER MSDC

The average stress in the inner leg case should satisfy this Allowable

TF Case and Winding Pack Analysis

Meshed areas from Tom’s Parasolids

Initial Geometry Without Added Outer Structures

Base Cross Section, Reflected and Swept Along Tom’s Arcs

kdm1 Field Vectors

Nodal Force VectorsField Vectors

Kdm1 Theta Displacement

Kdm1 Tresca Stress


Allowable = 666 MpaAccording to ITER MSDC

Added Upper Structure

Adde

d O

uter

Str

uctu

re

Added Lower Structure

Model with 16 fold Symmetry, 12 fold symmetry Expansion

Model with Added Structure



Results with Added Structure

Still Doesn’t Pass

From the NSTX structural criteria.

"An exception to this elastic analysis approach can be when the nature of the structure and its loading make it difficult to decompose the stresses into the above mentioned categories. In such an instance, a detailed, non-linear analysis that accounts for elastic-plastic behavior, frictional sliding and large displacement shall be used to determine the limit load on the structure. The limit load is that load which represents the onset of a failure to satisfy the Normal operating condition as described in Section I-2.6. The safety factor of limit load divided by the normal load shall be greater than 2.0.“

Similar wording is in the ITER Magnet Structural Design Criteria (MSDC)

Try Elastic-Plastic Limit Analysis.Must Show a factor of 2 on failure (Non-Convergence in ANSYS Model)

Results with Load Factor of 2.0

Plastic Strain at Twice Normal Loading

Un-Loaded Results After Twice the Normal Loads are Applied

Old 2D TF Cross Section

An approximation of the options suggested by Keeman Kim is analyzed. The model Inner leg has an inner radius of 2.0m and OR = 3.14m. The inner wedged section is .286 m thick.

This section can support the centering load but depending on the position of the outer leg and the stiffness/strength of the outer structures, the inner leg cross section could be acceptable. However with only 27% of the vertical separating force on the inner leg, the cross section is inadequate.

Limit analysis is used to evaluate the section. With only the centering load, the load factor is above 3. With 27% of the bursting force applied to the inner leg, the load factor goes to only 1.5. It should be at least 2.0.

Heavy/stronger, and stiffer outer structures are needed to support ,most of the vertical bursting load.

The Bursting Force – is Applied on the Inner Leg Cross Section at a Coupled Node Set.

In the runs with the bursting load, 200MN is applied of the 11946/16 = 750 MN per coil, or 27% – The remainder is assumed taken by the outer structures

16 Fold Symmetry Expansion

Model Materials

Conductor Stress Strain

316 SST Stress Strain

Bmax=13.13

ANSYS Nodal Forces

ANSYS Displacement Constraints

ANSYS CP’s on Top Face

Vertical Separating Force is Applied on One of the Coupled Nodes on the Top Face

Von Mises Stress 2.5*Load

Von Mises Plastic Strain 2.5*Load

Excluding Vertical Separating Force

/DSCALE,1,20(20 times actual)

Including Scaled 200MN Vertical Separating Force

/DSCALE,1,20(20 times actual)

Radial Displacement Under Increasing Load

Collapses at Step 7 > 3 times the Nominal Load

Including Scaled Vertical Separating Force

Excluding Scaled Vertical Separating Force


Collapses at Step 3 or 1.5 times the Nominal Load


Collapses at Step 7 > 3 times the Nominal Load

Plastic Strain in the Nose

Remains Elastic up to Load Step 4, 2.0Times the Nominal Load



Conductor Total StrainNormal Loading Including 200MN Vertical Separating Force

Radial Total Strain

Theta Total Strain Von Mises Total Strain

Axial Total Strain

Normal Loading Including 200MN Vertical Separating Force

Normal Loading Including 200MN Vertical Separating Force

Insulation Von Mises Stress

kdemo structural analysis p. titus june 26 2013. ! kdemo coil axisymmetric analysis pfcb 21 1,...

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