LHQ Curing Mold

Miao Yu

Fermilab

07/26/2011

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HQ and LQ Curing

HQ coil curing (LBNL)

LQ coil curing

• For HQ, the pressure of the mandrel cylinder is set at 500 psi• The pressure of the main cylinder is 2,500 psi and the cavity is closed.• Hold the platen position during curing. • The pressure of the main cylinder increases to 3,500 psi.

• For LQ, the pressure of the mandrel cylinder is set at 600 psi• The pressure of the main cylinder is 750 psi and the cavity is closed.• Keep the pressure in both the mandrel cylinder and the main cylinder during curing. • Adjust the platen position.

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LHQ Curing Mold

• Modification on the HQ curing mold cross-section.

9.25[234.95]

0.25

2.75[69.85]

Die spring 1” OD * 1.25” LengthMax. load: 321 lbs (Mcmaster)

10.000 [254.0]

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LQ Mold Deflection

5.5 µm

4.3 µm

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HQ Mold Deflection

14.9 µm

8.3 µm

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LHQ Mold Deflection

19.7 µm

8.8 µm

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Curing Pressure

Mandrel Cylinder (pump psi)

Main Cylinder (pump psi)

Mandrel Support (MPa)

Coil (MPa)

TQ 600 2000 0.7 17.9

LQ 600 750 1.4 24.5

HQ 500 2500 (3500) 0.4 19.5 (27.3)

LHQ 1250 1015 1.4 20

Note: the cylinder pressure is converted to the effective load• TQ Press: Mandrel cylinder (6), 10,000 pump psi ~ 10 tons Main cylinder (7), 10,000 pump psi ~ 60 tons• LQ & LHQ Press: Mandrel cylinder (24), 10,000 pump psi ~ 15 tons Main cylinder (28), 10,000 pump psi ~ 200 tons• HQ Press: Mandrel cylinder (7), 10,000 pump psi ~ 10 tons Main cylinder (10 + 4), 10,000 pump psi ~ 55.2 tons + 25.8 tons

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EDM Block or Lamination

168 ’’ long 2” EDM block

168 ’’ long 1/16” Lamination

348 ’’ long 1/16” lamination

• The short assembly requires the steel cylinders as the spacers put in between the top and bottom platens.

40 transport systems (wheel assembly)Max. load: 321*40 = 12,840 lbs

348” mold cavity weight: ~6600 lbs160” coil envelop weight < 1700 lbs (SS)348” coil envelop weight < 3700 lbs (SS)

Rods+heaters+tie bars+… : ~500 lbs

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Comparison of Cost Estimation

Method/Category M & S Tech Labor EDIA Total

348” EDM $217 k $23 k $52 k $291 k ± 58 k

168” EDM $109 k $15 k $52 k $176 k ± 35 k

348” Lamination $91 k $24 k $52 k $167 k ± 33 k

168” lamination $71 k $15 k $52 k $138 k ± 28 k

*Note: the cost of the cylinders for the168’’ long mold was not included.

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Cost Estimation for LaminationLHQ 348" Curing Mold Assembly

Variation 20% $ 33,000 Sub-total $ 167,000

M & S $ 91,072 Tooling unit amount $/unit $ 42,440

Lamination stamping die ea 1 $ 30,000.00 $ 30,000 Final stamping profile, Note 1Pre-notch die ea 1 $ 10,000.00 $ 10,000 Pre-stamp for stress-relief, Note 1Short-stack tooling ea 1 $ 600.00 $ 600 Stacking 2' stacksStacking tooling ea 1 $ 1,200.00 $ 1,200 ~7' stack on inclined tableMandrel for emery cloth ea 2 $ 320.00 $ 640 Polishing profile interior

Mold parts unit amount $/unit $ 48,632 1050 Sphero Annealed Steel lbs 11200 $ 1.60 $ 17,920 Note 1 2.01#/Lam @$.80/#Stamping ea 5600 $ 1.02 $ 5,712 Note 1Tie bars (staggered pieces) set 6 $ 120.00 $ 720 Tie rods (welded at FNAL) ea 6 $ 480.00 $ 2,880 Wheel assemblies assy 40 $ 420.00 $ 16,800 Top shim plates ea 8 $ 550.00 $ 4,400 Hardened, counterboredHardware, misc lot 1 $ 200.00 $ 200

Total Labor $ 76,216 Technician /hr $100 techs hrs/tech qty parts $ 24,376

Clean 5600 laminations 2 16 1 $ 3,200 Inspect 10% to verify crown 1 4 1 $ 400 Stack short stacks 2 1 15 $ 3,000 Weld short stacks $112/hr 1 1 15 $ 1,680 Attach wheel assemblies 2 1 40 $ 8,000 Align on transfer table 2 8 1 $ 1,600 Weld tie rods (set of 6) $112/hr 1 8 1 $ 896 Dress welded tie rods (set of 6) 1 4 1 $ 400 Assemble with tie bars 2 8 1 $ 1,600 Polish contour with emery cloth 2 16 1 $ 3,200 Inspect assembly 1 4 1 $ 400

EDIA num. wks pay rate/hr $ 51,840 ~ 0.25 FTEEngineer 1 6 108 $ 25,920 Designer 1 3 108 $ 12,960 Drafter 1 2 108 $ 8,640 QA 1 1 108 $ 4,320

Notes: 1) The above utilizes material values supplied by TD's Q&M Material Control Group. 2) Machining of short stacked packs can be more cost effective by mounting multiple stacks on the mill to make the cuts. 3) Heating element are excluded from this estimate. 4) EDIA: Engineering, Design, Inspection and Administration. 5)Sharpen the die after 3,000 pieces of lamination.

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Conclusion

• The HQ curing mold cross-section can be modified to fit in the curing press.

• The deflection of the LHQ cavity is simulated and compared with the other curing cavities.

• The LHQ coil deflection in x-direction (open) during curing process is less than 8.6 µm.

• The cost of mold assembly using 2”EDM block and 1/16” lamination is estimated and compared.

• The long mold lamination assembly is preferred, and the total cost is estimated.