preliminary calculation of the tracking detector barrels and the support tube szymon sroka clicdp...

Preliminary Calculation of the Tracking Detector Barrels and the Support Tube

Szymon Sroka

CLICdp Tracker Technology Meeting

Szymon Krzysztof Sroka 30/07/2015

2Szymon Krzysztof Sroka 30/07/2015

Presentation Layout

I. Tracking Detector

Barrels General Description

Analytical Solution

Comparison to FEA solution

Different Lay-ups

III. Beam Pipe & Support Tube Beam pipe

- Dimensions

- Support

- FEA Calculations

Support Tube - FEA Calculations

IV. Conclusions & Outlook

II. Conclusions


Tracking Detector Barrels


General Description Current tracker dimensions

Gap for services of inner region (cables + air cooling ducts) and connection of support tube to the ECAL barrel

Tracking Detector Barrels – Dimensions

Number of

Barrels

Radii of Barrels [mm]

Length of

Barrels [mm]

Thickness of Honeycomb Core [mm]

Thickness of CF Skins [mm]

Mass of each

Barrel [kg]

1 230 860 10 0.6 2.853 840 2060 15 1.2 48.14 1145 2660 25 1.2 90.15 1450 3260 25 1.2 140

Basic Requirements:

- Lightweight structure

- minimizing the radiation length

- Maximum deflection in the range of 100 [µm]


General DescriptionComposite Construction

Benefits of HONEYCOMB Sandwich Construction:Analogy Sandwich Panel to an I-Beam

The facing skins of a sandwich panel can be compared to

the flanges of I-beam. They carry the bending stresses to

which the beam is subjected. With one facing skin in

compression and the other is in tension.

The Honeycomb Core corresponds to the web of I-beam.

The core resists the shear loads, increase the stiffness of

the structure by holding the facing skins apart


General DescriptionCross section of the Barrels

T2T1

Inne

r D

iam

eter

T1

Out

er D

iam

eter

Honeycomb Layer

CFRS Layer

Deflection of Barrel

Natural 1. vibration mode of Barrel

Materials - choices (as an example)CF Skins - Toray M55J + Cycom 950-1

Honeycomb Core - XRH-10/OX-3/16-1.8


General Description Different Honeycomb Features

Material Property Honeycomb Advantages

Foam includes

- polyvinyl chloride (PVC)

Relatively low crush strength and stiffness Excellent crush strength and stiffness

- polymethacrylimide Increasing stress with increasing strain Constant crush strength

- polyurethane Friable Structural integrity

- polystyrene Limited strength Exceptionally high strengths available

- phenolic Fatigue High fatigue resistance

- polyethersulfone (PES)

Cannot be formed around curvatures

OX-Core and Flex-Core cell configurationsfor curvatures

Wood-based includes

- plywood Very heavy density Excellent strength-to-weight ratio

- balsa Subject to moisture degradation Excellent moisture resistance

- particleboard Flammable Self-extinguishing, low smoke versions available


General DescriptionSandwich Structure – Failure Modes1. Strength - Skin Compression failure 2. Stiffness – Excessive deflection 3. Buckling

4. Shear Crimping 5. Skin wrinkling 6. Intra cell buckling

7. Local compression


General Description Boundary Conditions

BC.s - Considered cases: Simply Supported

Clamped

Clamped – Simply Supported

Cantilever

BC.s - Considered cases: 2-vertices plus Elastic Support

4-vertices Support (the most extreme case in

the context of deflection)


Two gravitational forces:

- Own weight of the Barrels

- External load = Mass of Modules + Mass of Cold plates+ Mass of Power Buses

(Material budget for the modules, cooling system and cables was extrapolated for CLIC from ALICE’s upgrade project )

External Load

ComponentMateria

lThickness

[µm]

Module

FPC Metal Layer Aluminium 50

FPC Insulating Layers Polyimide 100

Module Plate Carbon Fibre 120Pixel Chip Silicon 300

Glue Eccobond 54 100

Cold Plate

Carbon fleece 40

Graphite foil 30Cooling pipe Polyimide 64Cooling fluid Water -Carbon Plate Carbon Fibre 120

Glue Eccobond 54 100

Power Bus Metal Layer Aluminium 200

Insulating layers Polyimide 200Glue Eccobond 54 100

General Description Loads from ALICE


Analytical SolutionFirst step; easy and simple caseSimplifications: Composite Laminate material (Matrix plus Fibres) and Honeycomb Core are considered as a homogenous,

isotropic material for the hand calculations

Carbon Fibre Skins are modelled as transversely Isotropic Material for FEA

Honeycomb Core is modelled as Orthotropic Material for FEA

The comparison between the hand calculations and FEA simulations was done without any Lay-up

BC.s - Simply supported

Carbon Fibre Skins (top and bottom one)- selected material Toray M55J + Cycom 950-1


Orthotropic Material An Orthotropic material has three planes of symmetry that coincide with the coordinate planes .

One plane of symmetry is perpendicular to the fibre direction, and to other two can be any pair

of plane orthogonal to the fibre direction. - The x-axis is aligned with the fibre direction

- The y-axis is in the plane of the layer and perpendicular to the fibres

- The z-axis is perpendicular to the plane of the layer and thus perpendicular

to the fibres.

Only nine constants are required to describe an orthotropic material.

Transversely Isotropic Material A transversely isotropic material has one axis of symmetry

Transversal isotropic materials are orthotropic materials characterized by isotropic material behaviour in

one material symmetry plane

A unidirectional layer has transversal isotropic material behaviour with the fiber direction as symmetry axis

- The z-axis is perpendicular to the plane of the layer and thus perpendicular to the fibres.

The number of constants to define is reduced to 5.

Analytical Solution


Analytical SolutionDeflections of the TD Barrels

1. Bending Deflection 2. Shear Deflection

Calculation of the deflection due to bending: Calculation of the deflection due to shear:

Assumption: B.C. - Simply supported Beam (Timoshenko Beam Theory)

Bending depends on the skins properties; Shear depends on the core properties

x

L

Q

Flexural Stiffness:

Shear Stiffness:


3. Total Deflection = Bending Deflection + Shear Deflection Flexural Stiffness:Shear Stiffness:

Analytical SolutionDeflections of the TD Barrels


Deflection of Barrels made of Sandwich Structure ( CF SKINS PLUS HONEYCOMB CORE)

Number of CASE 1

Number Of

Cylinders

Radii Of Barrels [mm]

Length Of

Barrels [mm]

THICKNESS OF CF SKINS

[mm]

THICKNESS OF

HONEYCOMB CORE [mm]

Mass Of each Barrels

[kg]

Mass of Equipment [kg]

Deflection of Barrels -

Handmade Calculations

[µm]

Deflection of Barrels - ANSYS

[µm]

Eigenvalue - Natural

frequency of Cylinders [Hz]

Difference between Handmade Calculations and

Ansys Simulations [%]

% Of Radiation Length of each Barrels - Mechanics [%]

% Of Radiation Length of each Barrel - SEN+COOLING [%]

% Of Radiation Length of each

Barrel - TOTAL [%]

% Of Radiation Length of Barrels - TOTAL SUM [%]

1 230 860 0.6 10 2.834 3.916 5.3949 6.2065 224.04 13.07661323 0.5368 1.012 1.549

9.387

2 525 1460 0.6 15 11.8989 15.159 15.5162 20.574 107.97 24.58345485 0.572 1.001 1.573

3 840 2060 1.2 15 48.018 33.396 21.4647 31.048 67.21 30.86607833 1.0385 1 2.039

4 1145 2660 1.2 25 90.0349 59.113 36.6811 55.585 57.897 34.00899523 1.1088 1.004 2.113

5 1450 3260 1.2 25 139.7364 91.449 55.0187 85.759 40.179 35.8449842 1.1088 1.004 2.113

Comparison to FEA SolutionAnalytical Calculations vs FEA simplistic model

1 2 3 4 50

10

20

30

40

50

60

70

80

90

100 Defl ection of Tracking Detector Barrels

Deflection of Barrels - Handmade Calculations [µm] Deflection of Barrels - ANSYS [µm]

Number of Barrels

Sag

[µm

]


Different Layup

Tracking Detector Barrels Configuration

number Lay -up

1 [0/-45/+45/+45/-45/0]

2 [90/-45/+45/+45/-45/90]

3 [90/-45/+10/+10/-45/90]

4 [0/-15/+15/+15/-15/0] !

5 [90/-15/+15/+15/-15/90]

6 [0/-75/+75/+75/-75/0]

7 [0/-45/90/90/-45/0]

8 [90/-45/0/0/-45/90]

9 [90/30/-30/-30/30/90]

10 [0/60/-60/-60/60/0]

11 [45/-45/0/0/-45/45]

12 [0/90/0/0/90/0]

13 [90/0/90/90/0/90]

Each Lay-up consists of 6 sub-layers

Thickness of 1 sub - layer:

- 100 µm (Thickness of CFS -0.6 mm)

- 200 µm (Thickness of CFS -1.2 mm)

1730/07/2015

Tracking Detector Barrels – Dimensions

Number of Barrels

Radii of Barrels [mm]

Length of Barrels [mm]

Thickness of Honeycomb Core

[mm]

Thickness of CF Skins [mm] Mass of

each Barrel [kg]

1 230 860 10 0.6 2.85

3 840 2060 15 1.2 48.1

4 1145 2660 25 1.2 90.1

5 1450 3260 25 1.2 140

Different LayupFEA simulations in ANSYSThickness of CFS and Honeycomb Core

Second Barrel is not treated here. It was replaced by the Support Tube

30/07/2015 Szymon Krzysztof Sroka


1 2 3 4 5 6 7 8 9 10 11 12 130

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Defl ection of 1st Tracking Detector Layer

Deflection of TS Layers - for BCs Simply Supported [µm] Deflection of TS Layers - for BCs Clamped [µm]Deflection of TS Layers - for Invented BCs_1 (4E+2V) [µm] Deflection of TS Layers - for Invented BCs_2 (4V) [µm]Deflection of TS Layers - for BCs Clamped - Simply Supported [µm] Deflection of TS Layers - for BCs Cantilever [µm]Deflection of TS Layers - for BCs Elastic Support + 2_VERTEX for Xefs_1 [µm]

Lay-up

Sag

[µm

]

Different Layup ANSYS Results


1 2 3 4 5 6 7 8 9 10 11 12 130

20

40

60

80

100

120

Defl ection of 3rd Tracking Detector Layer


Lay-up

Sag

[µm

]

100 [µm] – Limit Value



1 2 3 4 5 6 7 8 9 10 11 12 130

50

100

Defl ection of 4th Tracking Detector Layer


Lay-up

Sag

[µm

]




1 2 3 4 5 6 7 8 9 10 11 12 130

50

100

150

200

250

300

Defl ection of 5th Tracking Detector Layer


Lay-up

Sag

[µm

]



22

Conclusions:


Comparison between Analytical and FEA calculations on ≤ 40 %

Deformation critically depending on specific Lay-up and Boundary Conditions

All Tracker Detector Barrels seem to be feasible and can obtain small deformation


Beam Pipe & Support Tube


Beam pipe - Dimensions

SSt

Be

CFRP

(based on modified CLIC_ILD design)

Objectives:

- Determining the z - location for the Supports in

order to minimize stresses in the sensitive

connection area between Beryllium & Stainless

Steel

Cylindrical Part1: R1=30 [mm], L= 308 [mm], T1= 0.6 [mm]

Conical Part2: R1=30 [mm], R2=240 [mm, L= 1820 [mm], T2= 4.8 [mm]


Conical part2

Cylindrical part3

Cylindrical part1

Support_1 Support_2

z1z2


Beam Pipe - SupportIterative identification of the supports location

Assumptions/ Simplifications: Based on the symmetry was modelled one quarter of the Beam Pipe.

In the first approach the beam pipe is supported in two places on the edges (only displacements in x-axis and y

axis are blocked).

During the determination of the support position, only solely weight of the Beam pipe is taken into account

Support_1 –> z=1750 [mm]

Support_2 –> z=350 [mm]

Be

SSt

Cylindrical part1

Conical part2


Conical Part2: R1=30 [mm], R2=240 [mm, L= 1820 [mm], T2= 4.8 [mm]


Cylindrical part3


1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 24000

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

2.2

2.4

2.6

2.8

Z - Location of the Support_1 vs Stresses for the fixed Location of Support_2 z = 350 [mm]

P10 - Support_loc1 (mm)

z - Location of the Support_1 [mm]

σ [M

Pa]



350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 17000

0.020.040.060.08

0.10.120.140.160.18

0.20.220.240.260.28

0.30.320.340.360.38

0.40.420.440.460.48

0.5

Z - Location of the Support_2 vs Stresses for the fixed Location of Support_1 z = 1750 [mm]

P9 - Support_loc2 (mm)

z- Location of the Support_2 [mm]

σ [M

Pa]



60 degrees

S1_T

S1_B

S3_T

S3_B

90 degrees

S1_T S1_T

S1_B S1_B

120 degrees

S2_B S2_B

S2_T

Beam Pipe - SupportDesign Proposal of the Beam Pipe Support

29

Max.Defomration = 2.4 [µm]


Beam Pipe - FEA Calculations

Max.Defomration = 75 [µm]

σ. max = 0.63 [MPa]

Rod properties

Sn ln [mm] kn [N/mm]Pre-Load [N]

R.Force [N]

S1_T 428 1327.5 500 440

S1_B 428 1327.5 163 122

S3_T 428 1327.5 500 440

S3_B 428 1327.5 163 122

S2_T 537 1058 40 42

S2_B 538 1055 20 19

The results under its own weight:


Beam Pipe - FEA Calculations The results under its own weight and the pressure influence (UHV):

σ. max = 44 [MPa]Max.Defomration = 42 [µm]

Alert - Front flange of the Beam pipe only 1 mm thick !

Max.Defomration = 8210.9 [µm] !


Support Tube - FEA Calculations Assumptions for the analysis : Support Tube is also modelled as a sandwich structure (Cylinder consists of three layers; honeycomb core

including top and bottom carbon skin). We are considering two different Core thickness (15 and 30 mm) and two

different thickness of Carbon Fibres Skins (0.6 and 1.2 mm).

Boundary conditions are the same for each of the Tracking Detector Barrels

Loads in the performed analysis take into account the weight of the Support Tube and all the forces coming from

the beam pipe.

In the framework of FEA analysis have chosen only four layup

Support Tube Configuration

number Lay -up

1 [0/-45/+45/+45/-45/0]

6 [0/-75/+75/+75/-75/0]

11 [45/-45/0/0/-45/45]

13 [90/0/90/90/0/90]



Example:

CFS thickness – 1.2 [mm]

Honeycomb Core – 30 [mm]

Max.Local.Deflection – 207 µm

BC.s -Simply Supported

Layup 6

33

1 6 11400

450

500

550

600

650

700

750

800

850

900

Defl ection of Support Tube in terms of Layup (for CFS 0.6 [mm] and Core Thickness 15 [mm] )

Deflection of ST- for BCs Simply Supported (Core thickness - 15 mm )[µm] Deflection of ST- for BCs Clamped (Core thickness - 15 mm ) [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 15 mm ) [µm] Deflection of ST- for BCs Elastic Support for Xefs_1 + 2_VERTEX (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 15 mm ) [µm]

Lay-up

Sag

[µm

]




1 6 11200

250

300

350

400

450


Deflection of ST- for BCs Simply Supported (Core thickness - 15 mm )[µm] Deflection of ST- for BCs Clamped (Core thickness - 15 mm ) [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 15 mm ) [µm] Deflection of ST- for BCs Elastic Support for Xefs_1 + 2_VERTEX (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 15 mm ) [µm]

Lay-up

Sag

[µm

]


35

1 6 11300

400

500

600


Deflection of ST- for BCs Simply Supported (Core thickness - 30 mm ) [µm] Deflection of ST- for BCs Clamped (Core thickness - 30 mm [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 30 mm [µm]Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm]

Lay-up

Sag

[µm

]



36

1 6 11150

250

350


Deflection of ST- for BCs Simply Supported (Core thickness - 30 mm ) [µm] Deflection of ST- for BCs Clamped (Core thickness - 30 mm [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 30 mm [µm]Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm]

Lay-up

Sag

[µm

]



37

Conclusions:


Front flange of Beam Pipe will need to be thicker as it, there is too much deformation under

vacuum.

From the results the Support Tube is suitable but there is some local deformation due to

gravitational load on the Beam Tube.

Outlook: Space Frame structure made of composite material maybe be valid for CLIC tracker -

investigation needed

Continuation work on Support Tube validation plus more detailed Beam Pipe analysis

preliminary calculation of the tracking detector barrels and the support tube szymon sroka clicdp...

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