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HiRadMat Window Design report v3.0

HiRadMat Window Design report v3.0. Specifications v3.0. Interface between machine vacuum and Atmospheric pressure 10 -8 mbar / P atm Protective atmosphere !!! Aperture min 60 mm Resist to a proton beam size on the window : 1 s = 0.5 mm. “Beam Size at the TT66 Vacuum Window”,

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HiRadMat Window Design report v3.0

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  1. HiRadMat WindowDesign report v3.0 Michael MONTEIL - 12 April 2010

  2. Specifications v3.0 • Interface between machine vacuum and Atmospheric pressure 10-8 mbar / Patm • Protective atmosphere !!! • Aperture min 60 mm • Resist to a proton beam size on the window : 1s = 0.5 mm “Beam Size at the TT66 Vacuum Window”, C. Hessler, 26.02.2010 Michael MONTEIL - 12 April 2010

  3. Solution #5 : Be + C-C • Same as solution #4 but the pressure load is supported by a C-C plate • Simple window assembly • Thin thickness (no differential pumping…) • Be cannot pollute vacuum chamber unless C-C fail • Tight • Price of Be but no pumps Michael MONTEIL - 12 April 2010

  4. Solutions - Sum-up • #1: C-C (Differential pumping) • Protective atm (Nitrogen ?) • Radiations? • #2: C-C + Graphite foil (useless now) • #3: Tight steel “ring” with a C-C plate • #4: Beryllium • Safety problem • #5: C-C + Beryllium  Today Michael MONTEIL - 12 April 2010

  5. Different grades of Be Data: Brush Wellman Michael MONTEIL - 12 April 2010

  6. Different grades of Be • PF-60 ? • Low rate of Beryllium oxide compare to PS-200 • Good quality-price ratio (Next slides…) • 1.5 to 2 time cheaper than IF-1 • Almost the same temperature distribution as pure Be and IF-1 (IF-1 a bit better…) • Used in CNGS… Collaboration: J. Blanco Michael MONTEIL - 12 April 2010

  7. Design • Specification • Be & C-C • Aperture min. 60mm • DN80 or DN60 conical flange connection • 15 cm depth maximum • Remark • Cannot machine Be at CERN Michael MONTEIL - 12 April 2010

  8. Design • Common design – Choices • Standard flanges only (cheaper) • Be window assembled in lab between 2 flanges (safety) • Conical flange (faster assembly once in experimental area) • Design • Conical Flange (plug-in flange) • Tube (connection conical flange <--> conflat flange) • 2 x Conflat (Window in-between) Michael MONTEIL - 12 April 2010

  9. “CNGS” like CNGS HiRadMat – Option 1 Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 12 April 2010

  10. “CNGS” like Data: Brush Wellman Michael MONTEIL - 12 April 2010

  11. “CNGS” like Data: Brush Wellman Michael MONTEIL - 12 April 2010

  12. “TED @ TI2, TT40” – Beryllium version “TED @ TI2, TT40” HiRadMat – Option 2 Michael MONTEIL - 12 April 2010

  13. “TED @ TI2, TT40” – Beryllium version • Quote from BW Michael MONTEIL - 12 April 2010

  14. 2 design proposals Option 1 Option 2 Not that much Precautions for the assembly Non Standard conflat assembly (Tightness) Might be careful to not cut (shear cut) the Be foil during assembly • Life warranty on Be + flange assembly • Easy to assembly • Standard conflat assembly • Tightness OK • Not that much Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 12 April 2010

  15. 2 design proposalsCost estimationBe Foil Option 1 Option 2 Number of foil to order : 3 Spare : 1 Window installed : 1 “In case we break a foil while assembling” : 1 • Number of flange to order : 2 • Spare : 1 • Window installed : 1 Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 12 April 2010

  16. 2 design proposalsCost estimationBe Foil Option 1Flange Option 2Foil Nota: Those drawing are drafts. Above dimensions are not representative of the reality Michael MONTEIL - 12 April 2010

  17. About thickness, how does BW design their own Be foils? With (Thickness 0.25mm, radius 35mm, pressure 1.01 kPa, E 303Gpa, Poisson 0.08) Results • sedge= 305MPa > 275 Mpa !! • scenter= 297Mpa > 275 Mpa !! Data: Brush Wellman Michael MONTEIL - 12 April 2010

  18. However… • BW : “With confirm that your calculations with reference to the DB450277 assembly are correct and show over the recommended values, however, the assembly was designed using empirical data as well taking into consideration the calculated values. We have performed tests on this design and found it to be reliable, with units sold to customers over the years performing well under real-life conditions.” • Explanation • Because of plasticity effects, Be foil withstands 1 Atm (according to BW tests) even if Roark’s calculation says that it doesn’t withstand Data: Brush Wellman Michael MONTEIL - 12 April 2010

  19. To know • Be have ultra high resistance to fatigue cracking • High endurance strength level Data: Brush Wellman Michael MONTEIL - 12 April 2010

  20. Solutions #5stresses and deflection - C-C+Be under DP = 1 atm • Linear circular fixed support • 2 planes of symmetry • Geometry • Diameter f 80 mm • Thickness: 0.254 mm • Aperture: f 60 mm • Pressure 1 atm Michael MONTEIL - 12 April 2010

  21. ANSYS Study - Solutions #5stresses and deflection - C-C+Be under DP = 1 atm • Beryllium foil study • Smooth and continuous temperature distribution • Through-thickness energy deposition • Coefficient of Thermal Expansion varying with temperature • Be (pure elasticity): • Poisson’s ratio = 0.08 • High Re = 303 Mpa Michael MONTEIL - 12 April 2010

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  33. Conclusion: influence of gap reducing • So if we flatter the foil on the C-C, we reduce the Max stress (as shows ANSYS calculation with non plasticity model), maybe also stay in elastic domain (Bellow 275Mpa at room Temp).  We will manage to reduce this gap (flattering the Be foil as much as possible on C-C plate) Michael MONTEIL - 12 April 2010

  34. Easiness to reduce Gap C-C / Be Option 1 Option 2 - + Michael MONTEIL - 12 April 2010

  35. To do : • Order Beryllium • Delivery: 4 Weeks ARO for flanges (Option 1) • Delivery: 6 Weeks ARO fro foil (Option 2) • Assembly • Test Michael MONTEIL - 12 April 2010

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  37. V2.0 slides Michael MONTEIL - 12 April 2010

  38. Window geometry – C-C option • Carbon/Carbon composite: 1501 G from SGL • Cylindrical window • Diameter f 80 mm • Aperture f 60 mm • Thickness: 0.5 cm • Aperture (flange internal diameter): f 60 mm Michael MONTEIL - 12 April 2010

  39. Solutions #1 for C-C tightness problem:Differential vacuum (V2.0) • 1 Window C-C • Pumping speed needed: 2.3x108 l/s … • 2 Windows C-C with differential pumping • Pumping speed needed: 8.94x102 l/s OK ! • 3 Windows C-C with differential pumping • Pumping speed needed: 13 l/s Too low ?! Michael MONTEIL - 12 April 2010

  40. Solutions #1 • What about radiations in this area ? • Possible maintenance needed on the roots pump… • Protective atmosphere • Decreasing pressure in Vacuumside with serial pumps Michael MONTEIL - 12 April 2010

  41. Reference • P2 : Roots pump • 100 –> 1500 m3/h • 10-3 -> 10 Bar • P3 : Ion pump • 400 l/s Michael MONTEIL - 12 April 2010

  42. Solutions #2 for C-C tightness problem: Add a Graphite foil (v1.0) Solution #3 : Tight steel“ring” with a C-C plate (v1.0) Solution #4 : Beryllium Michael MONTEIL - 12 April 2010

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  44. ANSYS Study - Solutions #1stresses and deflection - C-C under DP = 1.4atm • Linear circular fixed support • 2 planes of symmetry • Geometry • Diameter f 80 mm • Thickness: 5 mm • Aperture: f 60 mm • Pressure 1.4 bar Michael MONTEIL - 12 April 2010

  45. ANSYS Study - Solutions #1stresses and deflection - C-C under DP = 1.4atm • Orthotropic properties : 18 plies [0°/90°…] • Smooth and continuous temperature distribution • Through-thickness energy deposition • Coefficient of Thermal Expansion varying with temperature and directions Michael MONTEIL - 12 April 2010

  46. C-C - Pressure load - Deflection 7.4 μm Michael MONTEIL - 12 April 2010

  47. C-C - Pressure load – Von-Mises 5.9 Mpa Michael MONTEIL - 12 April 2010

  48. C-C - Pressure load – Tsaï-Wu Michael MONTEIL - 12 April 2010

  49. C-C - Thermal load ANSYS input =FLUKA output • C-C | 1s = 0.5 mm | 1.7e11 p+ | 288 bunches • Axisymmetrical radial temperature field Radial T (°C) T (°C) R (cm) Z (cm) Depth Michael MONTEIL - 12 April 2010

  50. C-C - Pressure + Thermal load – Deflection 10.6 μm Michael MONTEIL - 12 April 2010

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