Industrialization Studies in the KEK Cavity Fabrication Facility (CFF) H. Hayano The 2nd workshop on SCRF Cavity Technology and Industrialization for the 2011 S. Yamaguchi, K. Ueno, T. Saeki, H. Inoue, Y. Ajima, Y. Watanabe, K. Enami, S. Koike, S. Kato, E. Kako, Y. Yamamoto, A. Yamamoto; KEK 1

KEK Cavity Fabrication Facility(CFF): main R&D Center cell R&D End-group R&D EBW Quality Control Technology ( multi-dumbbell, multi-cell, multi-cavity Jigs for EBW ) Deep Drawing Technology Fine-blanking (Water-jet cut) and Press-forming Technology ( End-group Jigs for EBW ) KEK initiative on mass-production technology R&D in CFF KEK also like to invite industry participation in CFF it will start soon. ✓ ✓ ✓ 2

KEK Cavity Fabrication Facility Building inside Plant clean room Chemical Room Trimming Machine Press Machine EBW Crane range Inspection area 19m x 14m clean room STF ATF 3

12 th April 2011 EBW delivery on April 12,

SST EBOCAM KS-110 – G150KM Chamber (Stainless Steel chamber) Main Machines in the facility EBWPressTrim AMADA digital-survo-press SDE t, 50stroke/min, 225mmstroke MORI VKL-253 Vertical CNC lathe Chemi-room Tape-cut Ceremony on July 13,2011 for EBW operation start. 5

Center Cell Fabrication R&D KEK 9cell cavity #0 (w/o HOM couplers) fabrication 6

Press, Trim, EBW R&D before KEK-EBW delivery by using EBW Job-shop EBW at Tosei-electrobeam co., Tokyo (SST-EBW) Cell Press at KEKTrimming at KEKStiffener Press at KEK BCP at KEK 7

Dumbbell EBW at Job-shop (Dec.2010 – Feb.2011) Total 13 dumbbells were fabricated. 8 of them went to cavity fabrication 8

stretching of dumbbell stiffener insertion after insertion Stiffener Insertion and EBW EBW settingStiffener EBW After Stiffener EBW 9

2 - Dumbbell EBW at Job-shop (Dec.2010 – Feb.2011) 10

30 June – Dumbbell, 8 - Dumbbell EBW at Job-shop (June.2011 – July 2011) Beam 8 July July

8 - Dumbbell EBW-Seam inspection * End-group fabrication will be done in September – October, 2011, right after delivery of Nb pipes. KEK –EBW machine will be used there. Center cell equater: typical seam Center cell equater: seam end 12

End Group Fabrication R&D 13

KEK-End-Group, KEK-HOM-coupler At First, we started HOM coupler fabrication study (1) Deep Drawing of HOM-cup, (2) Cut-out of holes, or Burring of holes. (3) Develop cost effective shape of tuning knob. (4) Press cut-out from thick plate, (5) Press cut-out of slope region, (6) Press forming into design shape 14

Blank diameter: 120mm Inner diameter : 40mm Cup height : 65mm One press-action Deep drawing First step study : Using existing press-setup, 1.5mm Nb sheets were deep-drawn into cup, by one press-action. 15

HOM-cup Tuning-Knob forming First step study : Using existing press-setup, deep-drawn cup bottom shape and knob were formed, by two press-action. Knob: 10mm diameter, 6mm height 16

Study of Press-forming is underway Water-Jet cut Press forming of Nb HOM Antenna press forming HOM Antenna forming 17

Mass-production R&D, others 18

Idea of Multi-action Press for cell forming 19 Conceptual design of automated cell-press KEK-Shinohara Press *Automated product transfer mechanism in the press machine are also under design.

20 reception Eddy-current scan Press forming TrimmingInspection CP stock EBW Bulk EP anneal Inspection Tuning machine Jacket Stock area AC power area Plant Simulation study using CFF housing area （ 53m x 30m ） Assuming Nb plates for cell, fabricated end-group parts are input, 200 working days/year, 2 shifts/day with 30 people times 2 shifts Max. production rate will be ~530 cavities/year, ~2650 cavities for 5years. Estimation of cavity production plant KEK-MHI Assuming that final treatment and vertical test will be done in other place. parts delivery shipping of jacketed cavity

21 cavities Vacuum vessel, themal shield KEK-Hitachi Cold-mass, thermal shield Estimation of cryomodule assembly plant Assembly Plant Analysis using KEK assembly hall area （ 120m x 50m ） Assuming VT-passed cavity, fabricated cold-mass parts, vaccum cessel are input, 200 working days/year, 2 shifts/day with 37 people times 2 shifts Max. production rate will be ~57 cryomodules/year, ~285 cryomodules for 5years. Assuming that cryomodule power test will be done in other place.

22 Concept of rotational jig for multi-dumbbell and end-parts EBW Conceptual Design Study

23 Concept of EBW rotational jig for multi 9 cell cavities Conceptual Design Study

Schedule Plan 24

CFF schedule plan for industrialization 7,8,910,11,12 1,2,3 4,5,6 7,8,9 10,11,121,2,3 4,5,6 7,8, KEK-#0 w/o HOM fabrication EP, VT EBW fixture development operation and upgrade 2012 KEK #1 KEK #2 KEK #3 Design of multi-dumbbell fixture EP, VT HPV application fabricationoperation and upgrade Design of multi 9-cell cavity fixture fabricationoperation and upgrade Design of endgroup EBW fixture KEK #4 KEK #5 KEK #6 EP, VT Jacketing HPV inspection Trim fixture development fabrication operation and upgrade Design Automated BCP fabrication operation and upgrade Design Deep-drawing, Forming press development Basic R&D deep drawing jig fabrication operation and upgrade Design of press- shape 2011 materials procurement CFF industrial production 2012 materials procurement Hayano’s proposal; June

STF Plans for cavity production and test CY2011 CY2012 CY2013 CY2014 S1-Global cryomodule STF phase-2 Phase2 Injector part operation as “Quantum-Beam Project” 1st Cryomodule Phase2 CM-2 construction or cavities replacement of CM-1 operation Phase-2 Injector construction Phase2 CM-1 cryomodule construction Cavity Fabrication Facility Startup & EBW jig constructionCFF Industrialization Operational (4 cavities/year) operation KEK EBW operational 1st cavity2 nd cavity, 3 rd, 4 th, …. operation finished CY2015CY2016 disassembly cavity replace operation 26 Start beam operation ILC Cryomodule operation Cavity Industrialization Start cavity replace 4 cavities/year from Industries

Summary R&D status of KEK Cavity Fabrication Facility Center cell R&D End-group R&D 1. EBW Technology Experience through KEK-#0 9-cell cavity (w/o HOM) production. 2. By using EBW job-shop, center cell part was finished its fabrication. 3. After Nb pipes delivery, end group fabrication will be done in September – October, 2011, by using KEK EBW. 1. R&D on Deep Drawing Technology, Press forming technology are on-going. 2. Using existing press setup, possibility of end group parts fabrication from Nb sheet and from Nb thick sheet is under demonstration. Mass-production Studies 1. Conceptual Design Studies on Press-forming and EBW is started. 2. Cavity production plant and Cryomodule assembly plant are in study. End 27 Cavities by CFF, and cavities from industries, will be tested in cryomodule.