LHQ Curing Mold Simulation Analysis Miao Yu Fermilab 08/02/2011

LHQ Lamination Cross-section 2

Loading Sequence 3 Assumption: 1.p mandrel ~1.4 MPa & p coil ~20 MPa just close the mold. 2.Once the mold is close, all the increased pressure from the main cylinder is applied on the mold, p mold The maximum mandrel cylinder pressure is 15 tons (10,000 psi), which provides p mandrel 11 MPa on the mandrel block. The maximum main cylinder pressure is 200 tons (10,000 psi), which provides p coil 20 MPa on the coil and p mold 84 MPa on the mold. Steel 1050 annealed: σ y = 365 MPa F s = 3, σ allowable = σ y / F s = 121 MPa p mandrel p coil p mold

LHQ: Maximum Pressure on the Mold 4 p mandrel : 1.4 MPa, p coil : 20 MPa, p mold : 84 MPa σ max = 290 MPa d max = 99.3 µm

LHQ: Allowable Pressure on the Mold 5 p mandrel : 1.4 MPa, p coil : 20 MPa, p mold : 35 MPa σ max = 118 MPa d max = 44.1 µm Main cylinder: = 4761 psi

LQ: Maximum Pressure on the Mold 6 p mandrel : 1.4 MPa, p coil : 24.5 MPa, p mold : 86.4 MPa σ max = 250 MPa d max = 99.0 µm

LQ: Allowable Pressure on the Mold 7 p mandrel : 1.4 MPa, p coil : 24.5 MPa, p mold : 40 MPa σ max = 119 MPa d max = 48.0 µm Main cylinder: = 5032 psi

HQ: Maximum Pressure on the Mold 8 p mandrel : 0.4 MPa, p coil : 19.5 MPa, p mold : 282 MPa σ max = 296 MPa d max = 112 µm

HQ: Allowable Pressure on the Mold 9 p mandrel : 0.4 MPa, p coil : 19.5 MPa, p mold : 115 MPa σ max = 119 MPa d max = 48.5 µm Main cylinder: = 5552 psi

Main Cylinder Allowable Operation Pressure Pressure on Coil (MPa) Pressure on Mold (MPa) Main Cylinder Pressure (psi) LQ HQ LHQ To operate the curing press safely for LQ and HQ, the main cylinder pressure is suggested below the number in the above table. For LHQ, after the pressure on coil is known to close the cavity, the allowable main cylinder pressure can be re-calculated.