Pure Tungsten HCal: ‘staircase’ design Structural analyses and possible optimizations

The design Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Basic Facts Total weight: c. 640 tons + weight of ECal Length: 3500mm Interior arc width: 494mm Exterior arc width: 972mm Internal radius: 1400mm

3 MODULES = 1 SECTOR ExternalMiddleInternal

TUNGSTEN PLATES INSERTION next plate screw spacer The first 6 plates are bolted together between spacers and the followings two by two A specific tool for insertion is needed due to the fragility of the plates side view First module ready to be assembled with the next

What has been looked at? Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Added rigidity of tungsten plates in single sector Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Added rigidity of tungsten plates in single sector Crane supports of single sector Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Added rigidity of pure tungsten plates in single sector Crane supports of single sector Initial analysis of individual pure tungsten plates Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Added rigidity of tungsten plates in single sector Crane supports of single sector Initial analysis of individual tungsten plates Initial analysis of entire module Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Added rigidity of tungsten plates in single sector Crane supports of single sector Initial analysis of individual tungsten plates Initial analysis of entire module Effect of the added load of the ECal Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What has been looked at? Initial analysis of single sector Added rigidity of tungsten plates in single sector Crane supports of single sector Initial analysis of individual tungsten plates Initial analysis of entire module Effect of the added load of the ECal Optimization Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Single sector Dimensions of note: Exterior shell/ plate: 75mm Interior shell/ plate: 46.5mm “Fins” External: 30mm Middle: 25mm Internal: 18mm 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Single sector - Deformation Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Single sector – V. Mises Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Analysis of added rigidity of tungsten plates to a single sector 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig) Model 1 (steel structure only): The Tungsten plates are represented by a virtual density. In this case, the tungsten is ‘dead weight’. Model 2 (both steel structure & the connected Tungsten plates): The plates are ‘bonded’ to the structure as opposed to bolted. The added rigidity of the plates will, in reality, not be so great. Both models are supported at the section’s external face, and are loaded under Standard Gravity.

Analysis of added rigidity of tungsten plates to a single sector 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane supports 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane supports 4 different configurations were chosen and compared 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “1” Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Crane support “1” -Deformation Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Crane support “1”- V. Mises Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Crane support “2” 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “2” -Deformation 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “2” – V. Mises 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “3” 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “3” - Deformation 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “3” – V. Mises 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

“Ideal” crane support 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

“Ideal” crane support - Deformation 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

“Ideal” crane support – V. Mises 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support “3” 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Crane support It is clear from the analyses where from one should support the sector while it is being hoisted by a crane during assembly. (This analysis will be useful again as comparison with the optimization of the number of contact regions between sectors). 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Simple Tungsten plate analysis 2 different plates were analyzed: 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Simple Tungsten plate analysis 2 different plates were analyzed: -The top plate of a sector, 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Simple Tungsten plate analysis 2 different plates were analyzed: -The top plate of a sector, -and the bottom plate of a sector 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Simple Tungsten plate analysis The bottom plate was also analyzed at 3 different thicknesses: -10mm -12mm -13,5mm 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig) 12mm appears to be a reasonable value

Entire Lattice Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009 Max. V. Mises: MPa. Max. Deformation: mm. *Virtual density applied = 62.55

Additional loading of the ECal The loading of the ECal is approximated by a remote force applied at the centre of the structure 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Additional loading of the ECal The loading of the ECal is approximated by a remote force applied at the centre of the structure And it acts on the inner surface of the HCal. 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Additional loading of the ECal 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

What next? Following the initial analyses, the next step was to see where the structure could be optimized, in doing so optimizing the tungsten’s surface area within the structure. Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What next? Possible optimization points of the structure: Contact regions between sectors Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What next? Possible optimization points of the structure: Contact regions between sectors “Fin” thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What next? Possible optimization points of the structure: Contact regions between sectors “Fin” thickness Exterior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

What next? Possible optimization points of the structure: Contact regions between sectors “Fin” thickness Exterior shell thickness Interior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of level of contact between sectors Three configurations were analyzed: Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of level of contact between sectors Three configurations were analyzed: -All 4 steel plates are connected Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of level of contact between sectors Three configurations were analyzed: -All 4 steel plates are connected -Only 3 steel plates are connected. Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of level of contact between sectors Three configurations were analyzed: -All 4 steel plates are connected -Only 3 steel plates are connected. -Only the 2 end plates are connected. Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

All 4 contact regions are in contact – an entirely homogeneous structure This is similar to the “ideal” crane support, as seen earlier. 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

1 steel plate is not in contact This is similar to crane support ”3”, as seen earlier. 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

2 steel plates are not in contact This is similar to crane support “1”, as seen earlier. 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Effect of level of contact between sectors 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Effect of “fin” thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009 External Middle Internal

Effect of “fin” thickness [mm] 4 different configurations of fin thicknesses were studied: Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009 DimensionsExternalMiddleInternal Conservative Original Optimal Extreme1512,59

27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Effect of exterior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of exterior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of exterior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of interior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of interior shell thickness Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009

Effect of different shell thickness configurations Considering a reasonable “fin” thickness configuration of (25, 20, 15), I took 4 models of the entire lattice, each with different exterior and interior shell thicknesses: Niall O Cuilleanain (Supervisor: H. Gerwig)27 August, 2009 Change of dimensionsExterior shell [mm]Interior shell [mm] Original Moderate6040 Optimal ?5030 Extreme3520

Effect of different shell thickness configurations 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Issues to be addressed What key areas should be modified next? 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Issues to be addressed What key areas should be modified next? The exterior shell thickness at both the 3 & 9 o’clock positions may be increased. 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Issues to be addressed What key areas should be modified next? The exterior shell thickness at both the 3 & 9 o’clock positions may be increased. The thickness of certain “fins” in the internal modules may be increased in order to sufficiently increase their compressive strength. 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

Conclusions Accounting also for construction issues etc., optimum values (for the moment) look like 50mm for outer shell, 30mm for inner shell and A fin thickness going from 14mm thickness inside smoothly to 26 mm at the outside, N.B. These values correspond to a fraction of ca. 5,5% of the total surface of a tungsten plate (and thus is lost for physics). 27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)

27 August, 2009Niall O Cuilleanain (Supervisor: H. Gerwig)