1. MICE Target Mechanical Design
Contents
Status of modelling and drawing
Work being undertaken at RAL on shaft and bearing prototypes
Procedure for shaft manufacture to ensure straightness QA
Procedure for alignment of bearings in core
Manufacturing ‘database’
Cut-off date
Assembly location (discussion)
Stator

2. MICE Target Mechanical Design
Status of drawings
All modelling complete bar few last minute changes (prototyping) see later
Shaft piece parts and assemblies finished, ready for checking
Engineering check (N Sage provisional)
Tecvac OK for coating
W/S OK for manufacturing
Weld contractor OK for joining (also for jigging)

3. MICE Target Mechanical Design
Status of drawings
Bearings almost ready for checking
Engineering check (N Sage provisional)
Tecvac OK for coating
W/S OK for manufacturing
Core drawings to be finished (AL)
Overall assembly drawing (JT)
Parts list
Peripheral parts to be drawn (TJ)

4. MICE Target Mechanical Design
Prototype work at RAL
Shaft
Conventionally turned top section accurate size but not straight
Use centreless grinding technique (size, geometry, finish) shaft design changed
Cutting 1 flat bends shaft (as expected!)
Use very small cuts (stress zone ~ depth of cut)
Flat on both sides – 3 stage production
Socket prototype
Taper socket with shallow angle to centre and align top and bottom sections (preferred by weld contractor)

5. MICE Target Mechanical Design
Prototype work at RAL
Bearings
Can be bored accurately but best with pre-ream
Polishing showing ‘bell-mouthing’
Location in housing using taper or close fit
About 1mm square

6. MICE Target Mechanical Design
Recent changes
Shaft
Double flat
Taper joint
Bearings
Thickened base bearing
‘Start part’ with features for machining
Taper OD for location (parallel option too)
Core Assembly
Decreased vacuum tube length to allow taper location of bearings

7. MICE Target Mechanical Design
Shaft Procedure – (up to 4 shafts)
Rough m/c & straighten stock materials
Rough turned as necessary
Stress relieve heat treatment
vacuum oven
650degC 30 minutes
Max rate heat & cool to minimise grain growth
Review oven cycle from print-out
Final machine upper shaft
Centreless grind to size
Return to RAL for Metrology
Machine on features on upper shaft
Polish bearing regions(?) then Metrology to determine Ra Rz etc

8. MICE Target Mechanical Design
Shaft Procedure...
Pre-weld assembly
Upper shaft press on rough machined socket
Lower shaft fit stop
Weld on socket & stop
Undertaken in chuck in EB (Electron Beam) welder
Rapid weld in precise location minimises heat (added to low thermal conductivity of Ti = minimal HAZ)
Procedure variables and QA schedule agreed with contractor
Final machine socket ends of upper and lower shaft
Machine to fit on taper
Partner pieces identified

9. MICE Target Mechanical Design
Shaft Procedure...
Press fit (with T)
Involve metrology to ensure geometric location between bearing sections
Weld both together
Requires jig with bearings and compliant couple to powered chuck in EB welder
2nd Stress relieve heat treatment
Vertical orientation (under tension?)
Metrology
Relative location of 2x bearing sections

10. MICE Target Mechanical Design
Shaft Procedure...
DLC Coating
Clean
Coat
Tecvac to advise on QA
Metrology
Final check on dimensions and geometry of bearing sections
Where manufactured outside CofC required
Transportation
Transportation boxes required (2 off with capacity for 4 shafts each (= despatch flexibility)

11. MICE Target Mechanical DesignQA
Materials
Certificates
Element analysis (Bodycote)
Size & geometry
Dimensional measurements (RAL Metrology)
Surface Finish
Surface trace (RAL Metrology)
DLC coating (Tecvac to advise)
Adhesion test
Wear test on swatch
Print out of cycle

12. MICE Target Mechanical Design
QA...
Welding
NDT method on shaft (e.g. X-ray)
Tests on pre- & post-production samples undertaken immediately before/after shaft weld
Section & micrograph
Tensile test (qualification of procedure?)
Request definition of ‘quality weld’
Heat Treatment
Cycle data from vacuum oven
Copy of certificate of calibration of vacuum oven
Swatch testing

13. MICE Target Mechanical DesignQA
Recording information
Traveller document linked to specific shafts
Method of identifying particular shaft
Sign off at each stage with sign off criteria
Prototyping
Enables definition of what is achievable on drawing, quicker sign off

14. MICE Target Mechanical Design
Bearing - Core Procedure
Bearing production
Machine ‘start part’
Send off for wire cutting of wedge (Di-Spark or ICL?)
Inspect fit upon return
Add features to clamp wedge
Add dowels
Add bores (incl. polish) and turn taper and part off (all in one)
Highly accurate location of bore to OD
Metrology
Add reverse features
DLC coat

15. MICE Target Mechanical Design
Bearing - Core Procedure
Core production
Produce core cap part (1130) with precision fit but not bearing recess - Metrology
m/c features of main core (1128) on general lathe & part off - Metrology
Add fixing holes to flange
Fit precision lathe with drilled flange and face off
Fit m/c core and clock concentric
Machine fit for cap
Add cap and machine bearing recess (use molyslip or similar!)
Remove, dowel on mill remove cap
Turn around and clock concentric
Add bearing recess

16. MICE Target Mechanical Design
Bearing - Core Procedure
Core production – Alignment features
Best alignment
Precision lathe for fine tolerance work (sole operator Eamonn Capocci)
Bearing ID / OD machined w/o changing position in chuck
Bearing holes machined in assembled parts on same dedicated jig using same reference datums
Taper fits on bearings & dowels to give consistent repeatable alignment
Dowelled cap on core body for accurate reassembly

17. MICE Target Mechanical Design
Manufacturing ‘database’
General assembly of MICE Target
Parts list used as BOM
Decide responsibility for:
Manufacture QA
Sign off etc
Individual item (critical) or batch log
Logs...materials certs, processes, when, where/who, inspection, sign off
Held by responsible

18. Schedule – for cut-off date
(V2)
No contingency