1. Thermo-mechanical simulations jaws + tank
TDIS WP14 – Internal review meeting 2016/12/01
David Carbajo Perez (EN-STI-TCD)

2. Thermo-mechanical simulations jaws + tank
Introduction
Jaws material definition
Loads scenarios overview
RW heating
Vacuum tank simulation
Summary
Annex: temperature distribution plots
2016/12/01

3. Thermo-mechanical simulations jaws + tank
Introduction
Several simulations conducted to assess mechanical strength of the different jaw components against potential beam impacts.
Base for such studies is the output of Fluka energy deposition analysis presented by Matthias Immanuel Frankl.
In addition, thermal impact on the jaws due to impedance phenomena has been simulated.
Last but not least, vacuum tank structural simulation results are presented
2016/12/01

4. Thermo-mechanical simulations jaws + tank
Material definition overview id
Component Name
Material
Remarks 1
Absorbing block
1st / 2nd segments: Graphite R4550
3rd segment:
Aluminum Alloy EN-AW-5083 O – H111
CuCr1Zr En annealed
Alternative material for 1st / 2nd segments: 3D CfC 2
Clamp
Stainless steel 304L EN 3
Stiffener
Aluminum Alloy
EN-AW-5083 O – H111
Significant drop of mechanical properties is observed after bake-out phase (Yield strength ≈ 110 MPa) 4
Cooling circuit
Copper Alloy UNS C70600
Alternative materials under investigation to improve cooling system thermal efficiency 5
Stiffener back plate 6
Compression spring
Stainless steel EN
Springs not considered in the simulation since thermal shock on them is not relevant 7
Cooling pipes support plate 8
Spring support plate
Copper Alloy UNS C10100 8 5 6 7 4 3 2 1
TDIS Jaw cross-section view
2016/12/01

5. Thermo-mechanical simulations jaws + tank
Run3 Standard beam - 2mm orbit error
Pulse bunches: 288
Pulse protons: 6.624E13
Pulse time: µsec
Loads scenarios overview P2
Direct impact on absorbing blocks
Shower effect
Large impact parameter
Grazing impact
Grazing impact (jaw misalignment)
1 sigma impact
1 sigma impact (jaw misalignment)
Small impact parameter P8
Direct impact on absorbing blocks
Shower effect
Central (large) impact parameter
Grazing impact
Grazing impact (jaw misalignment)
1 sigma impact
1 sigma impact (jaw misalignment)
Small impact parameter
Same conditions as P2
2016/12/01

6. Thermo-mechanical simulations jaws + tank
Run3 Standard beam - 2mm orbit error
Pulse bunches: 288
Pulse protons: 6.624E13
Pulse time: µsec
Loads scenarios overview – Shower effect on jaws
case #
jaw
injection point
impact type
most stressed components
thermal simulation
structural simulation
remarks 1 U P8
central impact parameter - shower
cooling pipes / stiffener
YES
some plastic deformation is observed on both cooling pipes and stiffener although the amount of distortion expected to be negligible for the function.
Further analysis required, including possible modifications on design. 2 M NO
thermal shock comparable to case #1 3 D
soft thermal shock 4 P2 5 6 7
0/1 sigma impact - shower
Graphite absobing block
Standard beam impact leads to lower temperature than BCMS beam 8 9
Alu/Cu absorbing blocks
High-Z blocks length and materials under analysis 10
0/1 sigma impact jaw misalignment - shower 11 12
U – upstream / M- middle / D- downstream
2016/12/01

7. Thermo-mechanical simulations jaws + tank
Loads scenarios overview – Shower effect on jaws
case #
jaw
injection point
impact type
most stressed components
ANSYS simulation
remarks 1 U P8
central impact parameter - shower
cooling pipes / stiffener
YES
some plastic deformation is observed on both cooling pipes and stiffener although the amount of distortion expected to be negligible for the function.
Further analysis required, including possible modifications on design
Stiffener - Plastic strain ca. 0.3%
Stiffener - Temperature distribution
U – upstream / M- middle / D- downstream
2016/12/01

8. Thermo-mechanical simulations jaws + tank
Loads scenarios overview – Shower effect on jaws
case #
jaw
injection point
impact type
most stressed components
ANSYS simulation
remarks 1 U P8
central impact parameter - shower
cooling pipes / stiffener
YES
some plastic deformation is observed on both cooling pipes and stiffener although the amount of distortion expected to be negligible for the function.
Further analysis required, including possible modifications on design
Cooling pipes – temperature distribution
Cooling pipes – plastic strain ca. 0.2%
U – upstream / M- middle / D- downstream
2016/12/01

9. Thermo-mechanical simulations jaws + tank
Loads scenarios overview – Focus on blocks Applicable for both P2/P8
Studies in the framework of the LIU-TCDI are taken as reference given the equivalency of the beam parameters
Graphite absorbing blocks
Simulations done by Inigo Lamas in 02/2015
High-Z absorbing blocks
2016/12/01

10. Thermo-mechanical simulations jaws + tank
Loads scenarios overview – Focus on blocks Applicable for both P2/P8
Studies in the framework of the LIU-TCDI are taken as reference given the equivalency of the beam parameters
Graphite absorbing blocks
Simulations done by Inigo Lamas in 02/2015
High-Z absorbing blocks
As indicated in the table 11, tensile stresses can reach up to 37 MPa (BCMS beam) in the case of the Graphite R4550. It must be noticed that measurements at EN/MME Mechanical Lab have revealed higher yield strength values that the ones shown there.
In the case of 3D C/C the safety margin is larger
For further details please refer to documents
EDMS (
TDI thermo-mechanical simulations: Boron Nitride versus Graphite 235th LHC Machine Committee 16/09/2015)
2016/12/01

11. Thermo-mechanical simulations jaws + tank
Loads scenarios overview – Focus on blocks Applicable for both P2/P8
Studies in the framework of the LIU-TCDI are taken as reference given the equivalency of the beam parameters
Graphite absorbing blocks
Simulations done by Inigo Lamas in 02/2015
High-Z absorbing blocks
Since the yield strength of the block Aluminum alloy drops after the bake- out stage down to 110 MPa (at room temperature) the stress level highlighted in the analysis turns out to be too high.
As alternative, Titanium was evaluated showing much better results.
No weakness detected on copper blocks.
2016/12/01

12. Thermo-mechanical simulations jaws + tank
RW heating
Resistive wall heating effect takes place while the beam passes between the jaws.
The considered input cycle is represented hereunder
Estimated total power loss injection : 1250 W
( 30% higher in case of 3D C-C! )
Beam injection
Beam circulation
5 hours
45 min.
Temperature evolution of the graphite
2016/12/01

13. Thermo-mechanical simulations jaws + tank
RW heating
Resistive wall heating effect takes place while the beam passes between the jaws.
It induces temperatures of 40°C in the graphite during injection and less than 30°C maintained over the beam circulating period.
Cooling system water temperature: 27°C
Estimated total power loss injection : 1250 W
( 30% higher in case of 3D C-C! )
Heat flux
2016/12/01

14. Thermo-mechanical simulations jaws + tank
Vacuum tank simulation
Most critical conditions take place at bake-out stage.
Max. stress level (63 MPa) is reached at the edges of the largest-area => lower than yield strength (100 Mpa)
Material: AISI Type 304L Stainless Steel (grade )
2016/12/01

15. Thermo-mechanical simulations jaws + tank
Vacuum tank simulation
Displacement of the pins that support the platines with the jaws :
Pin #
Displacement [µm] (direction) x y z u1 -4
-11 -9 u2 -3
-16 u3 5
-22
-21 u4
-28
-27 l1 6 3 2 l2 1 13
-12 l3 -2 15
-19 l4 14 u1 u2 u3 u4 l1 l2 l3 l4
Material: AISI Type 304L Stainless Steel (grade )
2016/12/01

16. Thermo-mechanical simulations jaws + tank
Summary
Stresses at the stiffener are on the borderline. Reinforcement options are currently under analysis
Cooling pipes expected to have a small amount of plastic deformation not critical for the function though. On the other hand, alternative materials such us pure nickel or pure copper will be assessed for thermal efficiency improvement
Graphite R4550 shows sufficient strength to be used as material for primary absorbing blocks
Aluminum absorbing blocks shall be upgraded to titanium ones (further simulations are in any case needed)
RW heating lead to over-time maintained temperatures lower than 30°C
No weakness detected on vacuum tank strength. Pins displacement below admissible threshold
2016/12/01

17. Thermo-mechanical simulations jaws + tank
THANKS FOR YOUR ATTENTION
2016/12/01

18. Thermo-mechanical simulations jaws + tank
Annex: temperature distribution plots
P8 central impact. Upstream upper jaw
stiffener

19. Thermo-mechanical simulations jaws + tank
Annex: temperature distribution plots
P8 central impact. Middle upper jaw
stiffener

20. Thermo-mechanical simulations jaws + tank
Annex: temperature distribution plots
P8 central impact. Downstream upper jaw

21. Thermo-mechanical simulations jaws + tank
Annex: temperature distribution plots
P2 central impact. Upstream upper jaw

22. Thermo-mechanical simulations jaws + tank
Annex: temperature distribution plots
P2 central impact. Middle upper jaw

23. Thermo-mechanical simulations jaws + tank
Annex: temperature distribution plots
P2 central impact. Downstream upper jaw