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ELECTROMAGNETIC, THERMAL, AND STRUCTURAL ANALYSIS OF RF CAVITIES USING ANSYS 2.1 GHz 3-Cell Cavity Cliff Brutus 6/15/15 Job Name: 2.1ghz_Symmetry_4-25-15.

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Presentation on theme: "ELECTROMAGNETIC, THERMAL, AND STRUCTURAL ANALYSIS OF RF CAVITIES USING ANSYS 2.1 GHz 3-Cell Cavity Cliff Brutus 6/15/15 Job Name: 2.1ghz_Symmetry_4-25-15."— Presentation transcript:

1 ELECTROMAGNETIC, THERMAL, AND STRUCTURAL ANALYSIS OF RF CAVITIES USING ANSYS 2.1 GHz 3-Cell Cavity Cliff Brutus 6/15/15 Job Name: 2.1ghz_Symmetry_4-25-15

2 Overall Layout Waveguide RF Window Beam Direction Compact NEG and Ion Pump combination Arc Detector Viewport Cold Cathode Gauge Tuner Actuator Field Probe

3 Overall Layout Arc Detector Viewport Conceptual Cavity Support System RF Window

4 RF Contact Overall Layout HZB Tuner RF Contact

5 Waveguide Field Probe Port Field Probe Tuner Port RF Contact Beam Tube Port Copper Braze Joints Diamond tool for milling and turning Suggested RF surface < or equal to 0.2 micrometer or 8 micro inches

6 CAD ModelRF Analysis Thermal AnalysisStructural Analysis RF, Thermal and Structural Simulation

7 Full Model Symmetry RF Analysis The cavity is not symmetric about its mid-plane since field probe port is on one side. Model is simplified by removing all the flanges, bolts and some ports that are not needed in the analysis Then the model is constructed to take advantage of the symmetry of the cavity about the beam axis

8 CRITICAL AREAS: 0.0008 mVOLUME: 0.005 m 6,423,586 Elements Frequency: 2114781678.364 Hz BODY AREAS: 0.0015 m Regions near coupling slots, nose cones, waveguide and tuner are especially important for accurate frequency prediction Mesh density enhanced 6x in this region Maintains accuracy while keeping solution time convenient RF Analysis

9 Electric Wall AreasUnselected surfaces for BC 284,799 Nodes RF Analysis

10 E-sum Nodal Solution 3.509E6 V/m

11 H-sum Nodal Solution 1.372E4 A/m

12 Ez path from -0.146m to 0.207m E-field along beam axis

13 Thermal Analysis Must determine scaling factor for power dissipation -> used the integral of the E-field along the beam axis also the stored energy as a comparison Scaling Factor = sqrt(U 250k /U ansys ) = 3902790.61 Thermal loads Calculated heat flux on walls from RF solution (H-field) Cooling channel convection HF = ½ * H 2 * R

14 ANSYS Freq.2.1147816GHz U @ 250KV0.0096875 J Epk3.509E6 V/m Hpk1.372E4 A/m Integ. Ez280164.1656 V Q-factor13902.0013 Workbench reaction: - 4706.89 W for ½ model ANSYS APDL Total Est. Power Loss including Tuner9261.92W ANSYS Workbench Total Est. Power Loss including Tuner9413.78W Est. Power Loss on cavity surface8728.58W Est. Power Loss on tuner685.2W Est. Power Loss on windowTBDW >> For the window, Binping has not finish the design to move the window further away from the cavity. Scaling Factor = sqrt(U 250k /U ansys ) = 3902790.61 Est. Power Loss @ 200KV = 5927.630773 W Est. Power Loss @ 250KV = 9261.923084 W -202.36 W -1127.4 W -166.83 W -342.6 W-2867.7 W

15 2.856 GHz ELI-project Manufacturer: RI

16 Nose Cone and Coupling Slots Cooling Numerous engineering analyses carried for design validation

17 Nose Cone and Coupling Slots Cooling

18 ODIDx = yR 15.889.523.181.5mm 0.6251950.3748020190.1251960.059055in Flow3GPM h 12131 W/m^2-K Velocity 8.71 Ft/sec h = 24262 W/m^2-K ID=.1875in Flow1.5GPM Velocity17.43Ft/sc 340.2 K Worst Case Water Ambient Temperature : 305.15 K Thermal Simulation # 8494 h = 13153 W/m^2-K Dh=.2634in Flow1.5GPM Velocity8.83Ft/sc

19 Sliding and Rotating Support Structural Simulation Fix Support

20 Without vacuum & displacement on one end Axial thermal expansion: 0.0043” Body sizing: 0.001m Radial thermal expansion: 0.0014” Structural Simulation Coupling Slots Sizing: 0.0005m 9267 psi

21 Frequency Shift and Tuning

22 Water Cooled RF Window Main elements of the window Completed windowBasic design of the window The ceramic was ground from AL-995 material and metallized with a conventional tungsten-manganese process. The ceramic was first brazed to the copper eyelet using 50-50 coppergold alloy. This assembly is then brazed to the copper plated stainless steel flange using copper- silver eutectic alloy. After brazing and leak checking, the ceramic window is coated with 35 of chrome oxide on the vacuum side to prevent multipacting. DEVELOPMENT OF A 50 KW CW L-BAND RECTANGULAR WINDOW FOR JEFFERSON LAB FEL CRYOMODULE

23 Current Progress  Cavity engineering design nearly complete - finalize with input from design review and final RF simulation  Thermal, RF and mechanical analyses are nearly complete Additional Tasks  Perform additional analyses Tuner RF/heating analysis Window and waveguide design Frame design and support system  Complete of overall layout of 2.1 GHz Cavity  Generate drawings for RFP  Write documents for RFP (SOW)

24 Thanks Silvia Verdu Andres Binping Xiao Chen Pai Steve Bellavia Chris Cullen Andrew Lambert (Berkley National Lab) Tom Schultheiss (AES)

25 Backup Slides

26 Nose Cone and Coupling Slots Cooling

27 ODIDx = yR 14.229.532.351.59mm 0.5598410.3751957190.0925190.062598in Flow3GPM h 12131 W/m^2-K Velocity 8.71 Ft/sec h = 24262 W/m^2-K ID=.1875in Flow1.5GPM Velocity17.43Ft/sc 341.02 K Worst Case Water Ambient Temperature : 305.15 K 250 KV

28 Without vacuum & displacement on one end Axial thermal expansion: 0.0038” 13464 psi Body sizing: 0.001m Radial thermal expansion: 0.00133” 250 KV Coupling Slots Sizing: 0.0005m

29 Nose Cone and Coupling Slots Cooling

30 ODIDx = yR 15.889.523.181.5mm 0.6251950.3748020190.1251960.059055in Flow3GPM h 12131 W/m^2-K Velocity 8.71 Ft/sec 337.78 K Worst Case Water Ambient Temperature : 305.15 K 250 KV # 8494 h = 13430 W/m^2-K Dh= 0.2604 in Flow1.5GPM Velocity9.03Ft/sc

31 Without vacuum & displacement on one end Axial thermal expansion: 0.0037” Body sizing: 0.001m Radial thermal expansion: 0.0013” 250 KV Coupling Slots Sizing: 0.0005m 13252 psi

32 Nose Cone and Coupling Slots Cooling

33 ODIDx = yR 15.889.523.181.5mm 0.6251950.3748020190.1251960.059055in Flow3GPM h 12131 W/m^2-K Velocity 8.71 Ft/sec 392.67 K Worst Case Water Ambient Temperature : 305.15 K 250 KV # 8494

34 Without vacuum & displacement on one end Axial thermal expansion: 0.0043” Body sizing: 0.001m Radial thermal expansion: 0.0022” 250 KV Coupling Slots Sizing: 0.0005m 37773 psi

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