1. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 1/20 EuCARD-WP7-HFM MPWG Bending Test Pierre MANIL CEA/iRFU/SIS March 18, 2010 at Wroclaw

2. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 2/20 Ackowledgement Thanks to the task and working group members. Especially: ► @ CERN: Attilio Milanese, Juan Carlos Perez, Gijs de Rijk, Ezio Todesco ► @ Saclay: Mélanie Bruchon, Maria Durante, François Kircher, Jean-Michel Rifflet, Etienne Rochepault, Françoise Rondeaux ► Tooling specification: MPWG ► Theoretical analysis: Attilio Milanese (CERN) ► Draftsman: Jean-François Millot (CEA) ► Fabrication: CERN workshop, followed by Juan Carlos Perez (CERN)

3. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 3/20 MPWG Activities WP7: HFM Gijs de Rijk (CERN) 7.3: High Field Model Jean-Michel Rifflet (CEA) Specification WG Ezio Todesco (CERN) EuCARD Magnet Pre-design WG myself (CEA) Cable Design WG Luc Oberli (CERN) 7.2: Support Studies Jaroslaw Polinski (WUT) 7.4: HTc insert Pascal Tixador (Grenoble) 13 T magnet, so-called ‘Fresca 2’HTc insert Preliminary models Preliminary tests Configuration choice Optimization Model realization Realization other tasks

4. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 4/20 MPWG Activities Magnet Pre-design Workin Group ► Collaborative work between CERN and CEA »cf. talk from Jean-Michel at the beginning of the session ► First task is to discriminate between two options: “ Block vs. Cos(θ)” »cf. talk from Attilio, just before »Magnetic comparison => first analysis done »Mechanical comparison => on-going (CAST3M, ANSYS) »Feasibility –Winding => 1 st step = Bending Test, next week (this talk) –Pre-stress –…–… »Configuration choice by April 2010 (DWG) »Magnetic Optimization » Mechanical optimization » Trials »In parallel: characterization tests

5. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 5/20 Bending Test: Goal We know by experience that if the Cos(θ) design is selected, we can manage with the ends What about the Block design ends? Φ100 mm Pre-stress The Bending Test considers only the Block configuration! Flat racetracks Block 2 Block 1 Block 4 Block 3 Flared ends like for HD2 [1] sketch: A. Milanese picture from HD2, courtesy of LBNL

6. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 6/20 Bending Test: Historical approach In the 80’s, the HERA magnet experienced a Block design at Saclay [2] Stacking similar to a Block Stacking similar to a Cos(Θ) Sol. A Sol. B courtesy of J.M. Rifflet

7. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 7/20 Bending Test: Zones The baseline coil geometry divides into 3 or 4 zones: ► straight section (SS) parallel to the mid-plane of the magnet ► hard-way bend zone (HW) in a plane containing the cable ► optional straight section (OS) part on an inclined plane ► easy-way bend zone (EW) on an inclined plane

8. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 8/20 Bending Test: Mockup Cardboard mockup illustrating the zones: End (flat) Hard-way bend zone (planar) Straight section Φ120 mm clear bore (including mechanics) Minimal radius (> 10.t cable ) ~220 mm BLOCK 2 Block 1 Block 2 courtesy of Attilio Milanese

9. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 9/20 Bending Test: Ideas dor the ends “Side”: double clothoid + flat part Flat “racetrack” end 2 layers of cable Flat end courtesy of Attilio Milanese

10. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 10/20 End shape: Analytical approach Analytic study by Attilio to identify ‘best’ end configurations [3] ► Ideal beam is assumed ► Good solution must: »Not be too long »Be smooth up to second derivative »Be convex »Minimize the total strain energy »Avoid peaks of strain energy ► 5 geometries are compared: φ120 circle ellipse superellipse least energy clothoid courtesy of Attilio Milanese Curvature k(x)

11. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 11/20 3 geometries are selected for the Bending Test: The best one will be kept for the FRESCA2 magnet End shape: Selected options circleellipsesuperellipse

12. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 12/20 Bending Test Parameters (1/3) Remarks: HFM dummy cable is used (see sample) The first dummy cable has a p of ~120 mm (Luc Oberli, 02/10) (mechanical instabilities with p > 140 mm) No insulation for the first test campaign (bare dummy cable)

13. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 13/20 Bending Test Parameters (2/3) sketch: A. Milanese Y2 Remarks: w p includes Φ b + 20 mm for mechanics Block 2 is considered (minimal radius) N t corresponds to ~1/4 Block Y2 corresponds to the lowest possible position for the Block 2

14. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 14/20 Bending Test Parameters (3/3) The Bending Tooling will allow to try many different configurations, with several degrees of freedom for each zone

15. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 15/20 Tooling Specified by the MPWG from Jaunary on Detailed design by Saclay (February) Fabricated last week at CERN Delivered at Saclay today (18/3)! with J.F. Millot

16. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 16/20 L HW = 160 Tooling d.o.f values in mm. with J.F. Millot L SS = 320 80 Y2 = 21.8 r W = 120 L OS = 0 / 20 / 50 r b = 50Θ Return end Φ121.82 end (3 options) 0/5/10/15/20/25° The full configuration corresponds to approx. 2 m / turns

17. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 17/20 Example: flat configuration with J.F. Millot The flat configuration corresponds to approx. 1.5 m / turns

18. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 18/20 Experimental Design #L SS (mm) L HW (mm) L OS (mm) Θ (°) End typeHW template NtNt Cable Length L c Flat test 320000circle/23 m Flat end test 320000others/26 m Ramp test #1 3201605025bestNo24 m (Ramp test #N) 32016050…bestNo216 m OS test 3201600 / 20best No28 m Optimal config’ 320160best No1020 m HW shape test 32080 / 160best Yes28 m Insulated test 320best 1020 m CABLE NEED ~90 m Additional parameters: winding tension (~50 kN with gradual decrease) transposition pitch

19. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 19/20 Next Steps ► Bending Test: next week at Saclay ► MPWG Meeting 06: Friday next week (26/3) at Saclay => Test conclusions ► Configuration choice: by April ► Mechanical modeling ► Magnetic optimization ► Mechanical characterization of the conductor: »Young modulus at RT & 2K »Thermal coefficient »Ultimate compressive stress (critical current)

20. HFM High Field Model, EuCARD WP7 meeting, 18/03/2010, Pierre Manil, 20/20 References [1] Recent test results of the High Field Nb3Sn dipole magnet HD2 P. Ferracin, B. Bingham, S. Caspi, D. W. Cheng, D. R. Dietderich, H. Felice, A. R. Hafalia, C. R. Hannaford, J. Joseph, A. F. Lietzke, J. Lizarazo, G. Sabbi, X. Wang Submitted to MT21, Hefei, Oct. 2009 [2] The HERA dipole magnet: J. Pérot, J.-M. Rifflet Ref [3] Shapes of coil ends in racetrack layout for superconducting magnets A. Milanese CERN TE-Note-2010-04, Jan. 2010, EDMS 1057916 [4] FRESCA2 magnet specification SWG version 2.0, Feb. 2010, accessible on the Task 7.3 workspace + Previous talks this day