1. Christian Löffler TE-MSC

2. Current design (25.11.14) Goals for analysis Pushing unit – structural strength - pushing unit – uniformity of stress in the bullets -> affects instrumentation quality -distribution of stress in the bullets caused by the deflection of the end plate End plate 2in1 – structural strength - end plate – deflection - end plate 21/04/2015 150420_2in1-Bullet gauges - Current design and structural analysis 2

3. Two bullets per coil on one pushing plate Torsion free bullet Ball notch for compensation for angular mismatch 21/04/2015 3 150420_2in1-Bullet gauges - Current design and structural analysis 0.5mm gap Location strain gauges

4. Aspects: Structural strength – Pushing unit – End plate Deflection of end plate Influence of deflection on instrumentation Boundaries: Force: – Theory 400kN per coil per side – Measured 153kN at 11.8kA – For analysis 200kN Pre stress in the bullets 20MPa Max. angle 1 degree Uniform temperature condition 21/04/2015 4 150420_2in1-Bullet gauges - Current design and structural analysis

5. model – Simplified – No groove for wire boundary – Frictionless contacts – Fixed screw load – 50kN on bullet gauge 130% of measured – uniaxial 21/04/2015 5 150420_2in1-Bullet gauges - Current design and structural analysis screw Bullet gauge Locking pad

6. Screw - Y - normal stressScrew – stress concentration 21/04/2015 6 150420_2in1-Bullet gauges - Current design and structural analysis

7. Locking pad / bullet side - Y - normal stress 21/04/2015 7 150420_2in1-Bullet gauges - Current design and structural analysis

8. Locking pad / screw side - Y - normal stress 21/04/2015 8 150420_2in1-Bullet gauges - Current design and structural analysis

9. Bullet - Y normal stress 21/04/2015 9 150420_2in1-Bullet gauges - Current design and structural analysis

10. conclusion The contact area should be increased to exclude plastic deformation These results are without safety margin and simplified geometry / boundaries Cross-section - Y - normal Stress 21/04/2015 10 150420_2in1-Bullet gauges - Current design and structural analysis

11. model – Full model with cable groove boundary – Frictionless contacts – Fixed screw load – 50kN on bullet gauge 130% of measured – Uniaxial // angle 1 degree 21/04/2015 11 150420_2in1-Bullet gauges - Current design and structural analysis screw Bullet gauge Locking pad

12. Pushing unit – Eq - StressBullet– Eq - Stress 21/04/2015 12 150420_2in1-Bullet gauges - Current design and structural analysis

13. Pushing unit - X - normal stressPushing unit - Z - normal stress 21/04/2015 13 150420_2in1-Bullet gauges - Current design and structural analysis

14. Pushing unit - Y - normal stress 21/04/2015 14 150420_2in1-Bullet gauges - Current design and structural analysis 8mm Measured in MBHSP101 100MPa x30%=130MPa

15. model – Full model with cable groove boundary – Frictionless contacts – Fixed screw load – 50kN on bullet gauge 130% of measured – Uniaxial // angle 1 degree 21/04/2015 15 150420_2in1-Bullet gauges - Current design and structural analysis screw Bullet gauge Locking pad

16. 21/04/2015 16 150420_2in1-Bullet gauges - Current design and structural analysis Max. angle in pushing unit 0.1 degree at 200kN from one aperture

17. Pushing unit - Y - normal stress 21/04/2015 17 150420_2in1-Bullet gauges - Current design and structural analysis Measured in MBHSP101 100MPa x30%=130MPa

18. Conclusion Bullets are suitable for instrumentation maximum difference in the location of the instrumentation 10MPa under 1 degree load 21/04/2015 18 150420_2in1-Bullet gauges - Current design and structural analysis screw Bullet gauge Locking pad

19. 21/04/2015 19 150420_2in1-Bullet gauges - Current design and structural analysis model – Full model with cable groove boundary – Frictionless contacts – Fixed end plate load – 100kN on coil 130% of measured – Coil only one DOF screw bullet gauge locking pad pressing plate coil

20. Bullet contact - Ball notchBullet contact – norm 21/04/2015 20 150420_2in1-Bullet gauges - Current design and structural analysis

21. 21/04/2015 21 150420_2in1-Bullet gauges - Current design and structural analysis

22. 21/04/2015 22 150420_2in1-Bullet gauges - Current design and structural analysis Conclusion Deformation caused by ball notch shifts the stress concentration Line contact in ball notch is under high stress screw bullet gauge locking pad pressing plate coil

23. model – Full model of end plate with pushing unit boundary – Frictionless contacts – Shell fixed – Symmetry condition load – 100kN on coil 130% of measured – Coil only one DOF 21/04/2015 23 150420_2in1-Bullet gauges - Current design and structural analysis

24. Weld – Y – norm StressWeld – Equ. Stress 21/04/2015 24 150420_2in1-Bullet gauges - Current design and structural analysis Full theoretical EM force 200kN

25. End Plate – Y – norm StressEnd Plate – Equ. Stress 21/04/2015 25 150420_2in1-Bullet gauges - Current design and structural analysis Full theoretical EM force 200kN

26. End Plate – Equ. Stress 21/04/2015 26 150420_2in1-Bullet gauges - Current design and structural analysis Full theoretical EM force 200kN

27. End Plate – Y- Deformation End Plate – Y- Defo 50kN = 0.15mm 100kN=0.35mm 150kN=0.5mm 200kN=0.73mm 21/04/2015 27 150420_2in1-Bullet gauges - Current design and structural analysis EM force 100kN

28. Conclusion Structural strength on narrow geometries not guaranteed Deformation of 0.35mm at expected load 21/04/2015 28 150420_2in1-Bullet gauges - Current design and structural analysis