HQ Tooling

FNAL QXF Curing MoldMiao Yu, FNAL05/07/2013FNAL Short Curing Press2

2 meter longCapacity (pump psi)Max. force/cylinderkN (ton)Spacing cm(inch)Unit force kN/m-pump psi (lb/in-pump psi)Main Cylinders10000534 (60)15 (6)0.356 (2)Mandrel Cylinders1000090 (10)15 (6)0.06 (0.34)FNAL Long Curing PressCapacity (pump psi)Max. force/cylinderkN (ton)Spacing cm(inch)Unit force kN/m-pump psi (lb/in-pump psi)Main Cylinders100001780 (200)30 (12)0.6 (3.34)Mandrel Cylinders10000134 (15)15 (6)0.09 (0.5)

38.8 m long3Curing Mold Analysis

1.2 MPa22 MPa5 MPa Unit: mmComponentMaterialCoilNb3SnMold1050 steelMandrelSS 304Sector pusherSS 304Stop barA2 SteelCylinder Load (kN/m)Short Press(pump psi)Long Press(pump psi)Main Cylinder167232001380Mandrel Cylinder18030002000Assume the coil az. pressure 22 MPa, and the mold is just closed.4Main Press = (Load/Unit force) x (Coil length/Mold length)

Normal OperationPmandrel =1.2 MPa Pmandrel =1.2 MPaPcoil =22 MPaPmandrel =1.2 MPaPcoil =22 MPaPmold =5 MPaStress(MPa)Deflection (m) in x,yStress(MPa)Deflection (m) x, yStress(MPa)Deflection (m) x, yCoil (MPa)2.7-18.0-19.5-Mold (MPa)6.13, 143.632, 1645.438, 215Disassembly MoldDisassemble IR Quad short inner coil mold and LHQ curing moldReuse most of the tooling (tie rods, wheels, keys, bars, etc)6

Curing Mold Assembly

7SQXF and LQXF MoldsSQXF Mold: ~$56k2.08 m (78) long, one stacking section. Procure two end blocks ($5,600)1250 pieces of laminations ($38,000 + $10,000)one wheel assembly, one heater outlet box and one alignment cylinder. ($2,000)LQXF Mold: ~$52k8.84 m (348) long, 5 stacking sectionsProcure two end blocks ($5,600)5600 pieces of laminations ($45,000)Two heater outlet boxes (power at both ends) ($1,000)8Post Curing Mold ReviewMiao Yu05/14/2013Review note 1: D. & Proc.Procurement of LQXF formblock laminations should be delayed until design develops for SQXF. In the event that conductor width or other changes are incorporated, revisions to the stamping die may be implemented before LQXF laminations are stamped. Mike

2 step procurement process, short tooling now, long tooling later. - Fred

10Action1: Design &ProcurementFY13: SQXF curing mold FY14: LQXF curing mold

Keep the same cross-section design on both SQXF and LQXF curing mold.Keep the 60 mil thick curing retainer. Adjust the shim in between the retainer and the coil to compensate the difference in final cable dimension. (current design has 20 mil shim)

11ProcurementLQXF dieReview note 2: Curing PressValues of applied load to coils for given hydraulic pressure assumed that cylinders beyond the length of the coil contributed to the coil pressure. This should be revised to reflect that only cylinders directly loading coils contribute to applied load. Mike

Applied pressure of 22 MPa on coils during curing was considered to be high. However, planning for unexpectedly high loads is a conservative measure. Furthermore, this is a tooling review, not a coil curing procedural review, and so extra safety margin in the tooling design is appropriate. Mike

Adjust formula on page 4, load per unit length on coil only. - Fred

12Action 2: Curing Press13Cylinder Load (kN/m)Short Press(pump psi)Long Press(pump psi)Main Cylinder167246902780Mandrel Cylinder18030002000Capacity (pump psi)Max. force/cylinderkN (ton)Spacing cm(inch)Unit force kN/m-pump psi (lb/in-pump psi)Main Cylinders10000534 (60)15 (6)0.356 (2)Mandrel Cylinders1000090 (10)15 (6)0.06 (0.34)2 meter PressCapacity (pump psi)Max. force/cylinderkN (ton)Spacing cm(inch)Unit force kN/m-pump psi (lb/in-pump psi)Main Cylinders100001780 (200)30 (12)0.6 (3.34)Mandrel Cylinders10000134 (15)15 (6)0.09 (0.5)8.8 meter PressUnder these load, ~22 MPa will go to the coil azimuthally.The pressure starts low Main pressure: 700 psi Mandrel pressure: 500 psi5 loading steps up to the limit pressure, each step we measure the mold gapUpper limitReview note 3: Heat transferMandrels do not include holes for electric heaters. LHQ mandrel temperatures will be monitored to determine if coil reaches proper temperature at all locations along inner radius during cure. Thermal analysis of the QXF curing assembly (mandrel, pushers, coil and formblock installed in press) should also be completed to validate the experimental results. Note that if results are unsatisfactory, in this respect also carbon steel mandrel material may be advantageous due to superior thermal conductivity as compared to stainless steel. Analysis should also include the effect of candidate steel versus mylar spacers between coil and liner during cure. - Mike

Analyze heat transfer in coil during curing. Use coil LHQ02 to measure mandrel & coil shell temperature during curing with Mylar radial spacer. Compare the time to heat the coil shell temperature with LQH01. Apply results to FQX curing tooling. - Fred

14Action 3: Heat transferIn LHQ coil 02, coil mandrel temperature will be monitored, at two locations close to the end of the coil, to determine if the coil reaches the proper temperature. (Mylar shim will be used in between the retainer and this coil)

Thermal analysis of QXF.15Review note 4: Coil End LoadCoils are cured without end pressure. Instead set screws on pusher blocks attached to the mandrel apply an initial load to the coil end shoe after winding. This load is applied before azimuthal pressure is applied to put conductors in proper azimuthal position, i.e., before the end shoes are fully seated, and therefore remains a concern. Use of Belleville washers or some other means to be able to complete the seating of the coil end shoe after the azimuthal pressure is applied should be considered. - Mike

16Action 4: Coil End LoadBelleville washers will be used in LHQ coil 02 between the screw and the coil end pusher, which will help the coil saddle sit better after coil compressed azimuthally.

17Review note 5: Material304 stainless steel is planned for mandrel and pushers (apparently this is being considered for use at CERN as well). Carbon steel should be considered for relatively lower material and machining costs. Mike

Material selection or the tooling is acceptable. - Fred

18Action 5: Material19ComponentQXFMandrel support 4140 H.T steelMandrelSS 420Curing SpacerSS 420Sector pusherSS 420Side pusherA2 steelRetainer1074 spring steel

SQXF/LQXFMandrel Mandrel support block Sector pusherSector pusherSide pusherSide pusherCoilRetainer

Curing Spacerduring IL curingThe price for SS 420 is roughly 4 time more than the low carbon steelUsing steel will save us ~$30k, however there may be high risk to do so.Review note 6: Model compareFNAL and CERN curing tooling drawings should be compared. -Mike

20Action 6: Model Status at FNALWe are still working on the winding and curing tooling. (1~2 month)Try to fit all the other existing tooling, such as winding table and rotation table.Waiting for the final cross-section and coil design for the curing spacer at layer jump area. 21