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A. Ryabov, A. Soldatov, S.Chernichenko (IHEP, Protvino)

V.Demitchev, A.Timofeev

(RDP Corp. KOMPOZIT, Korolev)

TThe design studyhe design studyof the vacuum system elementsof the vacuum system elements

((KOPIO experimentKOPIO experiment) )

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Geometry. General ViewGeometry. General View

LidPipe

Ribs

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FE-Analysis ModelsFE-Analysis Models

• Three geometry models of the pipe-lid connection have been used in the Finite Element Structural Analysis (FE-Analysis): GA - the joint without any additional intermediate element; GB - the joint thru an intermediate conic surface; GC - the joint thru an intermediate “horn” surface.

GC – connection GA – connection GB – connection

• Three sets of thickness for the lid, pipe and ribs have been considered. Values of these thickness (TS1, TS2 and TS3) are shown in table on next slide.

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The basic parameters of modelsThe basic parameters of models

Thickness Set (TS) Lid, mm(inch) Pipe, mm(inch) Rib, mm(inch)

TS1 12.7 (1/2) 6.35 (1/4) 9.525 (3/8)

TS2 6.35 (1/4) 6.35 (1/4) 9.525 (3/8)

TS3 8.89 (~1/3) 8.89 (~1/3) 8.89 (~1/3)

Materials Modulus of Elasticity, E [GPa]

Poisson’s Ratio,

Yield Limit, [MPa]

Radiation length X0,[cm]

Be Alloy (32%Be-68%Al) 135 0.20 500 ~ 17

Carbon-plastic composite (65%C-35%Plastic)

90 0.35 800 ~ 20

Parameter Description Value, mm (inch)

D_c The lid diameter 3200 (126.0)

S_c The lid sagitta 254 (10)

W_p Width of the pipe cross-section 1778 (70)

H_p Height of the pipe cross-section 228.6 (9.0)

H_r Height of ribs 152.4 (6 )

Dx_r Distance between ribs 178 (7.0)

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FE-Analysis FE-Analysis (the stress distribution)(the stress distribution)

V1: Von Mises Stress [MPa] SEQV_max = 330 MPa

V2: Von Mises Stress [MPa] SEQV_max = 154 MPa

Critical zone P1

Critical zone P2

Two versions of FE-Analysis have been done for each combination of the geometry model and thickness: first one for a free pipe end (V1), the second one for a fixed pipe end (V2).

A typical example of a stress distribution with two critical zones

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FE-Analysis FE-Analysis (displacements)(displacements)

V1: USUM_max = 2.17 mm V2: USUM_max = 1.91 mm

A typical example of a maximum displacement (GA, TS1)

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FE-Analysis FE-Analysis (the pipe displacements)(the pipe displacements)

V1

Uz = -1.23 Uz = -0.05

V2

V1

Uy = ± 1.31

V2

Uy = ±1.34

Longitudinal displacements UZ [mm]

Vertical (Flexure) displacements UY [mm]

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Summary Results of FE-AnalysisSummary Results of FE-Analysis

TS1: t_cover = 1/2, t_pipe = 1/4, t_ribs = 3/8 inch

TS2: t_cover = 1/4, t_pipe = 1/4, t_ribs = 3/8 inch

TS3: t_cover = 1/3, t_pipe = 1/3, t_ribs = 1/3 inch

ModelStresses [MPa] for

V1/V2Max Displacements [mm] for V1/V2

P1 zone P2 zone UZ (pipe) UY (pipe) USUM

Be Alloy (32%Be-68%Al)

GA_TS1 331 / 103 130 / 154 1.22 / 0.05 1.31 / 1.34 2.17 / 1.91

GB_TS1 121 / 83 113 / 147 1.00 / 0.06 1.31 / 1.34 2.11 / 1.99

GC_TS1 130 / 80 110 / 144 1.04 / 0.05 1.31 / 1.34 2.07 / 1.89

GB_TS2 312 / 157 95 / 135 2.56 / 0.07 1.31 / 1.34 4.88 / 3.98

GB_TS3 202 / 105 70 / 99 1.40 / 0.05 1.20 / 1.22 3.15 / 2.67Carbon-plastic composite (65%C-35%Plastic)

GB_TS3 191 / 110 66 / 93 2.27 / 0.06 1.79 / 1.84 4.48 / 3.85

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ConclusionsConclusions

• For all design variants of the lid-pipe system, the fixed end of a pipe allows to decrease the maximum displacements of pipe and to reduce also the stress of lid in critical zones (P1, P2) up to acceptable values.

• The base variant of the lid-pipe design of the vacuum system (Beryllium alloy with thickness of 1/2”) can’t be made due to technological reasons - the today technology and the equipment allow to weld sheets of Beryllium alloy with the thickness up to 1/4”.

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ConclusionsConclusions

• The variant of the lid-pipe design with Beryllium alloy of the thickness of 6 mm and with the conic joint of lid-pipe can be made on the modernized technological equipment. The estimated cost of this variant will be more than $2M, period of manufacturing will be 3 years. But, two comments have to be done for this version:

- Even for this thickness of Beryllium alloy, ribs on the beam pipe will be soldered by silver, but not welded, because the existing technology allows to weld only an end-to-end shape, but not T-shape.

- Opportunity of appearance of micro-cracks in the welded seams because of cyclic loading (vacuum - atmosphere). It will demand an additional polymeric covering on the product surfaces.

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ConclusionsConclusions

• However, the today technology allows to produce the alternative variant of the lid-pipe design with a carbon-plastic composite of the thickness of 1/3” and with the conic joint of lid-pipe, which provides a safety factor almost 7 and the radiation thickness of 0.05X0. The estimated cost of this variant will be ~ $600K, period of manufacturing will be 2-3 years.

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Schedule and the cost estimation for Schedule and the cost estimation for production of the composite versionproduction of the composite version

Activity Description of activity Schedule of activity

Cost (k$)

Results of activity

1. Prototyping •Development of the manufacturing technique;

•Production of the special equipment for the manufacturing of the mockup samples in a 1/5 scale;

•The manufacturing of 5 mockup samples in a 1/5 scale;

•The vacuum test of the mockup samples;

•The out-gassing test of the mockup sample;

•The test for the complete corrupting of sample by pressure.

0,5 year,

End of 2003.

50 The documentation for production of the full-scale sample.

Five 1/5 – scale samples.

The test report.

2. Development of technology for production of the full-scale samples

•Development of the manufacturing technique for production of the full-scale samples;

•Production of the special equipment for the manufacturing of the full-scale samples;

•The manufacturing of 2 full-scale samples;

•The vacuum and out-gassing test of the full-scale samples;

•The test for the complete corrupting of one sample by pressure.

1.0 year,

End of 2004.

400 The corrected technology documentation for production of the final full-scale sample.

Two full-scale pre-production samples.

The test report.

3. Production of the final set of the lid-pipe system

The manufacturing of the final set of full-scale lid-pipe system. 0,5 year,

July 2005.

125 The final set of the lid-pipe system.

The test report.

The technical documentation.

4. Delivery in BNL

Production of special package box, custom procedures, shipping to BNL.

2 months,

Fall of 2005.

25 The shipping documentation