co-op update #1
TRANSCRIPT
Outline
• Focus on two recent Projects
– Nanofiber Sample Tensile Grip
– Vacuum Lifting Fixture Engineering Note
• Additional Projects This Term
• Projects From Previous Term
6/8/20172
Nanofiber Sample Tensile Grip (Background)
• Sujit Bidhar (of TSD) is using a
process called electrospinning to
create samples of webbed nanofibers
• The nanofibers are made out of a gel-
like polymer mixed with various types
of powdered metals (titanium,
tungsten, etc.)
• Sujit’s goal is to bake out the polymer
and be left with a sample of metallic
nanofibers
• A mesh of metallic nanofibers would
cool more easily than a solid body of
material, therefore is an ideal target
material for future high intensity beams
6/8/20173
Nanofiber Sample Tensile Grip (Background)
• A tensile testing machine, along with a
2N load cell was purchased in order to
test the mechanical properties of these
samples
• The stock grips are too heavy for the 2N
loadcell
• My task was to design a lightweight grip
to hold the nanofiber samples
6/8/20174
Nanofiber Sample Tensile Grip
• Design Requirements:
– Attaches to purchased tensile
tester
– Weighs less than 50 grams
– Can hold samples with variable
tightness
– Holds sample of dimensions
roughly 5mm wide, 50 mm long,
and 1mm thick
6/8/20175
Nanofiber Sample Tensile Grip
• After initial hand drawing, created model in NX
• Material choice for body/holding plate was PEEK due to its
low density and high strength
• Found applicable hardware on McMaster
• Made spreadsheet to calculate weight and price of current
design in order to make accurate design decisions
• After going over initial design with Sujit, a vertical layout
was preferred in order to save weight (35g 30g)
• Removable dowel pin was added in order to keep holding
plate aligned as best as possible
6/8/20176
Nanofiber Sample Tensile Grip
• After checking this final design with Sujit, I began making
drawings with the help of Dirk from drafting
6/8/20178
Nanofiber Sample Tensile Grip
6/8/20179
• Status:
– Need to create an assembly drawing to aide in the
manufacturing process
• Grand Scheme:
– Sujit would like to use this grip to test the material properties of
his samples
– Use laser microscopy to evaluate the cross-section of samples
(for stress-strain curves)
– Ultimately test the entirely metallic samples if all goes to plan
Vacuum Lifting Fixture Engineering Note (Background)
• Vacuum cup lifting fixture originally built at Argonne and used
at Fermilab for several years is now at the University of
Virigina for use by collaborators who need it to move modules
for Cosmic Ray Veto (CRV)
• An engineering note was written previously to certify the
fixture for a 1500lb load
• Now, the group at UVA would like to use the fixture for a load
capacity of 2500lb
• Our job was to determine whether the lifting fixture could
sustain the new load and update the Engineering Note
accordingly
• Dave Pushka (of TSD) was my supervisor on this project
6/8/201710
Vacuum Lifting Fixture Engineering Note
• At first, I went through the original EN to
get an idea of what was required and to
become familiar with ASME BTH
• As I became familiar with the
calculations I began to re-do them with
the new load of 2500lb to see whether
any major modifications would need to
be made to the lifter
• I contacted the collaborator at UVA to
get a better understanding of the current
state of the lifter (as modifications had
been made) and what vacuum cups
were available to them
6/8/201711
Vacuum Lifting Fixture Engineering Note
• At UVA, they had twenty 7”
diameter vacuum cups, with a load
rating of 160 lbs each (already
rated with safety factor)
• The lifter would need a minimum of
16 cups to meet the 2500lb
capacity
• The use of all 20 cups was agreed
upon as the safest and most
practical application, therefore the
Engineering Note was updated
with all 20 cups in mind
6/8/201712
Vacuum Lifting Fixture Engineering Note
• Updated calculations
included
– Bending of the main box
section
– Bending of the “arms”
– Torsion on the “arms” due to
offset vacuum cups
– Capacity of the cups
themselves
– Shear on bolts that attach
vacuum pack
– Weld strength connecting
“arms”
– Strength of the center lug
6/8/201713
Vacuum Lifting Fixture Engineering Note
• An additional analysis was done in ANSYS to determine
whether the deformation of the module (to be lifted) under
self weight was more than the cups could swivel
• Conservative estimates gave a deformation of less than ¼”
which was determined to be safe.
6/8/201714
Vacuum Lifting Fixture Engineering Note
• Status:
– The Engineering Note has been completed and is currently in
the TeamCenter review process
• Grand Scheme:
– Make any needed edits upon review and get it checked off
6/8/201715
Additional Projects This Term
• Mu2e Septa Fluorinert Circulation System
• MEBT Emittance Scanner Motion Study
• CMTS Waveguide Lifting Fixture
6/8/201716
Mu2e Septa Fluorinert Circulation System
• FC-40 was to act as an electrical isolator for the high voltage
feedthroughs of the Mu2e Septa
• I was asked by Dez to begin setting parameters and
ultimately design a piping system to circulate this Fluroinert
because it would otherwise dissociate due to the high
radiation environment
• I began to determine system requirements and calculate
theoretical head losses but the project was put on hold
6/8/201717
MEBT Emittance Scanner Motion Study
• One day project at PIP-II to help
determine whether the MEBT
Emittance Scanner’s encoder was
locating correctly
• Set up dial indicator to cross-reference
inputted position
• Took several measurements both
lowering and raising the Emittance
Scanner
• Entered data into excel and made
error and hysteresis plots
• Wrote short write-up describing my
procedure and data
6/8/201718
CMTS Waveguide Lifting Fixture
• Currently the waveguides at CMTS
are moved using a combination of
slings and human power
• Brian Hartsell asked me to design a
custom lifting fixture which could be
attached to these waveguides and
used for more secure maneuverability
• I took measurements at CMTS, found
the CoG, and after a few iterations
have come up with a design that
seems feasible
• This design still needs to be assessed
and will most likely be passed on to
the next co-op
6/8/201719
Projects From Previous Term
• LBNF Window Module
• AP0 Structural Analysis
• CMTF Powerline Road Dust Mitigation
• SEM Engineering Support and Stand Design
• NuMI Shielding Fixture Cart
6/8/201720
LBNF Window Module
• Window leading into helium decay
pipe in the LBNF Target Chase was
originally designed for a 1 meter
diameter
• I was asked to upgrade the window
module to a 1.5 meter diameter
along with making several
adjustments per Dave Pushka’s
request
– Added airflow channel and supports
– Widened and added height to
module
6/8/201721
AP0 Structural Analysis
• Old Tevatron beam dump was
going to be placed into a coffin in
A0 over an empty pit
• Ryan Shultz had found I-beams
that could be used to support
concrete blocks and create a
surface to place the coffin and
ultimately the beam dump
• Did several calculations to
determine the max stress and
safety factors on the 6 different I-
beams in 3 possible loading
situations
6/8/201722
CMTF Powerline Road Dust Mitigation
• The unpaved road just west of
CMTF was causing dust to clog
filters and made it more difficult to
maintain clean rooms
• I researched several dust
mitigation options to determine
cheapest and safest way to
reduce the impact
• Found a company that is used in
the Village and other areas of the
lab, contacted them, and got a
quote for calcium chloride which
is now being applied 1-2 times a
summer
6/8/201723
SEM Engineering Support and Stand Design
• A Secondary Emission Monitor is a
device used to measure beam flux
• Matt Alvarez designed and
procured this SEM
• My job was to take inventory and
assemble the SEM at the NWA
cleanroom
– I also wrote a paper to help
optimize assembly procedure
in future
• Helped Matt with Engineering Note
for vacuum windows
• Designed a stand to hold the SEM
in the beamline (did not end up
being used)
6/8/201724
NuMI Shielding Fixture Cart
• A moveable, liftable, lockable
cart needed to be designed to
transport 3 shielding base rails
throughout the NuMI Target
Hall Chase
• I drew up a concept and
worked with Steiner Electric to
end up with a bill of materials
• Adjusted the order to cut costs
by 35%
• Once everything came in,
worked with Zac (previous
intern) at MI-8 to build it
6/8/201725
Thank You!
• Co-op Supervisors
– Kavin Ammigan
– Matt Alvarez
– Maurice Ball (last term)
• Project Supervisors
– Dave Pushka
– Ryan Shultz
– Jerry Leibfritz
– Cory Crowley
– Sujit Bidhar
– Abhishek Deshpande (Dez)
– Brian Hartsell
• Anyone else I’ve worked with! (Techs, Physicists, Engineers, etc.)
6/8/201726