mechanical engineering issues

7/21/2019 Mechanical Engineering Issues

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1 BROOKHAVEN SCIENCE ASSOCIATES

Abstract

Mechanical Engineering Issues

Sushil Sharma, NSLS-II Project

The NSLS-II storage ring requires multipoles and dipoles of unprecedented field qualit in order to achie!e its

performance goals of high "rightness and "eam sta"ilit# Man mechanical engineering issues $ere encountered in

producing the magnets of such high field qualit $ithin the constraints phsical en!elops and interface requirements#These mechanical engineering issues are descri"ed as the $ere encountered during the !arious phases of the project,

namel, lattice design, conceptual designs, specifications, interface requirements, magnet production and assem"l,

and magnet transportation# Some technical solutions and recommendations that $ere de!eloped in resol!ing these

issues are also discussed#

%&or' performed under auspices of the (nited States )epartment of Energ, under contract )E-*+-./+01//


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BROOKHAVEN SCIENCE ASSOCIATES

Mechanical Engineering Issues

Sushil Sharma

ME Group Leader ASD/NSLS-II

April 11-12, 212


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!u"line

Mechanical design, engineering and produc"ion issues rela"ed "o#

$ La""ice and magne" "%pes

$ &oncep"ual designs

$ Speci'ica"ions

$ In"er'aces# girders, u"ili"%, (acuum cham)ers

$ Magne" *roduc"ion# s"ac+ing and )onding

$ Magne" eassem)l%

$ Magne" ranspor"a"ion


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La""ice and Magne" %pes

$Design e''or"$&on"rac"ual e''or"

$Suppliers. suppor"$Girder assem)lies$Schedule remedia"ion plans$Spares

NSLS-II La""ice

he La""ice should )e 'inalied

earl%0 Su''icien" spaces should )e

alloca"ed )e"een "he magne"s0 he magne" "%pes should )e

op"imied0 Mul"iple magne" "%pes

impac" on#


5/23


NSLS-II Segmen"ed-*ole Designs, Decem)er 2

NSLS-II emo(a)le Mid-

pole Design, 3une 24

&oncep"ual Designs - 1

$ Segmen"ed-pole , or hal'-%o+e cons"ruc"ions$ 5al'-%o+e cons"ruc"ion 'or se6"upoles re7uires

remo(a)le mid pole0

$ Mee"ing 'ield 7uali"% re7uiremen"s i"h remo(a)le mid

pole has )een challenging0$ he magne"s mus" ha(e su''icien" iron "o a(oidmagne"ic sa"ura"ion and "o ma+e "hem s"ruc"urall%

ro)us"0

Segmen"ed-*ole &ons"ruc"ion


6/23


&oncep"ual Designs - 2

$ Secondar% machining 8EDM, milling or pro'iling9 should )e are7uiremen" e(en i' "he magne"s are procured as per

speci'ica"ions0

Soleil Magnets were precision stamped but mating surfaces for

some magnets had to machined precisely (grinding).

$ he inclusion o' nose pieces 8solid or lamina"ed9 and end pla"esneed "o )e clearl% speci'ied and "a+en in"o accoun" in "erms o'

magne"ic leng"h, 'ield 7uali"%, 'ield ma"ching and mechanicalin"er'erences0

:;-mm Dipole


7/235 BROOKHAVEN SCIENCE ASSOCIATES

Magne" Speci'ica"ions IssuesA lac+ o' clari"% on magne" speci'ica"ions a''ec"s design, produc"ion,

"es"ing, accep"ance, and leads "o unnecessar% paperor+ 8D=s, Ds,

>ai(ers, e"c09

$Missing "olerances on speci'ica"ions 8ma6, min, range90

$Missing or imprecise speci'ica"ions # eproduci)ili"% 8de'ini"ion, 'irs"-ar"icles/produc"ion90

Magne"-"o-magne" (aria"ion o' %o+e leng"hs0

&urren" 8I9 range 'or 'ield harmonics0

$Speci'ica"ion on deri(ed ra"her "han primar% 7uan"i"% 8in"egra"ed 'ield (smagne"ic leng"h90

$!(er-cons"rained speci'ica"ions 8pressure drop, 'lo, "empera"ure rise9

$S"ringen" speci'ica"ions 8"hermal si"ch resis"ance, na"ural 're7uencies90

$Speci'ica"ions no" en'orced 8eigh" densi"% o' "he %o+es90

$A(oid using ?or e7ui(alen"@ in "he speci'ica"ions0


8/23/ BROOKHAVEN SCIENCE ASSOCIATES

Vibration Specifcation - 1

5orion"al Mo"ion

$ Magne"s. s"a)ili"% speci'ica"ion 2; nm 8rms, -; 59$ Girder-assem)l% na"ural 're7uenc% should )e B : 50$ he girder na"ural 're7uenc% is a''ec"ed )% "he magne"s.

na"ural 're7uencies0


9/23. BROOKHAVEN SCIENCE ASSOCIATES

he girder-assem)l% resonan" 're7uencies do no" change

signi'ican"l% hen Cn 8magne"9 B 2 Cn8assem)l%90

=i)ra"ion Speci'ica"ion -2



>a"er lo Speci'ica"ion

$ 8-1 o&9 "empera"ure-rise speci'ica"ion i"h an inle" "empera"ure o'

20o

& insures hea" remo(al )% cooling "oers0$ !nl% one supplier pro(ided a 'lo res"ric"or "o mee" "he 8-1 o&9"empera"ure-rise speci'ica"ion0

$ he 'lo res"ric"or s"ar"ed clogging i"hin a 'e hours0 I" as decided"o use "hin "u)e 'lo res"ric"ors )e"een "he magne"s and "he magne"

headers0 he "empera"ure rise speci'ica"ion as a(ed0

$ he hole in "he copper conduc"or could ha(e )een smaller

loes"ric"ors

lo es"ric"or Loca"ion



Girder In"er'ace

$ he in"er'ace "o "he girder 8magne"s. )asepla"e, sie andloca"ions o' "he moun"ing holes, slo"s 'or a"er

connec"ions9 need "o )e precisel% de'ined in "he

in"er'ace con"rol draings0 re7uen" in"er'erence chec+s

are necessar%0

$ Fase pla"es and moun"ing hardare should "a+e in"oaccoun" alignmen", s"a)ili"% and "ranspor"a"ion

re7uiremen"s 8 o(ersie rods, 'la" nu"s, small gap

)e"een "he nu"s90Fase *la"e, &orrec"or

Magne"

*re-assem)l% o' a Girder Fase *la"es and Moun"ing 5ardare



"ili"% In"er'ace

Mani'old connec"ions'or dis-assem)ling a

7uadrupole0

APS Water Connections

$ ecommenda"ion o' Accelera"or Ad(isor%&ommi""ee# No 'orces should )e applied "o

"he magne"s 8such as in ma+ing a"er

connec"ions9 a'"er "he magne"s are aligned

)% (i)ra"ing ire0$ Girders are e7uipped i"h magne" headers0$ he mani'old ma"erial should ha(e )een

uni7uel% iden"i'ied 8*EEH90



~ 280 mm

~ 3m

Beam Aert!re

2"mm # $% mm

E#it Port

Ante C&am'er

Magne" =acuum &ham)er In"er'ace - 1

$ Machining o' "he cham)ers. groo(es# 2-mm gap )e"een "he pole 'aces

and "he cham)er0 -mm gap )e"een "he coils and

"he cham)er0 1-mm e6"ra leng"h on each side0

$ &an (acuum cham)ers )e designedi"h an"e cham)er on "he in-)oard side Ins"alled =acuum &ham)er

Machined *ro'ile



Magne" =acuum &ham)er In"er'ace - 2

Girder No0 Girder No0

$ &-%pe magne" spacers are no"op"imum 'or magne" re-assem)l%0

$ A )e""er spacer design is possi)le )%op"imiing "he design o' "he e6i" por"# educe "he diame"er o' "he e6i"-

por" "u)e0 educe "he gap )e"een "he e6i"-

por" "u)e and "he spacer )loc+s0 Simpli'% e6i" por" o' cham)er no0 0 E6i"-*or" u)e

LFL - Ne Se6"upole

E6i" *or"



E Anal%ses *ressure in psi

E7ual ension on ie ods ( )

ension in &en"ral ods J : 6 !u"er ods

S"ac+ing i6"ure and Fonding Issues - 1

$ S"ac+ing 'i6"ure should )e a)le "o appl%uni'orm pressure 8: M*a9 on "he s"ac+ o'

lamina"ions0 : M*a is "he recommended

pressure, )u" a higher pressure resul"s in

)e""er pressure uni'ormi"%0$ he s"ac+ing 'i6"ure i"hou" "ie rods allos

more 'le6i)ili"% in dis"ri)u"ing "he pressure0

$ he s"ac+ should )e compressed a'"er each)undle o' K 2 mm o' lamina"ions0

Separa"el% Mo(ing

End *la"e

e'# &0 Spencer, Magne" Lec"ure 2, Guanaua"o, 212



S"ac+ing i6"ure and Fonding Issues - 2

$ S"ac+ shrin+age 8K ; mm/m9in o(en due "o compression

and ooing ou" o' "he epo6%coa"ing 8K m "hic+90 he

Felle(ille ashers s"ac+s

should )e designed "o "a+e

"his shrin+age in"o accoun" 0

$ ni'orm pressure is di''icul""o achie(e in a cur(ed dipole0

$ or epo6% curing,h%ssenHrupp recommends

a soa+ "ime o' 2 hours a"

160C, or 1 hour at 180C.A

"hermal anal%sis is

recommended "o es"a)lish"he e6pec"ed "empera"ure

pro'ile in "he %o+e0

Felle(ille >ashers - S"ac+ing

Load-De'lec"ion &ur(es

*io+e Stac, -

T&erma+ Ana+.sis

FE Analyses: by V. Ravindranath



Magne" eassem)l% - 1

$ eassem)l% speci'ica"ions should )e clearl% de'inedand (eri'ia)le0

$ A(oid )ending de'orma"ions and 'ric"ional sliding0 he

spacer )loc+s should )e under compression0$ A(oid mul"iple ma"ing sur'aces0$ Ma"ing sur'aces should )e machined precisel%0

Ma"ing Sur'aces

*re'erred Spacer Floc+

NSLS-II >ide ide Se6"upole


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/anet Reassem'+. - 2

Fol"ing Se7uence and Speci'ica"ions1

$NSLS-II magne"s e6perience

higher de'orma"ions under a

horion"al 'orce "han a (er"ical

'orce0

$ Spacer )loc+s ill pre(en"de'orma"ions under a (er"ical

'orce0

$ Appl%ing (er"ical 'orce 'irs" ill

increase "he 'ric"ion )e"eenhorion"al ma"ing sur'ace0

$ F% +eeping horion"al 'orce one-hal' "he (er"ical 'orce, "he

pro)a)ili"% o' horion"al sliding is

reduced0

ecommended Fol" or7ues 8NSLS-II9#

=er"ical# ;- N0m

5orion"al# 2;-: N0m

An"i-seie lu)rican" such as Hema G-1

Design the interface without

horizontal bolts !

itin rom To !s

FE Analyses: byV. Ravindranath


19/231. BROOKHAVEN SCIENCE ASSOCIATES

Magne" eassem)l% -:

$ Magne"s should )e s"ruc"urall% ro)us" "o insurereproduci)ili"% o' "he magne"ic 'ield0

$ &-clamps ere remo(ed 'rom NSLS-II normalse6"upoles "he% ad(ersel% a''ec"ed "he

repea"a)ili"%0

$ E anal%ses shoed "ha" "he spacer )ars cansigni'ican"l% s"i''en "he magne"s, "hus impro(ingreproduci)ili"%0

NSLS-II >ide Se6"upole NSS-II Norma+ Se#t!o+e NSLS-II


20/23


Magne" ranspor"a"ion - 1

SmaxJ0: M*a

Gra(i"% S"resses Gra(i"% De'orma"ions

Gap

Micro-'issures ere disco(ered in "he %o+es o' "he :;

mm dipoles0

$nder i"s sel'-eigh" "he ma6imum normal "ensiles"ress 8Smax) J0: Mpa0

$Adding e6"ra "op and )o""om pla"es ere no"e''ec"i(e0

$he magne" 'ee" are remo(ed during "ranspor"a"ion0$he ma6imum change in "he pole gap, K 1 m0

SmaxJ0: M*a

Addi"ional *la"es 2 mm hic+

FE Analyses: by V. Ravindranath


21/23


Magne" ranspor"a"ion - 2

SmaxJ01 M*aSmaxJ0 M*a

Li'"ing 'rom op Lugs Li'"ing 'rom Fo""om Lugs

$ Li'"ing "he magne"s 'rom "op lugs produced less s"resses "han"he less-op"imall% placed )o""om lugs0

$ Fo""om lugs ere su)se7uen"l% remo(ed0

FE Analyses: by

V. a!indranath


22/23


FIN* Direc"or.s !''ice oller Machine a" FIN*

Dipole Lamina"ion *eeling-!''FIN* >or+shop No0 4

eam >or+


23/23

2

Ac+noledgemen"

han+s "o all magne" "eams0

mechanical engineering issues

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