substrate-paddle-base peter cooke. peter cooke 28 feb - 1 march 2006 - velo prr2 substrate-...

Substrate-Paddle-Base

Peter Cooke

Peter Cooke 28 Feb - 1 March 2006 - VELO PRR

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Substrate-Paddle-Base

Substrate Production Paddle – Base – Feet Component

Production

LHCb Substrate


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LHCb Substrate Production

Substrate Dimensions Materials and preparation Lay-up Inspection and Packaging Recommended Curing Instructions Summary


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Substrate Dimensions

Carbon Fibre 177 x 123mm TPG 169 x 115mm 4mm Carbon Fibre frame

suppounding TPG


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Materials Preparation TPG

400um TPG board cut to 169 x 115mm

Abrade both sides with course emery paper

Cleaned and degreased with alcohol

Left to dry


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Preparation Carbon Fibre

Supplier; Amber Composites UK Carbon fibre Pre-preg 120 gm plain

weave, epoxy resin impregnated Cut to size 177 x 123mm 2 Pieces – weave direction 0 – 90 deg 2 Pieces – weave direction +/- 45 deg Pre-preg approximate cured thickness

0.125mm per layer


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Lay-up Procedure

Release film applied to flat steel plate 1st layer 0 – 90 deg on flat plate 2nd layer +/- 45 deg on top TPG placed centrally on 2nd layer 4mm strips of pre-preg surrounding TPG –

3 layers with orientation of fibres balanced

3rd layer +/- 45 deg placed over previous 4th layer 0 – 90 deg to complete


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Lay-up continued

RED

0 – 90 Deg

BLUE

+/- 45 Deg

GREY

TPG


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Inspection & Packaging

Visual Inspection Measurement – Micrometer/Smartscope Substrates have release film applied to

each face to protect resin 10 substrates are sandwiched together

between two 6mm thick aluminium plates

Surrounded in foam and packed in carboard box

Shipped off to Stevenage Circuits


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Recommended Cure

Amber Composites Fibre; T300 Resin E722.02 45% RW Increase temp. to 120 C @ 3 C/ min Increase pressure to 90 psi Hold for 1 hour Cool to 60 C before releasing pressure


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Summary Have all material to produce up to

70 substrates Carbon Fibre stored in freezer @ -

18 C TPG stored in locked cupboard Can produce 10 per week

LHCb Paddle/Base Components


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Paddle/Base Assembly


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Component Production

Base and Feet Manufacture Paddle Fabrication Paddle cure Inspection


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Base and Feet Manufacture

Base – Cut from solid sheet of carbon fibre and machined in-house.

Invar feet – CNC Wire Eroded in-house to guarantee accuracy. Spigot on right foot tolerance 0.000 to –0.008


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Paddle Fabrication

Material; Pre-preg ACG VTM264/CF0300-42%RW 200 gram

2 x 2 Twill (Stored–18deg C) Female mould tool CNC machined and

hand finished in two halves. Dowelled and fastened together during

lay-up Tool treated with PTFE release solution

and buffed to a gloss finish


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Paddle Lay-up Carbon fibre cut to templates, 2 layers per

face. 1 @ 0/90 deg and 1@ +/-45 deg Apply fibre to each face, 0/90 then +/-45 Final thickness over major area of paddle

0.5mm Rear face – fibre flush to tool surface Front face – overlapping tool face 6 –

2mm along length 3 x 12mm wide strips added to each face

at the topmost area of the tool.


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Paddle Lay-up (cont)

Add release film and bleed ply fabric to the exposed fibre

Add a strip of breather fabric to each side

Make vacuum bag and fit into front side of tool

Place rear side of tool over dowels on the top and fasten into place

Place assembly into large vacuum bag and seal inner to outer bags


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Paddle Cure In autoclave Apply vacuum Heat to 65 deg C at 0.5 deg C/ minute At 65 deg C apply 90 psi Hold for 16 hours Cool, release pressure and vacuum De-mould the part


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Parts Inspection

Visual inspection – Inside and Out Fitted to drilling jig


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Summary We have enough carbon fibre

stored in freezer to produce 80 paddles

Carbon Fibre Bases ready Invar Feet ready

substrate-paddle-base peter cooke. peter cooke 28 feb - 1 march 2006 - velo prr2 substrate-...

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