CONTENTS

2. CONTENTS ○ Workpackage overview ○ Workpackage overview ○ Introductory structural analysis task ○ Complex structural analysis task ○ Introductory thermomechanical analysis task

3. Workpackage overview • WP 5: Thermomechanical Engineering of In-Vessel Components • Starting date: • 06.07.2009. • Objective: • To become a thermomechanical analyst expert for the further fusion research. • Tools : • ANSYS Multiphysics and ANSYS Workbench • Short term aim: • To achieve the assured knowledge and routine on using the tools. • Implementation: • FEM tasks from simple to more complex under mentoring by Gábor Grunda

4. CONTENTS ○ Workpackage overview ○ Introductory structural analysis task ○ Complex structural analysis task ○ Introductory thermomechanical analysis task

5. COMPASS ion beam vacuum vessel • The challenge: • - An ion beam is developed for the COMPASS in our institute. • - We would like to know what is the stress field of the following part of the appliance. • - The structure has only static loads. Pressure, force and weight. • The task: • Check the strength of the vacuum vessel and thebolts of the flange • Used tool: ANSYS Workbench

6. The FEM model I. Geometry of the examined part: - Simple cylindrical part with bolts. Materials: - vacuum vessel: aluminium alloy: AlMgSi 0,5 - bolts: steel 8.8 - flange: PVC

7. The FEM model II. The mesh: - Fine tetra mesh has been chosen. Loads and supports: - 0,3 [MPa] inner pressure - forces on the bolts - gravitational field - fix support

8. Results The main stress in the vessel is 11 [MPa]. The maximal stress is 150 [MPa]. The yield strenght is 160 [MPa].

9. Results The maximal stress is 260 [MPa] in the bolts. The yield strenght is 640 [MPa]. The structure is adequate.

10. CONTENTS ○ Workpackage overview ○ Introductory structural analysis task ○ Complex structural analysis task ○ Introductory thermomechanical analysis task

11. AEU frame structure • The challenge: • - For the functioning of the ITER TBS we need a removable unit (AEU) which contains some sub-systems of TBS. • - The frame structure was a design concept for preliminary layout. • - To minimize the weight of the frame structure, so this is an optimizing task. • - To check the necessity of side frame structure. • - The frame structure has only static loads.

12. Dimensions of frame structure The outer dimensions are equal to the EQ Transfer Cask. Width of longitudinal beams is given by the space next to ATS.

13. Loads of frame structure Weight of sub-systems: Helium Cooling System (HCS): 359,5[kg] PbLi loop: 20000[kg] Tritium Extraction System (TES): 927[kg] Diagnostics: 7000[kg] Maintenance Equipment: 1162[kg] Layout of sub-systems: Diagnostisc HCS TES Maintenance Equipment PbLi loop

14. The FEM model Rough FEM models have been made in the first steps and these have been specified in the next phases. Solid model has been made and hexa mesh has been used. The mesh size has been finedduring the development procedure. The raw material is a good weldable structural steel S235JR (standard MSZ EN 10025-2). The numerical designation of material is 1.0038. 150 MPa maximal stress had aimed during the optimization. First the correct value of the standard stress has been aimed during the procedure of optimizing then the smaller stress maximums had corrected.

15. The first analysis Conception: - standard I beams and rectangular tube - frame structure without side beams Mesh: - rough tetra mesh Loads and supports: - one common pressure, gravity, fix support Weight: 3840 [kg]

16. Result of the first analysis The calculation confirmed frame structure without side beams is possible. The main stresses are nearby 30 [MPa]. The maximal stress is 90[MPa].

17. The first phase Conception: - standard I 120 cross beams IPE series - uniquely welded longitudinal beam Mesh: - rough tetra mesh Loads and supports: - pressures on the location of sub-systems, gravity, fix support Weight: 1855 [kg]

18. Result of the first phase The stresses in the cross beams are nearby 150[Mpa] but some cross beam is under sized. The longitudinal beam is over sized. The maximal stress is 347[MPa].

19. The second phase Conception: - standard I 120 cross beams IPE and HEB series - uniquely welded longitudinal beam with holed ridge Mesh: - fine tetra mesh Loads and supports: - pressures on the correct location of sub-systems, gravity, one bonded DOF Weight: 1959 [kg]

20. Result of the second phase The HEB I beams are proper, IPE beams are over sized. Local stress maximums are by the welded joints. The longitudinal beam is adequate.

21. The last phase Conception: - the IPE beams have been exchanged to rectangular tubes - ribs and node plates with large fillet have been used Mesh: - fine tetra mesh Loads and supports: - pressures on the correct location of sub-systems, gravity, one bonded DOF Weight: 1762 [kg]

22. Result of the last phase The stress is correct everywhere in the structure. Due to the ribs the stiffness is better. The maximal stress is 170 [MPa]. Calculations with non flat seat.

23. CONTENTS ○ Workpackage overview ○ Introductory structural analysis task ○ Complex structural analysis task ○ Introductory thermomechanical analysis task

24. MAST diagnostics The challenge: Thermal analysis for MAST Beam Emission Spectroscopy In-vessel Optics - the optics has to operate on 150 °C in vacuum environment - it is important to know what heater must be use and how long the heating going to last - to check the 750 W electric heater and thermal insulation The model of diagnostics - cylindrical vacuum vessel and mirror and lens support elements

25. The FEM model I. Geometry: - Vacuum vessel + heater + thermal insulation Materials: - vacumm vessel: A300 stainless steel: thermal conductivity: 15 W/mK specific heat: 500 J/kgK - thermal insulation: fiberglass: thermal conductivity: 0,032 W/mK specific heat: 670 J/kgK

26. The FEM model II. Mesh: - solid model has been built - tetra mesh has been applied

27. Steady state analysis Heat and convection: - Internal heat generation in the heater: 750W - Convection on the outer surface of thermal insulation

28. Calculation of convection Convection depends on: - thermal conductance of the environment (air): λ - temperature difference: Δt - acceleration due to gravity: g - kinematic viscosity : ν - thermal expansion of the environment (air): β - thermal diffusivity: a

29. Results of steady state calculation The maximum temperature is 436 °C on the cylindrical surface of the vacuum vessel. The temperature of support elements of mirrors is nearby 370 °C. The heater with 750 W power is enough but this simulation doesn’t give answer for the transient processions.

30. Transient analysis Heat , convection and radiation: - internal heat generation in the heater: 2x750W (double heater) - convection on the outer surface of thermal insulation - radiation between the surfaces • Radiaton depends on: • - surfaces: F • - emission factor: ε • temperatures: T • Stefan-Boltzmann ratio: σ Relative emission factor: Heat flow:

31. Results of transient calculation After 14400 sec the temperature of support elements of mirrors is nearby 150 °C. The heating time is too long with 750 W heating power. Two heaters must be used. This analysis was based some estimations, so the real laboratory test will give important feed-back about the validation.

32. Results of transient calculation Thank you!