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24-25 of June 2013

ATLAS-NSW 4 th MMM workshop thermo- mechanical simulations for the mm wedges (TDR options – Screwed quadruplets). Patrick PONSOT & Patrick GRAFFIN for the CEA-Saclay-Irfu group:

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24-25 of June 2013

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  1. ATLAS-NSW4thMMM workshopthermo-mechanical simulations for the mm wedges (TDR options – Screwed quadruplets) Patrick PONSOT & Patrick GRAFFIN for the CEA-Saclay-Irfu group: F.Bauer, P.Daniel-Thomas, E.Ferrer-Ribas, J.Galan, W.Gamache, A.Giganon, P-F.Giraud, S.Hassani, S.Herlant, S.Hervé, F.Jeanneau, H.LeProvost, O.Meunier, A.Peyaud, Ph.Schune 24-25 of June 2013

  2. OUTLINE • As reminder, the status presented during the MMM Saclay workshop (on the 18th of April 2013) • New results about thermo-mechanical simulations with 3 screwed modules on the spacer (tension of the mesh has been included,…) • New results about thermo-mechanical simulations with full size wedge screwed on the spacer (segmented skins ?) • Conclusion (2 parts) • The design of M4 prototype before these new results • Statement for the design of the quadruplets: Modifications of the prototypes ? 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  3. To keep in mind ! In all cases the thermo-mechanical simulations are made with simplified modeling. The results must be considered as predictive tendencies and not as absolute values. • Material used for all the simulations: 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  4. AS reminder • Status on the end of April : Presented at Saclay during the 3rd MMM workshop The modeling has been improved ! 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  5. NEWs on 2x3 screwed modules • Geometry, boundary and loading conditions • 2x3 modules + spacer • 3 kinematic mounts on the spacer • Self weight + Inclined at 0.704° + temperature gradient in Z direction ΔT=2°C • The tension of the meshisincluded: 15N/cm 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  6. NEWs on 2x3 screwed modules • 2x3 modules withaluminum frames and aluminum honeycombs, only screwed on their external frame on an aluminum spacer (FR4 skins 0.5mm, no sliding around the screws) • Displacement for the modules Sector 5 ~44µm Global 3D Only 16 microns out of the plane, if we can guarantee the full contact with the spacer (planarity) ~94µm ~16µm 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  7. NEWs on 2x3 screwed modules • 2x3 modules withaluminum frames and aluminum honeycombs, only screwed on their external frame on an aluminum spacer (FR4 skins 0.5mm, no sliding for the screws ) • Stresses for the modules Sector 5 ~111 MPa ~15 MPa Only ~2 MPa on the skins The increasing of the stresses up to 15MPa is localized around the screws. The detailed design should take in account this effect. Higher will be the stiffness of the quadruplets, higher will be the stresses around the fixations The increasing of the stresses up to ~111 MPa is localized around the support (it should be solved with kinematic mounts) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  8. NEWs on 2x3 screwed modules • 2x3 modules withaluminum frames and aluminum honeycombs, only screwed on their external frame on an aluminum spacer (FR4 skins 0.5mm, no sliding for the screws) • Statement: • Addition of the tension of the mesh at 15N/cm is possible without increasing of the displacements • Remark: In all cases the displacement out of the plane is very dependent of the symmetry and planarity of the components (full contact between the spacer and the modules reduced the Z displacement) • To keep under control the stresses, we must use the detailed design for the quadruplet according to its evolution inside the MM community • New questions for MM community: With mechanical prototypes, do we want to test also the screwing of the modules on the spacer frame? Can we measure the stresses with a temperature gradient? M4 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  9. News on 2 Full size wedges • Geometry, boundary and loading conditions • 2 Full size wedges + spacer • 3 kinematic mounts on the spacer • Self weight, Inclined at 0.704°, temperature gradient in Z direction ΔT=2°C • The tension of the mesh is included: 15N/cm • Modification of the boundary conditions for the screwing (2 DoF have been added) Sector 5 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  10. NEWS on 2 Full size wedges • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 skins 0.5mm, with 2 DoF for the screws) • Displacements Sector 5 ~55µm Global 3D 37 microns out of the plane, if we can guarantee the full contact with the spacer (planarity) ~37µm ~105µm 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  11. NEWS on 2 Full size wedges • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 skins 0.5mm, with 2 DoF for the screws) • Stresses Sector 5 Only ~1.5 MPa on the skins The stresses for the skins have been decreased a lot with additional DoF on the screws. Increasing of the stresses up to ~37 MPa, is localized around the support 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  12. With segmented skins • Geometry, boundary and loading conditions • 2 Full size wedges + spacer • 3 kinematic mounts on the spacer • Self weight, Inclined at 0.704°, temperature gradient in Z direction ΔT=2°C • The tension of the mesh is included: 15N/cm • Modification of the boundary condition for the screwing (2 DoF have been added) Sector 5 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  13. With segmented skins • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 segmented skins 0.5mm, with 2 DoF for the screws) • Displacement Sector 5 ~38µm Global 3D 30 microns out of the plane, but we found “unsticking” in the central part of the spacer ~30µm ~86µm 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  14. With Segmented skins • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 segmented skins 0.5mm, with 2 DoFfor the screws) • Behavior of the spacer Same behavior as the IP wedge Sector 5 Out of plane ~30µm Global 3D ~28 MPa is localized around the supports 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  15. With segmented skins • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 segmented skins 0.5mm, with 2 DoF for the screws) • Displacement of the 2 wedges HO wedge IP wedge Sector 5 ~10µm ~22µm Displacement out of the plane of the 2 wedges are not the same: 10 microns compare to 22 microns (Nota: All the simulations are done without the spacers inside the drift gap) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  16. With Segmented skins • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 segmented skins 0.5mm, with 2 DoFfor the screws) • Stresses Sector 5 Only ~1.2 MPa on the skins ~23 MPa on the screws Only ~4.5 MPa on the rectangular tubes which linked the segmented skins (20mmx10mmx1mm) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  17. News on 2 full size wedges • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 skins0.5mm, with 2 DoFfor the screws) • Statement: • Addition of the tension of the mesh at 15N/cm is possible without increasing of the displacements • Stresses for the skins can be decreased a lot if we have more DoF around the screws (friction factor is not still taken in account?) • Segmentation of the skins “introduced” different displacement for the 2 wedges. We should learn a lot of things with the mechanical prototypes (e.g. result with the spacers inside the drift gap) • Remark: In all cases the displacement out of the plane is very dependent of the symmetry and planarity of the components 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  18. Only one panel - Segmented skins ? • Only thermal behavior (temperature gradient on Z) for only one full size panel with aluminum frame and aluminum honeycomb, (FR4 skins 0.5mm) Difference about displacement is less than 5 microns 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  19. Only one panel - Segmented skins ? • Only thermal behavior for only a full size panel with aluminum frame and aluminum honeycomb, (FR4 skins 0.5mm) Difference about stresses: Structures: 1,9 MPa to 2,3 MPa Skins: 0,4 MPa for both 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  20. Checking with sector 7 (45°) • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 skins 0.5mm, with 2 DoF for the screws) Sector 7 Global ~100µm ~1,5MPa As for sector 5, only ~37 microns out of the plane, but we found also an “unsticking” at the center of the spacer ~20µm ~37µm 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  21. Checking with sector 7 (45°) • Full size wedges with aluminum frames and aluminum honeycombs, only screwed on the external frame of an aluminum spacer (FR4 segmented skins 0.5mm, with 2 DoF for the screws) Sector 7 Global ~75µm ~1,2MPa As for sector 5, only ~30 microns out of the plane, but we found “unsticking” on all the internal bars of the spacer ~20µm ~30µm 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  22. Before conclusion : Status of the design for M4 prototype • Where we stand before this workshop ! As in the simulation, all is glued inside the quadruplet and we have spacers inside the drift gap (~40 ceramic pillars) Nota: During the production, the mesh can be dismounted and replaced (the frame of the mesh is screwed on the drift panel) A tension of 15N/cm is applied on the mesh The sealing can be tested by putting pressure up to 6mbars 2 doublets and 3 drift panels made with 10mm aluminum honeycombs 3 kinematic mounts are directly fixed on the central drift panel (4 screws M6) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  23. Before conclusion : Status of the design for M4 prototype • Preliminary drawings have been prepared ! • But before to launch the manufacturing we need to know exactly the criteria for the qualification of the mechanical prototypes (assembly method with a spacer?) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  24. Conclusion 1/3 • Statement for the design and the fixation of the quadruplets • The screwing of the quadruplets on the spacer can work if we are able to provide DoF around the screws without lost of the positioning (fixed point, sliding between the quadruplets and the spacer, alignment system) • Segmentation of the skins “introduced” different deformation of the IP and HO wedges. A high rigidity and planarity of the spacer are required to avoid to amplify this phenomena (Spacer made of stainless steel ?) • Simulations were conservative for the deformation out of the plan (equivalent Young modulus 17GPa) but… We measured higher stiffness for the panel (+30%, see talk from Fabien, “news from Saclay”), the stresses around the fixation could be increased (tbc) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  25. Conclusion 2/3 • Thermal simulations demonstrated that the main issue is the assembly of the quadruplets on the spacer • Kinematic mounts have been rejected (expansive, complex, risk to lose the absolute positioning after installation…etc.) • Gluing of the quadruplets on the spacer is the backup option (risk to lose a full sector in case of failure during the assembly) • Screwing is possible if we have under control the displacements (positioning and alignment) 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  26. Conclusion 3/3 • Parameters to have under control the displacements with screwed quadruplets • All the frames inside a quadruplets should have the same displacements (alignment is only outside) : With spacers inside the drift gap, gluing of all the components (inside a quadruplet) is the best option. • The local stresses around the supports and fixations must be applied only on the frames (no contact between screws and skins) • A fix point is needed, but all other fixations should allow the sliding (clearance around the screws) • Planarity of the spacer and quadruplet (and symmetry of the structures) is required to avoid amplification of the bending (rotation of the frames) • The material of the spacer can be adapted to reduce the gap between coefficient of thermal expansion (mass, cost, …): to be checked with new simulations 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

  27. Thank you for your attention ! Commissariat à l’énergie atomique et aux énergies alternatives Centre de Saclay| 91191 Gif-sur-Yvette Cedex T. +33 (0)1 69 08 79 30 | F. +33 (0)1 69 08 89 47 Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019 DSM IrfuSIS/LCAP (PC N°12, Bt 123)Patrick PONSOT 4th MMM workshop - CEA-Saclay/DSM/Irfu - Patrick PONSOT & Patrick GRAFFIN

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