Preliminary Calculation of the Tracking Detector Barrels and the Support Tube - PowerPoint Presentation

1. Preliminary Calculation of the Tracking Detector Barrels and the Support Tube Szymon SrokaCLICdp Tracker Technology MeetingSzymon Krzysztof Sroka 30/07/2015

2. Szymon Krzysztof Sroka 30/07/2015Presentation LayoutI. Tracking Detector Barrels General Description Analytical Solution Comparison to FEA solution Different Lay-ups2III. Beam Pipe & Support Tube Beam pipe - Dimensions - Support - FEA CalculationsSupport Tube - FEA CalculationsIV. Conclusions & OutlookII. Conclusions

3. Szymon Krzysztof Sroka 30/07/2015Tracking Detector Barrels 3

4. Szymon Krzysztof Sroka 30/07/2015General Description Current tracker dimensionsGap for services of inner region (cables + air cooling ducts) and connection of support tube to the ECAL barrelTracking Detector Barrels – DimensionsNumber of BarrelsRadii of Barrels [mm]Length of Barrels [mm] Thickness of Honeycomb Core [mm]Thickness of CF Skins [mm]Mass of each Barrel [kg] 1230860100.62.8538402060151.248.1411452660251.290.1514503260251.2140Basic Requirements:Lightweight structureminimizing the radiation lengthMaximum deflection in the range of 100 [µm]4

5. Szymon Krzysztof Sroka 30/07/2015General DescriptionComposite ConstructionBenefits of HONEYCOMB Sandwich Construction:Analogy Sandwich Panel to an I-BeamThe facing skins of a sandwich panel can be compared to the flanges of I-beam. They carry the bending stresses to which the beam is subjected. With one facing skin in compression and the other is in tension.The Honeycomb Core corresponds to the web of I-beam. The core resists the shear loads, increase the stiffness of the structure by holding the facing skins apart 5

6. Szymon Krzysztof Sroka 30/07/2015General DescriptionCross section of the BarrelsT2T1Inner DiameterT1Outer DiameterHoneycomb LayerCFRS Layer6Deflection of Barrel Natural 1. vibration mode of BarrelMaterials - choices (as an example)CF Skins - Toray M55J + Cycom 950-1Honeycomb Core - XRH-10/OX-3/16-1.8

7. Szymon Krzysztof Sroka 30/07/2015General Description Different Honeycomb FeaturesMaterial Property Honeycomb Advantages Foam includes - polyvinyl chloride (PVC)Relatively low crush strength and stiffnessExcellent crush strength and stiffness- polymethacrylimideIncreasing stress with increasing strainConstant crush strength- polyurethaneFriableStructural integrity- polystyreneLimited strengthExceptionally high strengths available- phenolicFatigueHigh fatigue resistance- polyethersulfone (PES)Cannot be formed around curvaturesOX-Core and Flex-Core cell configurationsfor curvaturesWood-based includes- plywoodVery heavy densityExcellent strength-to-weight ratio- balsaSubject to moisture degradationExcellent moisture resistance- particleboardFlammableSelf-extinguishing, low smoke versions available7

8. Szymon Krzysztof Sroka 30/07/2015General DescriptionSandwich Structure – Failure Modes1. Strength - Skin Compression failure 2. Stiffness – Excessive deflection 3. Buckling 4. Shear Crimping 5. Skin wrinkling 6. Intra cell buckling7. Local compression8

9. Szymon Krzysztof Sroka 30/07/2015General Description Boundary ConditionsBC.s - Considered cases:Simply SupportedClamped Clamped – Simply Supported Cantilever 9BC.s - Considered cases:2-vertices plus Elastic Support 4-vertices Support (the most extreme case in the context of deflection)

10. Szymon Krzysztof Sroka 30/07/2015Two gravitational forces: - Own weight of the Barrels - External load = Mass of Modules + Mass of Cold plates+ Mass of Power Buses (Material budget for the modules, cooling system and cables was extrapolated for CLIC from ALICE’s upgrade project ) 10External LoadComponentMaterialThickness [µm]Module FPC Metal LayerAluminium 50FPC Insulating LayersPolyimide100Module PlateCarbon Fibre120Pixel ChipSilicon300Glue Eccobond 54100Cold PlateCarbon fleece40Graphite foil30Cooling pipePolyimide64Cooling fluid Water -Carbon PlateCarbon Fibre120GlueEccobond 54100Power Bus Metal LayerAluminium200Insulating layersPolyimide200GlueEccobond 54100General Description Loads from ALICE

11. Szymon Krzysztof Sroka 30/07/2015Analytical SolutionFirst step; easy and simple caseSimplifications:Composite Laminate material (Matrix plus Fibres) and Honeycomb Core are considered as a homogenous, isotropic material for the hand calculationsCarbon Fibre Skins are modelled as transversely Isotropic Material for FEAHoneycomb Core is modelled as Orthotropic Material for FEAThe comparison between the hand calculations and FEA simulations was done without any Lay-up BC.s - Simply supported Carbon Fibre Skins (top and bottom one)- selected material Toray M55J + Cycom 950-1 11

12. Szymon Krzysztof Sroka 30/07/2015Orthotropic MaterialAn Orthotropic material has three planes of symmetry that coincide with the coordinate planes .One plane of symmetry is perpendicular to the fibre direction, and to other two can be any pair of plane orthogonal to the fibre direction. The x-axis is aligned with the fibre directionThe y-axis is in the plane of the layer and perpendicular to the fibresThe z-axis is perpendicular to the plane of the layer and thus perpendicularto the fibres. Only nine constants are required to describe an orthotropic material. Transversely Isotropic MaterialA transversely isotropic material has one axis of symmetry Transversal isotropic materials are orthotropic materials characterized by isotropic material behaviour in one material symmetry plane A unidirectional layer has transversal isotropic material behaviour with the fiber direction as symmetry axis The z-axis is perpendicular to the plane of the layer and thus perpendicular to the fibres. The number of constants to define is reduced to 5. 12Analytical Solution

13. Szymon Krzysztof Sroka 30/07/2015Analytical SolutionDeflections of the TD Barrels1. Bending Deflection2. Shear Deflection Calculation of the deflection due to bending: Calculation of the deflection due to shear:Assumption: B.C. - Simply supported Beam (Timoshenko Beam Theory)Bending depends on the skins properties; Shear depends on the core properties13xLQFlexural Stiffness:Shear Stiffness:

14. Szymon Krzysztof Sroka 30/07/20153. Total Deflection = Bending Deflection + Shear Deflection 14Flexural Stiffness:Shear Stiffness:Analytical SolutionDeflections of the TD Barrels

15. Szymon Krzysztof Sroka 30/07/2015Deflection of Barrels made of Sandwich Structure ( CF SKINS PLUS HONEYCOMB CORE)Number of CASE 1Number Of CylindersRadii Of Barrels [mm]Length Of Barrels [mm]THICKNESS OF CF SKINS [mm]THICKNESS OF HONEYCOMB CORE [mm]Mass Of each Barrels [kg]Mass of Equipment [kg]Deflection of Barrels - Handmade Calculations [µm]Deflection of Barrels - ANSYS [µm]Eigenvalue - Natural frequency of Cylinders [Hz]Difference between Handmade Calculations and Ansys Simulations [%]% Of Radiation Length of each Barrels - Mechanics [%]% Of Radiation Length of each Barrel - SEN+COOLING [%]% Of Radiation Length of each Barrel - TOTAL [%]% Of Radiation Length of Barrels - TOTAL SUM [%]12308600.6102.8343.9165.39496.2065224.0413.076613230.53681.0121.5499.387252514600.61511.898915.15915.516220.574107.9724.583454850.5721.0011.573384020601.21548.01833.39621.464731.04867.2130.866078331.038512.0394114526601.22590.034959.11336.681155.58557.89734.008995231.10881.0042.1135145032601.225139.736491.44955.018785.75940.17935.84498421.10881.0042.113Comparison to FEA SolutionAnalytical Calculations vs FEA simplistic model15

16. Szymon Krzysztof Sroka 30/07/2015Different Layup Tracking Detector Barrels Configuration numberLay -up 1[0/-45/+45/+45/-45/0]2[90/-45/+45/+45/-45/90]3[90/-45/+10/+10/-45/90]4[0/-15/+15/+15/-15/0] !5[90/-15/+15/+15/-15/90]6[0/-75/+75/+75/-75/0]7[0/-45/90/90/-45/0]8[90/-45/0/0/-45/90]9[90/30/-30/-30/30/90]10[0/60/-60/-60/60/0]11[45/-45/0/0/-45/45]12[0/90/0/0/90/0]13[90/0/90/90/0/90]16Each Lay-up consists of 6 sub-layersThickness of 1 sub - layer:- 100 µm (Thickness of CFS -0.6 mm)- 200 µm (Thickness of CFS -1.2 mm)

17. 30/07/201517Tracking Detector Barrels – DimensionsNumber of BarrelsRadii of Barrels [mm]Length of Barrels [mm] Thickness of Honeycomb Core [mm]Thickness of CF Skins [mm]Mass of each Barrel [kg] 1230860100.62.8538402060151.248.1411452660251.290.1514503260251.2140Different LayupFEA simulations in ANSYSThickness of CFS and Honeycomb CoreSecond Barrel is not treated here. It was replaced by the Support Tube30/07/2015Szymon Krzysztof Sroka

18. Szymon Krzysztof Sroka 30/07/2015Different Layup ANSYS Results18

19. Szymon Krzysztof Sroka 30/07/201519Different Layup ANSYS Results

20. Szymon Krzysztof Sroka 30/07/201520100 [µm] – Limit ValueDifferent Layup ANSYS Results

21. Szymon Krzysztof Sroka 30/07/201521100 [µm] – Limit ValueDifferent Layup ANSYS Results

22. Conclusions:Szymon Krzysztof Sroka 30/07/201522Comparison between Analytical and FEA calculations on ≤ 40 %Deformation critically depending on specific Lay-up and Boundary ConditionsAll Tracker Detector Barrels seem to be feasible and can obtain small deformation

23. Szymon Krzysztof Sroka 30/07/2015 Beam Pipe & Support Tube 23

24. Szymon Krzysztof Sroka 30/07/2015Beam pipe - Dimensions SStBeCFRP(based on modified CLIC_ILD design)Objectives:- Determining the z - location for the Supports in order to minimize stresses in the sensitive connection area between Beryllium & Stainless Steel24Cylindrical Part1: R1=30 [mm], L= 308 [mm], T1= 0.6 [mm]Conical Part2: R1=30 [mm], R2=240 [mm, L= 1820 [mm], T2= 4.8 [mm]Cylindrical Part3: R2=240 [mm], L= 381 [mm], T3= 4.8 [mm] Conical part2Cylindrical part3Cylindrical part1Support_1Support_2z1z2

25. Szymon Krzysztof Sroka 30/07/2015Beam Pipe - SupportIterative identification of the supports location Assumptions/ Simplifications:Based on the symmetry was modelled one quarter of the Beam Pipe.In the first approach the beam pipe is supported in two places on the edges (only displacements in x-axis and y axis are blocked).During the determination of the support position, only solely weight of the Beam pipe is taken into accountSupport_1 –> z=1750 [mm]Support_2 –> z=350 [mm]BeSStCylindrical part1Conical part2Cylindrical Part1: R1=30 [mm], L= 308 [mm], T1= 0.6 [mm]Conical Part2: R1=30 [mm], R2=240 [mm, L= 1820 [mm], T2= 4.8 [mm]Cylindrical Part3: R2=240 [mm], L= 381 [mm], T3= 4.8 [mm] Cylindrical part325

26. Szymon Krzysztof Sroka 30/07/201526Beam Pipe - SupportIterative identification of the supports location

27. Szymon Krzysztof Sroka 30/07/201527Beam Pipe - SupportIterative identification of the supports location

28. Szymon Krzysztof Sroka 30/07/201560 degreesS1_T S1_B S3_T S3_B 90 degreesS1_T S1_T S1_B S1_B 120 degreesS2_B S2_B S2_T 28Beam Pipe - SupportDesign Proposal of the Beam Pipe Support

29. Max.Defomration = 2.4 [µm]Szymon Krzysztof Sroka 30/07/2015Beam Pipe - FEA Calculations Max.Defomration = 75 [µm]σ. max = 0.63 [MPa]Rod properties Snln [mm]kn [N/mm]Pre-Load [N]R.Force [N] S1_T4281327.5500440S1_B4281327.5163122S3_T4281327.5500440S3_B4281327.5163122S2_T53710584042S2_B53810552019The results under its own weight:29

30. Szymon Krzysztof Sroka 30/07/2015Beam Pipe - FEA Calculations The results under its own weight and the pressure influence (UHV):σ. max = 44 [MPa]Max.Defomration = 42 [µm]Alert - Front flange of the Beam pipe only 1 mm thick !Max.Defomration = 8210.9 [µm] !30

31. Szymon Krzysztof Sroka 30/07/2015Support Tube - FEA Calculations Assumptions for the analysis :Support Tube is also modelled as a sandwich structure (Cylinder consists of three layers; honeycomb core including top and bottom carbon skin). We are considering two different Core thickness (15 and 30 mm) and two different thickness of Carbon Fibres Skins (0.6 and 1.2 mm).Boundary conditions are the same for each of the Tracking Detector BarrelsLoads in the performed analysis take into account the weight of the Support Tube and all the forces coming from the beam pipe.In the framework of FEA analysis have chosen only four lay- upSupport Tube Configuration numberLay -up 1[0/-45/+45/+45/-45/0]6[0/-75/+75/+75/-75/0]11[45/-45/0/0/-45/45]13[90/0/90/90/0/90]31

32. Szymon Krzysztof Sroka 30/07/2015Support Tube - FEA Calculations 32Example:CFS thickness – 1.2 [mm]Honeycomb Core – 30 [mm]Max.Local.Deflection – 207 µmBC.s -Simply SupportedLayup 6

33. Szymon Krzysztof Sroka 30/07/201533Support Tube - FEA Calculations

34. Szymon Krzysztof Sroka 30/07/201534Support Tube - FEA Calculations

35. Szymon Krzysztof Sroka 30/07/201535Support Tube - FEA Calculations

36. Szymon Krzysztof Sroka 30/07/201536Support Tube - FEA Calculations

37. Conclusions:Szymon Krzysztof Sroka 30/07/201537Front flange of Beam Pipe will need to be thicker as it, there is too much deformation under vacuum. From the results the Support Tube is suitable but there is some local deformation due to gravitational load on the Beam Tube.Outlook:Space Frame structure made of composite material maybe be valid for CLIC tracker - investigation neededContinuation work on Support Tube validation plus more detailed Beam Pipe analysis

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