preliminary calculation of the tracking detector barrels and the support tube szymon sroka clicdp...
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Preliminary Calculation of the Tracking Detector Barrels and the Support Tube
Szymon Sroka
CLICdp Tracker Technology Meeting
Szymon Krzysztof Sroka 30/07/2015
2Szymon Krzysztof Sroka 30/07/2015
Presentation Layout
I. Tracking Detector
Barrels General Description
Analytical Solution
Comparison to FEA solution
Different Lay-ups
III. Beam Pipe & Support Tube Beam pipe
- Dimensions
- Support
- FEA Calculations
Support Tube - FEA Calculations
IV. Conclusions & Outlook
II. Conclusions
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Tracking Detector Barrels
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General Description Current tracker dimensions
Gap for services of inner region (cables + air cooling ducts) and connection of support tube to the ECAL barrel
Tracking Detector Barrels – Dimensions
Number of
Barrels
Radii of Barrels [mm]
Length of
Barrels [mm]
Thickness of Honeycomb Core [mm]
Thickness of CF Skins [mm]
Mass of each
Barrel [kg]
1 230 860 10 0.6 2.853 840 2060 15 1.2 48.14 1145 2660 25 1.2 90.15 1450 3260 25 1.2 140
Basic Requirements:
- Lightweight structure
- minimizing the radiation length
- Maximum deflection in the range of 100 [µm]
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General DescriptionComposite Construction
Benefits of HONEYCOMB Sandwich Construction:Analogy Sandwich Panel to an I-Beam
The 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
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General DescriptionCross section of the Barrels
T2T1
Inne
r D
iam
eter
T1
Out
er D
iam
eter
Honeycomb Layer
CFRS Layer
Deflection of Barrel
Natural 1. vibration mode of Barrel
Materials - choices (as an example)CF Skins - Toray M55J + Cycom 950-1
Honeycomb Core - XRH-10/OX-3/16-1.8
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General Description Different Honeycomb Features
Material Property Honeycomb Advantages
Foam includes
- polyvinyl chloride (PVC)
Relatively low crush strength and stiffness Excellent crush strength and stiffness
- polymethacrylimide Increasing stress with increasing strain Constant crush strength
- polyurethane Friable Structural integrity
- polystyrene Limited strength Exceptionally high strengths available
- phenolic Fatigue High fatigue resistance
- polyethersulfone (PES)
Cannot be formed around curvatures
OX-Core and Flex-Core cell configurationsfor curvatures
Wood-based includes
- plywood Very heavy density Excellent strength-to-weight ratio
- balsa Subject to moisture degradation Excellent moisture resistance
- particleboard Flammable Self-extinguishing, low smoke versions available
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General DescriptionSandwich Structure – Failure Modes1. Strength - Skin Compression failure 2. Stiffness – Excessive deflection 3. Buckling
4. Shear Crimping 5. Skin wrinkling 6. Intra cell buckling
7. Local compression
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General Description Boundary Conditions
BC.s - Considered cases: Simply Supported
Clamped
Clamped – Simply Supported
Cantilever
BC.s - Considered cases: 2-vertices plus Elastic Support
4-vertices Support (the most extreme case in
the context of deflection)
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Two 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 )
External Load
ComponentMateria
lThickness
[µm]
Module
FPC Metal Layer Aluminium 50
FPC Insulating Layers Polyimide 100
Module Plate Carbon Fibre 120Pixel Chip Silicon 300
Glue Eccobond 54 100
Cold Plate
Carbon fleece 40
Graphite foil 30Cooling pipe Polyimide 64Cooling fluid Water -Carbon Plate Carbon Fibre 120
Glue Eccobond 54 100
Power Bus Metal Layer Aluminium 200
Insulating layers Polyimide 200Glue Eccobond 54 100
General Description Loads from ALICE
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Analytical 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 calculations
Carbon Fibre Skins are modelled as transversely Isotropic Material for FEA
Honeycomb Core is modelled as Orthotropic Material for FEA
The 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
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Orthotropic Material An 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 direction
- The y-axis is in the plane of the layer and perpendicular to the fibres
- The z-axis is perpendicular to the plane of the layer and thus perpendicular
to the fibres.
Only nine constants are required to describe an orthotropic material.
Transversely Isotropic Material A 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.
Analytical Solution
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Analytical SolutionDeflections of the TD Barrels
1. Bending Deflection 2. 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 properties
x
L
Q
Flexural Stiffness:
Shear Stiffness:
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3. Total Deflection = Bending Deflection + Shear Deflection Flexural Stiffness:Shear Stiffness:
Analytical SolutionDeflections of the TD Barrels
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Deflection of Barrels made of Sandwich Structure ( CF SKINS PLUS HONEYCOMB CORE)
Number of CASE 1
Number Of
Cylinders
Radii 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 [%]
1 230 860 0.6 10 2.834 3.916 5.3949 6.2065 224.04 13.07661323 0.5368 1.012 1.549
9.387
2 525 1460 0.6 15 11.8989 15.159 15.5162 20.574 107.97 24.58345485 0.572 1.001 1.573
3 840 2060 1.2 15 48.018 33.396 21.4647 31.048 67.21 30.86607833 1.0385 1 2.039
4 1145 2660 1.2 25 90.0349 59.113 36.6811 55.585 57.897 34.00899523 1.1088 1.004 2.113
5 1450 3260 1.2 25 139.7364 91.449 55.0187 85.759 40.179 35.8449842 1.1088 1.004 2.113
Comparison to FEA SolutionAnalytical Calculations vs FEA simplistic model
1 2 3 4 50
10
20
30
40
50
60
70
80
90
100 Defl ection of Tracking Detector Barrels
Deflection of Barrels - Handmade Calculations [µm] Deflection of Barrels - ANSYS [µm]
Number of Barrels
Sag
[µm
]
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Different Layup
Tracking Detector Barrels Configuration
number Lay -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]
Each Lay-up consists of 6 sub-layers
Thickness of 1 sub - layer:
- 100 µm (Thickness of CFS -0.6 mm)
- 200 µm (Thickness of CFS -1.2 mm)
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Tracking Detector Barrels – Dimensions
Number of Barrels
Radii of Barrels [mm]
Length of Barrels [mm]
Thickness of Honeycomb Core
[mm]
Thickness of CF Skins [mm] Mass of
each Barrel [kg]
1 230 860 10 0.6 2.85
3 840 2060 15 1.2 48.1
4 1145 2660 25 1.2 90.1
5 1450 3260 25 1.2 140
Different LayupFEA simulations in ANSYSThickness of CFS and Honeycomb Core
Second Barrel is not treated here. It was replaced by the Support Tube
30/07/2015 Szymon Krzysztof Sroka
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1 2 3 4 5 6 7 8 9 10 11 12 130
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Defl ection of 1st Tracking Detector Layer
Deflection of TS Layers - for BCs Simply Supported [µm] Deflection of TS Layers - for BCs Clamped [µm]Deflection of TS Layers - for Invented BCs_1 (4E+2V) [µm] Deflection of TS Layers - for Invented BCs_2 (4V) [µm]Deflection of TS Layers - for BCs Clamped - Simply Supported [µm] Deflection of TS Layers - for BCs Cantilever [µm]Deflection of TS Layers - for BCs Elastic Support + 2_VERTEX for Xefs_1 [µm]
Lay-up
Sag
[µm
]
Different Layup ANSYS Results
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1 2 3 4 5 6 7 8 9 10 11 12 130
20
40
60
80
100
120
Defl ection of 3rd Tracking Detector Layer
Deflection of TS Layers - for BCs Simply Supported [µm] Deflection of TS Layers - for BCs Clamped [µm]Deflection of TS Layers - for Invented BCs_1 (4E+2V) [µm] Deflection of TS Layers - for Invented BCs_2 (4V) [µm]Deflection of TS Layers - for BCs Clamped - Simply Supported [µm] Deflection of TS Layers - for BCs Cantilever [µm]Deflection of TS Layers - for BCs Elastic Support + 2_VERTEX for Xefs_1 [µm]
Lay-up
Sag
[µm
]
100 [µm] – Limit Value
Different Layup ANSYS Results
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1 2 3 4 5 6 7 8 9 10 11 12 130
50
100
Defl ection of 4th Tracking Detector Layer
Deflection of TS Layers - for BCs Simply Supported [µm] Deflection of TS Layers - for BCs Clamped [µm]Deflection of TS Layers - for Invented BCs_1 (4E+2V) [µm] Deflection of TS Layers - for Invented BCs_2 (4V) [µm]Deflection of TS Layers - for BCs Clamped - Simply Supported [µm] Deflection of TS Layers - for BCs Cantilever [µm]Deflection of TS Layers - for BCs Elastic Support + 2_VERTEX for Xefs_1 [µm]
Lay-up
Sag
[µm
]
100 [µm] – Limit Value
Different Layup ANSYS Results
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1 2 3 4 5 6 7 8 9 10 11 12 130
50
100
150
200
250
300
Defl ection of 5th Tracking Detector Layer
Deflection of TS Layers - for BCs Simply Supported [µm] Deflection of TS Layers - for BCs Clamped [µm]Deflection of TS Layers - for Invented BCs_1 (4E+2V) [µm] Deflection of TS Layers - for Invented BCs_2 (4V) [µm]Deflection of TS Layers - for BCs Clamped - Simply Supported [µm] Deflection of TS Layers - for BCs Cantilever [µm]Deflection of TS Layers - for BCs Elastic Support + 2_VERTEX for Xefs_1 [µm]
Lay-up
Sag
[µm
]
100 [µm] – Limit Value
Different Layup ANSYS Results
22
Conclusions:
Szymon Krzysztof Sroka 30/07/2015
Comparison between Analytical and FEA calculations on ≤ 40 %
Deformation critically depending on specific Lay-up and Boundary Conditions
All Tracker Detector Barrels seem to be feasible and can obtain small deformation
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Beam Pipe & Support Tube
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Beam pipe - Dimensions
SSt
Be
CFRP
(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
Steel
Cylindrical 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 part2
Cylindrical part3
Cylindrical part1
Support_1 Support_2
z1z2
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Beam 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 account
Support_1 –> z=1750 [mm]
Support_2 –> z=350 [mm]
Be
SSt
Cylindrical part1
Conical part2
Cylindrical 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 part3
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1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 24000
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
Z - Location of the Support_1 vs Stresses for the fixed Location of Support_2 z = 350 [mm]
P10 - Support_loc1 (mm)
z - Location of the Support_1 [mm]
σ [M
Pa]
Beam Pipe - SupportIterative identification of the supports location
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350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 17000
0.020.040.060.08
0.10.120.140.160.18
0.20.220.240.260.28
0.30.320.340.360.38
0.40.420.440.460.48
0.5
Z - Location of the Support_2 vs Stresses for the fixed Location of Support_1 z = 1750 [mm]
P9 - Support_loc2 (mm)
z- Location of the Support_2 [mm]
σ [M
Pa]
Beam Pipe - SupportIterative identification of the supports location
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60 degrees
S1_T
S1_B
S3_T
S3_B
90 degrees
S1_T S1_T
S1_B S1_B
120 degrees
S2_B S2_B
S2_T
Beam Pipe - SupportDesign Proposal of the Beam Pipe Support
29
Max.Defomration = 2.4 [µm]
Szymon Krzysztof Sroka 30/07/2015
Beam Pipe - FEA Calculations
Max.Defomration = 75 [µm]
σ. max = 0.63 [MPa]
Rod properties
Sn ln [mm] kn [N/mm]Pre-Load [N]
R.Force [N]
S1_T 428 1327.5 500 440
S1_B 428 1327.5 163 122
S3_T 428 1327.5 500 440
S3_B 428 1327.5 163 122
S2_T 537 1058 40 42
S2_B 538 1055 20 19
The results under its own weight:
30Szymon Krzysztof Sroka 30/07/2015
Beam 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] !
31Szymon Krzysztof Sroka 30/07/2015
Support 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 Barrels
Loads 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- up
Support Tube Configuration
number Lay -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]
32Szymon Krzysztof Sroka 30/07/2015
Support Tube - FEA Calculations
Example:
CFS thickness – 1.2 [mm]
Honeycomb Core – 30 [mm]
Max.Local.Deflection – 207 µm
BC.s -Simply Supported
Layup 6
33
1 6 11400
450
500
550
600
650
700
750
800
850
900
Defl ection of Support Tube in terms of Layup (for CFS 0.6 [mm] and Core Thickness 15 [mm] )
Deflection of ST- for BCs Simply Supported (Core thickness - 15 mm )[µm] Deflection of ST- for BCs Clamped (Core thickness - 15 mm ) [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 15 mm ) [µm] Deflection of ST- for BCs Elastic Support for Xefs_1 + 2_VERTEX (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 15 mm ) [µm]
Lay-up
Sag
[µm
]
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Support Tube - FEA Calculations
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1 6 11200
250
300
350
400
450
Defl ection of Support Tube in terms of Layup (for CFS 1.2 [mm] and Core Thickness 15 [mm] )
Deflection of ST- for BCs Simply Supported (Core thickness - 15 mm )[µm] Deflection of ST- for BCs Clamped (Core thickness - 15 mm ) [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 15 mm ) [µm] Deflection of ST- for BCs Elastic Support for Xefs_1 + 2_VERTEX (Core thickness - 15 mm ) [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 15 mm ) [µm]
Lay-up
Sag
[µm
]
Support Tube - FEA Calculations
35
1 6 11300
400
500
600
Defl ection of Support Tube in terms of Layup (for CFS 0.6 [mm] and Core Thickness 30 [mm] )
Deflection of ST- for BCs Simply Supported (Core thickness - 30 mm ) [µm] Deflection of ST- for BCs Clamped (Core thickness - 30 mm [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 30 mm [µm]Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm]
Lay-up
Sag
[µm
]
Szymon Krzysztof Sroka 30/07/2015
Support Tube - FEA Calculations
36
1 6 11150
250
350
Defl ection of Support Tube in terms of Layup (for CFS 1.2 [mm] and Core Thickness 30 [mm] )
Deflection of ST- for BCs Simply Supported (Core thickness - 30 mm ) [µm] Deflection of ST- for BCs Clamped (Core thickness - 30 mm [µm]Deflection of ST- for BCs Clamped - Simply Supported (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4E+2V) (Core thickness - 30 mm [µm]Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm] Deflection of ST- for Invented BCs_1 (4V) (Core thickness - 30 mm [µm]
Lay-up
Sag
[µm
]
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Support Tube - FEA Calculations
37
Conclusions:
Szymon Krzysztof Sroka 30/07/2015
Front 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 needed
Continuation work on Support Tube validation plus more detailed Beam Pipe analysis