MSC/MME Seminar HTS Demonstrator Mechanics GaToroid Project Jérôme Harray May 12, 2020
MSC/MME Seminar
HTS Demonstrator Mechanics GaToroid Project
Jérôme Harray
May 12, 2020
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
GaToroid Project • Demonstration of HTS
technology
• Development of a prototype in scalable conditions
• Potential mechanical impact of the presence of a pole
• Optimization of impregnation stress-state
• Minimization of cable stress-state
• Preload scenario investigation
GaToroid Project • LTS gantry design in
collaboration with hadron therapy centers
• Demonstration of HTS technology
• Design of a prototype in scalable conditions
• Mechanical evidence of design choices by numerical approach
• Rigorous analysis to enhance behavior understanding
2
Prototype designSetting the baseline
3
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
4
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
Grades
5
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
Spacers
Grades
6
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
Spacers
Grades
7
Grade jumps
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
Spacers
Grades
Pole
8
Grade jumps
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
Spacers
Grades
Outer Rim
Pole
9
Grade jumps
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Prototype Layout
Bolts
Spacers
Grades
Outer Rim
Pole
10
Grade jumps
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Development sequence
Winding Impregnation Cool-down LorentzAssembly
11
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Development sequence
Winding Impregnation Cool-down LorentzAssembly
How to jump from one grade to another?
12
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Development sequence
Winding Impregnation Cool-down LorentzAssembly
How to bolt the whole assembly?
How to jump from one grade to another?
13
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Development sequence
Winding Impregnation Cool-down LorentzAssembly
How to bolt the whole assembly?
How to jump from one grade to another?
How should we impregnate?
14
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Development sequence
Winding Impregnation Cool-down LorentzAssembly
How to bolt the whole assembly?
How to select materials?
How to jump from one grade to another?
How should we impregnate?
15
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Development sequence
Winding Impregnation Cool-down LorentzAssembly
How to bolt the whole assembly?
How to jump from one grade to another? How to validate grade stress-state?
16
How to select materials?
How should we impregnate?
ApproachNumerical implementation
17
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Multi-step static analysis
t
t
t
F
T
F
(1) Bolt pretension
(2) Cool-down
(3) Lorentz forces
18
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Multi-step static analysis
t
t
t
F
T
F
(1) Bolt pretension
(2) Cool-down
(3) Lorentz forces
19
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Multi-step static analysis
t
t
t
F
T
F
(1) Bolt pretension
(2) Cool-down
(3) Lorentz forces
20
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 21
• Tape material composition 70 % SS & 30 % Cu
• Stacked layout anisotropic orthotropic
∼
→ ∼
HTS modeling
ref: Barth, Christian & Mondonico, Giorgio & Senatore, Carmine. (2015). Electro-mechanical properties of REBCO coated conductors from various industrial manufacturers at 77 K, self-field and 4.2 K, 19 T. Superconductor Science and Technology.
Anisotropic
Tape
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 22
• Tape material composition 70 % SS & 30 % Cu
• Stacked layout anisotropic orthotropic
• HTS cable with insulation composition 19 % SS & 81 % Cu
∼
→ ∼
∼
HTS modeling
ref: Barth, Christian & Mondonico, Giorgio & Senatore, Carmine. (2015). Electro-mechanical properties of REBCO coated conductors from various industrial manufacturers at 77 K, self-field and 4.2 K, 19 T. Superconductor Science and Technology.
Anisotropic Anisotropic
Tape Cable
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 23
• Tape material composition 70 % SS & 30 % Cu
• Stacked layout anisotropic orthotropic
• HTS cable with insulation composition 19 % SS & 81 % Cu
• Lack of input data simplified material model
∼
→ ∼
∼
→
HTS modeling
ref: Barth, Christian & Mondonico, Giorgio & Senatore, Carmine. (2015). Electro-mechanical properties of REBCO coated conductors from various industrial manufacturers at 77 K, self-field and 4.2 K, 19 T. Superconductor Science and Technology.
Anisotropic Anisotropic Isotropic
Tape Cable Model
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 24
Material thermal properties
• Consideration of different alloys for structural components
• Importation of thermal properties from database
T [K]
CTE [K−1] CTE(K)
Coefficient Thermal ExpansionCTE →
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 25
Material thermal properties
• Consideration of different alloys for structural components
• Importation of thermal properties from database
• Integrated thermal properties from K to K300 4T [K]
CTE [K−1]
4 K 300 K
CTE(K)
Coefficient Thermal ExpansionCTE →
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 26
Material thermal properties
• Consideration of different alloys for structural components
• Importation of thermal properties from database
• Integrated thermal properties from K to K
• averaged value as input for static simulations
300 4
CTE
Al SS Ti HTS mixture
1,44E-05 9,9E-06 5E-06 1,10E-05CTEeq [C−1]
Coefficient Thermal ExpansionCTE →
T [K]
CTE [K−1]
4 K 300 K
CTEeq
CTE(K)
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
• Type of contact between components
27
A. Bonded where resin withstand
B. Frictional with
→
μ = 0.3
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
28
A. Bonded where resin withstand
B. Frictional with
→
μ = 0.3• Type of contact between components
Contact breakdown
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
• Contact between grades and spacers
Assumed as bonded for all configurations→
29
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
• Contact between the most inner grade and the pole
Assumed as either bonded or frictional depending on the configuration→
30
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
• Contact between the most outer grade and the outer rim
Assumed as either bonded or frictional depending on the configuration →
31
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
• Contact between the cover/intermediate plate and grades/spacers/pole/outer rim
Assumed all time as frictional→
32
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Contact definition
• Contact between the cover/intermediate plate and grades/spacers/pole/outer rim
Assumed all time as frictional→
33
If bonded simplified computation provides evidence of delamination→
Mechanical conceptFrom theory to practice
34
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Ideally Reality
35
• Lorentz forces try to open the coil
• Load converted into hoop stress
• HTS cable works in tension
• HTS not under a critical mode of failure
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Ideally Reality
• Lorentz forces try to open the coil
• Load converted into hoop stress
• HTS cable works in tension
• HTS not under a critical mode of failure
• Bizarre grade shapes
• Cool-down with difference
• Grade jumps are single points of failure
• Resin can give birth to delamination
CTE
36
ResultsPreload strategy
37
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 38
Motivations
• Importation Lorentz forces from magnetic simulations
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Importation Lorentz forces from magnetic simulations
• Lorentz forces expand the coil outward
39
Motivations
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Importation Lorentz forces from magnetic simulations
• Lorentz forces expand the coil outward
• Balance of this trend by applying some preloads inward
40
Motivations
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Importation Lorentz forces from magnetic simulations
• Lorentz forces expand the coil outward
• Balance of this trend by applying some preloads inward
• Advantage taken from cool-down phase
• Use of difference between material
• Materials with larger CTE considered for outer components
• Materials with smaller CTE considered for inner components
CTE
41
Motivations
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Material configurations
HTS tape Cu/SS
42
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Material configurations
HTS tape Cu/SS
43
Cover
Outer rim
Pole
Spacers
Intermediate plate
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Material configurations
HTS tape Cu/SS
44
Cover
Outer rim
Pole SS
Spacers
Intermediate plate
SS
A
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Material configurations
HTS tape Cu/SS
45
Cover
Outer rim
Pole SS SS
Spacers
Intermediate plate
SS Al
BA
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Material configurations
HTS tape Cu/SS
46
Cover
Outer rim
Pole SS SS Ti
Spacers
Intermediate plate
SS Al Al
A B C
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 47
Material choice
• Overall stress-state dominated by the cool-down phase
• Lorentz forces have a marginal effect on the overall stress-state
• Large configurations lead to dangerously high stress-state in grades
• difference between components may not be desired
ΔCTE
CTE
1 2 30
100
200
300
1 2 30
50
100
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
100
200
300
1 2 30
50
100
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
100
200
300
ABC
1 2 30
20
40
60
80
10022
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 48
Material choice
• Overall stress-state dominated by the cool-down phase
• Lorentz forces have a marginal effect on the overall stress-state
• Large configurations lead to dangerously high stress-state in grades
• difference between components may not be desired
ΔCTE
CTE
1 2 30
100
200
300
1 2 30
50
100
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
100
200
300
1 2 30
50
100
0 0.2 0.4 0.6 0.8 10
0.5
1
22
Full Stainless Steel configuration preferred to match HTS cable → CTE
1 2 30
100
200
300
ABC
1 2 30
20
40
60
80
100
ResultsImpregnation strategy
49
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
50
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
51
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
52
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
53
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
54
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
55
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
56
Contact stress-state
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-30
-20
-10
0
1 2 30
50
100
1 2 3-5
0
5
10
Contact stress-state
• When bonded to the outer rim, free shrinkage is prevented resin mostly working in tension
• Delamination at the end of the cool-down
• When frictional to the outer rim, presence of the pole increases the work in compression during cool-down
• When Lorentz forces are applied, delamination occurs if bonded to the pole
• Beneficial effect of Lorentz forces if not bonded to to any pole
• No noticeable difference in terms of contact shear
→1 1.5 2 2.5 3
-30
-20
-10
0
w/o - bondedw/o - frictional rimw/ - bonded
w/ - frictional rimw/ - frictional rim & poledebonding limit
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3-5
0
5
10
57
ResultsVon-Mises stress
58
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Grades stress-state
• Presence of the pole or bonding to the outer rim both lead the overall stress-state during cool-down
• Application of Lorentz forces has a stronger impact on stresses when there is no pole
• Larger overestimate due to safety factor over J × B
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100w/o - bondedw/o - frictional rimw/ - bondedw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
20
40
60
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.5
1
59
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Presence of the pole or bonding to the outer rim both lead the overall stress-state during cool-down
• Application of Lorentz forces has a stronger impact on stresses when there is no pole
• Larger overestimate due to safety factor over J × B
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100w/o - bondedw/o - frictional rimw/ - bondedw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
20
40
60
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.5
1
60
Grades stress-state1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Presence of the pole or bonding to the outer rim both lead the overall stress-state during cool-down
• Application of Lorentz forces has a stronger impact on stresses when there is no pole
• Larger overestimate due to safety factor over J × B
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100w/o - bondedw/o - frictional rimw/ - bondedw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
20
40
60
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.5
1
61
Grades stress-state
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Presence of the pole or bonding to the outer rim both lead the overall stress-state during cool-down
• Application of Lorentz forces has a stronger impact on stresses when there is no pole
• Larger overestimate due to safety factor over J × B
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100w/o - bondedw/o - frictional rimw/ - bondedw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
20
40
60
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.5
1
62
Grades stress-state1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Presence of the pole or bonding to the outer rim both lead the overall stress-state during cool-down
• Application of Lorentz forces has a stronger impact on stresses when there is no pole
• Larger overestimate due to safety factor over J × B
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100w/o - bondedw/o - frictional rimw/ - bondedw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
20
40
60
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.5
1
63
Grades stress-state
Where does the peak stress occur?
Under which stress type the cable is subjected to?
→
→
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Stress distribution
• Worst case scenario for stresses during nominal conditions
• Peak stress remains below MPa
• Peak stress occurs far from jumps
• Grades perfectly work in tension
• Configuration seems viable in terms of grades overall stress-state
100
64
ResultsGrade jumps
65
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 66
Jump layouts
• Singular point of failure in winding
• Double pancake configuration
• One pancake winded clockwise
• One pancake winded anti-clockwise
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 67
Jump layouts
• Singular point of failure in winding
• Double pancake configuration
• One pancake winded clockwise
• One pancake winded anti-clockwise
• Local disturbance in field homogeneity
• Jumps avoided in beam zone
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 68
Jump layouts
• Singular point of failure in winding
• Double pancake configuration
• One pancake winded clockwise
• One pancake winded anti-clockwise
• Local disturbance in field homogeneity
• Jumps avoided in beam zone
• Jump design implemented in first prototype carefully analyzed
+ A couple of pairs are investigated and validated
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 69
Jump layouts
• Criteria to characterize jump validity
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 70
Jump layouts
• Criteria to characterize jump validity
• If spacers and grades are bonded
• Reaction force at the jumps interface
• Contact pressure
• Contact shear
p
τ
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 71
Jump layouts
• Criteria to characterize jump validity
• If spacers and grades are bonded
• Reaction force at the jumps interface
• Contact pressure
• Contact shear
• If resin breaks and contacts all turn frictional
• Sliding distance
• Deformation and interaction between components
p
τ
ResultsBolts assessment
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Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Assembly of components numerically modeled
• Bolt stress-state available by FEA
• Safety factor verification according to norm ISO3506
• Equivalent stress computation:
σred,B = σ2zb,max + 3 (kt ⋅ τmax)2
Bolt
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Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Assembly of components numerically modeled
• Bolt stress-state available by FEA
• Safety factor verification according to norm ISO3506
• Equivalent stress computation:
• Safety factor on each bolts of at least during all stages:
σred,B = σ2zb,max + 3 (kt ⋅ τmax)2
1.5
Bolt
74
σred,B
Rp0.2min> 1.5
ConclusionDesign guidelines summary
75
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (1)
• No preload induced by difference is desired components in Stainless SteelCTE →
76
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (1)
• No preload induced by difference is desired components in Stainless Steel
• Impregnation guideline:
• Bonding of the coil pack with the cover and the intermediate plate leads to global risk of delamination surface treatment before impregnation
• Bonding of the coil pack with the outer rim and the pole leads to local risk of delamination design of specific tooling for impregnation
CTE →
→
→
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Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (1)
• No preload induced by difference is desired components in Stainless Steel
• Impregnation guideline:
• Bonding of the coil pack with the cover and the intermediate plate leads to global risk of delamination surface treatment before impregnation
• Bonding of the coil pack with the outer rim and the pole leads to local risk of delamination design of specific tooling for impregnation
• Overall stress-state in grades verified and viable
CTE →
→
→
78
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (1)
• No preload induced by difference is desired components in Stainless Steel
• Impregnation guideline:
• Bonding of the coil pack with the cover and the intermediate plate leads to global risk of delamination surface treatment before impregnation
• Bonding of the coil pack with the outer rim and the pole leads to local risk of delamination design of specific tooling for impregnation
• Overall stress-state in grades verified and viable
• Grade jumps implemented in the first demonstrator version are validated
CTE →
→
→
79
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (1)
• No preload induced by difference is desired components in Stainless Steel
• Impregnation guideline:
• Bonding of the coil pack with the cover and the intermediate plate leads to global risk of delamination surface treatment before impregnation
• Bonding of the coil pack with the outer rim and the pole leads to local risk of delamination design of specific tooling for impregnation
• Overall stress-state in grades verified and viable
• Grade jumps implemented in the first demonstrator version are validated
• Components of assembly assessed safety factor on bolts all time greater than
CTE →
→
→
→ 1.5
80
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (2)
• Two remaining viable configurations:
A. With pole - frictional with pole & outer rim
B. Without pole - frictional with outer rim
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Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
Conclusion (2)
• Two remaining viable configurations:
A. With pole - frictional with pole & outer rim
B. Without pole - frictional with outer rim
A B
Could reach higher mean MPa
Smaller local deformation
σVM ∼ 40 Could reach smaller mean MPa
Larger local deformation
σVM ∼ 30
Stainless Steel structural components
Work similarly well in compression at resin/resin contacts
82
What’s next?Let’s move forward
83
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Major importance of accurate determination numerically demonstrated
• Experimental characterization of cable stacked samples
• measurements in different directions
CTE
CTE
What’s next? (1)
84
stre
ss v
aria
tion
[%]
-100
-50
0
50
100
CTE variation [%]
-10 0 10
stre
ss v
aria
tion
[%]
-1,5-0,75
00,75
1,52,25
3
E variation [%]
-10 0 10
coils mean stresscoils peak stress
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
• Numerical model with anisotropic cable model already defined
• Layered material
• Local coordinates system at the element level
• Experimental data waited as input for anisotropic modeling
What’s next? (2)
85
• Enrico Felcini and Tuukka Lehtinen as well as the whole Engineering Unit for their constant support and availability
• Luca Bottura and Diego Perini for their trust and supervision in these turbulent times
• Glyn Kirby, Daniel Schoerling, Gijs de Rijk, Juan Carlos Perez, Jacky Mazet, Nicolas Bourcey, Francois Olivier Pincot for their wise advices as well as all the insightful interactions and discussions
• EN/MME, TE/MSC and CERN-KT for their warm welcome
Acknowledgements
Je te l’avais promis!
Additional informationsBack-up slides
87
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 30
5
10
15
1 2 30
2
4
0 0.2 0.4 0.6 0.8 10
0.5
1
88
Contact shear
• All solutions mainly lead by the difference in
• Lorentz forces tend to curve/bend the bonded components increase of shear
• Solutions cannot be distinguished according to the behavior in shear
• Peak values seem acceptable for all solutions
CTE
→
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
50
100w/o - bondedw/o - frictional rimw/ - bondedw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
20
40
60
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.5
1
1 2 30
50
100
1 2 30
20
40
60
0 0.2 0.4 0.6 0.8 10
0.5
1
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 30
0.02
0.04
0.06
1 2 30
0.005
0.01
1 2 30
0.01
0.02
0.03
89
Outer rim gap
• The pole limits the overall structure shrinkage
• Bonding to the pole prevents structure expansion during Lorentz forces application
• Presence of the pole delays the contact with the outer rim
NB: Gap magnitude of the order of few tens of m
• If structure seen as an equivalent cylinder:
m
μ
deq = ΔCTE × Req × ΔT ∼ 75 μ
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.02
0.04
0.06
w/o - frictional rimw/ - frictional rimw/ - frictional rim & pole
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.005
0.01
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 30
0.01
0.02
0.03
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020
1 2 3-150
-100
-50
0
1 2 30
200
400
1 2 3
-20
-10
0
90
Contact pressure
• If bonded to the cover and the intermediate plate response dominated by the difference between HTS & SS
• Peak in compression reaches significant magnitude
• Work mainly in tension and above the debonding limit
Inevitable delamination at each grade
→ CTE
→
1 1.5 2 2.5 3-150
-100
-50
0
w/ - fully bondeddebonding limit
1 1.5 2 2.5 30
200
400
1 1.5 2 2.5 3
-20
-10
0
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 91
Grade jump layoutsv1.1
v1.2
v2.1
v2.2
Jérôme Harray | HTS Demonstrator Mechanics - GaToroid ProjectMay 12, 2020 92
home.cern 93