Welding Station Design Analysis Colin Narug - Fermilab HL-LHC AUP - - PowerPoint PPT Presentation

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Welding Station Design Analysis Colin Narug - Fermilab HL-LHC AUP Production Readiness Review Dec. 14 th 2018 Overview Requirements Areas of Interest FEA Setup Simulation Results Leveling Feet Results Weld Calculation

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Welding Station Design Analysis

Colin Narug - Fermilab

HL-LHC AUP Production Readiness Review – Dec. 14th 2018

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Overview ▪ Requirements ▪ Areas of Interest ▪ FEA Setup ▪ Simulation Results ▪ Leveling Feet Results ▪ Weld Calculation Results ▪ Results Summary ▪ Backup Slides

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Requirements ▪ The cold mass will be supported by 5 weld stations

▪ Each weld station will have 2-4 saddle supports ▪ Weight of cold mass is effectively evenly distributed

▪ Weld stations should minimize deformation ▪ Stress on all components should be below the allowable yield ▪ A combination of FEA and manual calculations was performed to verify design requirements

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Areas of Interest ▪ Stress in Frame ▪ Saddle Support Deformation ▪ Leveling Feet ▪ Welds

▪ Only on the sections supporting the saddle support

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Simulation Setup ▪ Simulation ran for each weld station configuration

▪ 5 weld stations

▪ 3 different configurations of saddle supports

▪ Load on each saddle support was calculated ▪ Models cleaned and imported into ANSYS 18.2

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Simulation Setup ▪ Models meshed

▪ Between 672K – 723K Nodes

▪ Boundary conditions applied

▪ Calculated reaction forces on each saddle support ▪ Fixed supports

▪ 6 for leveling feet ▪ 4 for alignment bolts

▪ Gravitational acceleration

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Simulation Setup ▪ Model setup for the 5 different configurations ▪ Properties solved for:

▪ Equivalent Stress ▪ Total Deformation ▪ Horizontal and Vertical Deformation ▪ Force Reactions:

▪ For welds of interest ▪ Fixed supports

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Material Density (g/cc) Modulus of Elasticity (GPa) Possion's Ratio Bulk Modulus (GPa) Shear Modulus (GPa) Allowable Yield (MPa) ASTM A500, Grade B 7.8 205.71 0.286 160 80 157.5 ASTM A36 Steel 7.8 200 0.26 138.8 79.4 125 6061-T6 Aluminum 2.7 68.9 0.33 67.5 25.9 137.5

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Deformation Results

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Stress Results

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Simulation Results Summary ▪ Across all models, deformation and stress are within requirements

▪ Peak stresses are located at critical weld locations ▪ Minimal energy loss through model ▪ Results similar to initial calculations performed

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Deformation Results ▪ Deformation along cold mass is within requirement

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Swivel Leveling Mount Verification ▪ Maximum force reaction across all models at fixed supports found

▪ Safety Factor calculated for the capacity of the swivel leveling mount

𝑇. 𝐺. = 𝑀𝑝𝑏𝑒𝑗𝑜𝑕 𝐷𝑏𝑞𝑏𝑑𝑗𝑢𝑧 𝑁𝑏𝑦𝑗𝑛𝑣𝑛 𝑊𝑓𝑠𝑢𝑗𝑑𝑏𝑚 𝑀𝑝𝑏𝑒 = 7,400 𝑚𝑐𝑡 2,242 𝑚𝑐𝑡 = 3.3

▪ Safety factor indicates there should not be an issue

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Weld Results ▪ Weld material used is ER70S-6

▪ Allowable stress of 162 MPa

▪ Shear on load found through calculations and FEA results

▪ Manual calculations lead to larger force reactions

▪ Rail across bar helped reduce reactions ▪ Manual calculations used for final results

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Results Summary ▪ Results adhere to requirements ▪ Realistic results may be different than simulations

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Backup Slides ▪ Weld Station 2 Simulation Results

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Backup Slides ▪ Weld Station 3 Simulation Results

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Backup Slides ▪ Weld Station 4 Simulation Results

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Backup Slides ▪ Weld Station 5 Simulation Results

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Backup Slides ▪ Position and reaction forces of spherical supports

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Backup Slides

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Backup Slides

▪ Weld Calculations:

▪ Reaction forces from saddle supports:

𝑆1 = 𝐺𝑐2 𝑚3 3𝑏 + 𝑐 𝑆2 = 𝐺𝑏2 𝑚3 3𝑐 + 𝑏 𝑁1 = 𝐺𝑏𝑐2 𝑚2 𝑁2 = 𝐺𝑏2𝑐 𝑚2

▪ Weld Area:

𝐵 = 1.414ℎ𝑒 𝐽𝑣 = 𝑒3 6 𝐽 = 0.707ℎ𝐽𝑣

▪ Weld Stress:

𝜐′ = 𝑆 𝐵 𝜐′′ = 𝑁𝑑 𝐽 𝜐 = 𝜐′2 + 𝜐′′2 1/2

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Backup Slides ▪ Weld Calculation Results:

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Backup Slides ▪ Weld Simulation Reaction Forces

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Backup Slides ▪ Convergence Study for Weld Station 1

▪ Study shows that while convergence was not fully reached, the stress was near the true value

▪ Since the peak stress at a weld location, it is assumed that the weld calculation would be more accurate

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Backup Slides ▪ Drawings

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Backup Slides ▪ Drawings

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Backup Slides ▪ Drawings

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Backup Slides ▪ Drawings

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Backup Slides ▪ Drawings

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Backup Slides ▪ Drawings

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