Transcript Document 7707508

NSTX Flex Strap Development
Tests Status Update
10-28-10
Flex Strap and Bolted Joint Design Verification Tests
• Tests Performed at 4 Different Levels
– Material Level
• C15100 H04 fatigue strength (R0) before and after soldering
• Coupon-stack solder cycle development tests
– Single Lamination Level
• Roll-formability
• In-plane bending stiffness
• Cyclic, simulated maximum combined loads
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– Stub Joint Level
• Tap-lok insert pull-out strength in C18150 copper stub, static and fatigue
• Inconel 718 custom Superbolt nut/ stud fatigue strength
– Flex Strap Assembly Level
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Manufacturability
In-plane bending stiffness
Cyclic, simulated maximum combined loads
Contact pressure distribution
– Bolt pretension only
– Bolt pretension + simulated maximum combined-load
• Superbolt nut tensioned in umbrella segment mock-up
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NSTX
NSTX Center Stack Upgrade PDR Review
June 23 & 24, 2010
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Cost-Optimized Design Flex Strap Assembly: Deformation and Force
Assembly: 31X .078” Thick Laminations
NSTX CSU Flex Strap Assembly and Applied Boundary
Conditions
Rout = 5.688”
31 Laminations:
- .078” thick
- .007” gap between laminations
- Mat’l: Full-Hard C15100 H04 CuZr
7.5”
Vertical Legs Vacuum Brazed
Rin = 3.255”
Upper Umbrella Assy
8x 5/8” Bolt Hole
Bvert= .24 T
5”
Uvert thermal = .3 in
I = 130 kA
Utor twist = .10 in
Urad thermal = .018 in
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NSTX
NSTX Center Stack Upgrade PDR Review
June 23 & 24, 2010
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ANSYS Static Structural Results: Lamination Tresca Stress
Current Scenario #82, 31 Laminations/ Strap, Center Strap
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NSTX
NSTX Center Stack Upgrade PDR Review
June 23 & 24, 2010
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Estimated C15100 H04 CuZr Fatigue S-N Curve
Olin Brass: Room Temperature; 40% CW; Reverse Bending (R-1)
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Su = 58 ksi
Sy = 57.6 ksi
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S - Strength (ksi)
50
20x Cycles
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30
2x Stress
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Ctr Flex Peak Stress
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1.00E+03
1.00E+04
1.00E+05
1.00E+06
1.00E+07
1.00E+08
N - Number of Cycles
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Modified Goodman Diagram: C18150 TL04 CuCrZr Thread
Tresca Stress
60
2/3 Sy
50
Stress Amplitude, sa (psi)
Su = 79 ksi
Sy = 75 ksi
40
30
Se
20
10
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40
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Mean Stress, sm (psi)
10
Su
2/3 Sy
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60
70
80
90
Modified Goodman Diagram: Inconel 718 AMS 5663 5/8" Bolt
Tension Stress
160
Su = 180
140
.9 Sy
Stress Amplitude, sa (psi)
120
100
80
Se
60
40
20
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20
40
60
80
100
120 .9
Mean Stress, sm (psi)
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Sy 140
160
180Su
200
Flex Joint Design using Superbolt Jack-Screw
Tensioned Nuts
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NSTX
NSTX Center Stack Upgrade PDR Review
June 23 & 24, 2010
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ANSYS Static Structural Results: Joint Tresca Stress
Current Scenario #82, 31 Laminations/ Strap
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NSTX
NSTX Center Stack Upgrade PDR Review
June 23 & 24, 2010
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NSTX Flex Strap Friction Stir Weld Reaction Loads: Joint B Forces
Note: Direction of reactions must be reversed when applied as loads to stub faces
NSTX Flex Strap Friction Stir Weld Reaction Loads: Joint B Moments
Note: Direction of reactions must be reversed when applied as loads to stub faces
ANSYS Static Structural Results: 5/8” Bolted Contact Pressure
Current Scenario #82, 31 Laminations/ Strap
Min. Pressure ~ 4500 psi
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NSTX
NSTX Center Stack Upgrade PDR Review
June 23 & 24, 2010
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Pressurex® is a unique, affordable and easy to use tool that reveals the distribution and magnitude of pressure between any two
contacting, mating or impacting surfaces. pressure indicating sensor film is extremely thin (4 to 8 mils) which enables it to conform
to curved surfaces. It is ideal for invasive intolerant environments and tight spaces not accessible to conventional electronic
transducers.
How It Works
Pressurex® is a mylar based film that contains a layer of tiny microcapsules. The application of force upon the film causes the
microcapsules to rupture, producing an instantaneous and permanent high resolution "topographical" image of pressure variation
across the contact area.
Simply place Pressurex® between any two surfaces that touch, mate or impact. Apply pressure, remove it and immediately the film
reveals the pressure distribution profile that occurred between the two surfaces. Like Litmus paper, the color intensity of the film is
directly related to the amount of pressure applied to it. The greater the pressure, the more intense the color.
Pressurex® has a wide array of uses. For example, Pressurex® can be used in a bolted joint interface, composite layup, heat sealing
and lamination or press. Our pressure indicating film acts as a force sensing resistor. It can measure surface pressure distribution
whether it is used as an impact force sensor, seat pressure sensor, as a strain gauge or even as nip impression paper.