ottó bede tbm consortium meeting, brasimone 16.10.2006. 1 wp5 - fem analyses iter ppe training...

WP5 - FEM analyses ITER PPE training session7 December – 11 December 2009, Cadarache, France József NÉMETH

Association EURATOM-HASKFKI Research Institute for Particle and Nuclear Physics

József NÉMETH ITER PPE trainig session, 7 December – 11 December 2009, Cadarache, France 2

WP5 - FEM analyses

CONTENTS

○ Introductory structural analysis task

○ Introductory thermomechanical analysis task

○ Workpackage overview

○ Complex structural analysis task



WP5 - FEM analyses

Workpackage overview

WP 5: Thermomechanical Engineering of In-Vessel Components

Starting date:

06.07.2009.

Objective :

To become a thermomechanical analyst expert for the further fusion research.

Tools :

ANSYS Multiphysics and ANSYS Workbench

Short term aim:

To achieve the assured knowledge and routine on using the tools.

Implementation:

FEM tasks from simple to more complex under mentoring by Gábor Grunda


WP5 - FEM analyses

CONTENTS






WP5 - FEM analyses

COMPASS ion beam vacuum vessel

The challenge:

- An ion beam is developed for the COMPASS in our institute.- We would like to know what is the stress field of the following part of the appliance.- The structure has only static loads. Pressure, force and weight.

The task:- Check the strength of the

vacuum vessel and thebolts of the flange

- Used tool: ANSYS Workbench


WP5 - FEM analyses

The FEM model I.

Geometry of the examined part:

- Simple cylindrical part with bolts.

Materials:

- vacuum vessel: aluminium alloy: AlMgSi 0,5- bolts: steel 8.8- flange: PVC


WP5 - FEM analyses

The FEM model II.

The mesh:

- Fine tetra mesh has been chosen.

Loads and supports:

- 0,3 [MPa] inner pressure- forces on the bolts- gravitational field- fix support


WP5 - FEM analyses

Results

The main stress in the vessel is 11 [MPa].The maximal stress is 150 [MPa].The yield strenght is 160 [MPa].


WP5 - FEM analyses

Results

The maximal stress is 260 [MPa] in the bolts.The yield strenght is 640 [MPa].

The structure is adequate.


WP5 - FEM analyses

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WP5 - FEM analyses

AEU frame structure

The challenge:- For the functioning of the ITER TBS we need a removable unit (AEU)

which contains some sub-systems of TBS.- The frame structure was a design concept for preliminary layout.- To minimize the weight of the frame structure, so this is an optimizing

task.- To check the necessity of side frame structure. - The frame structure has only static loads.


WP5 - FEM analyses

Dimensions of frame structure

The outer dimensions are equal to the EQ Transfer Cask.

Width of longitudinal beams is given by the space next to ATS.


WP5 - FEM analyses

Loads of frame structure

Weight of sub-systems:

Helium Cooling System (HCS): 359,5[kg]PbLi loop: 20000[kg]Tritium Extraction System (TES): 927[kg]Diagnostics: 7000[kg]Maintenance Equipment: 1162[kg]

Layout of sub-systems:

Diagnostisc HCS TES Maintenance Equipment PbLi loop


WP5 - FEM analyses

The FEM model

Rough FEM models have been made in the first steps and these have been specified in the next phases.

Solid model has been made and hexa mesh has been used. The mesh size has been fined during the development procedure.

The raw material is a good weldable structural steel S235JR (standard MSZ EN 10025-2). The numerical designation of material is 1.0038.

150 MPa maximal stress had aimed during the optimization.

First the correct value of the standard stress has been aimed during the procedure of optimizing then the smaller stress maximums had corrected.


WP5 - FEM analyses

The first analysis

Conception: - standard I beams and rectangular tube- frame structure without side beams

Mesh: - rough tetra mesh

Loads and supports: - one common pressure, gravity, fix support

Weight: 3840 [kg]


WP5 - FEM analyses

Result of the first analysis

The calculation confirmed frame structure without side beams is possible.

The main stresses are nearby 30 [MPa].

The maximal stress is 90[MPa].


WP5 - FEM analyses

The first phase

Conception: - standard I 120 cross beams IPE series- uniquely welded longitudinal beam

Mesh: - rough tetra mesh

Loads and supports: - pressures on the location of sub-systems, gravity, fix support

Weight: 1855 [kg]


WP5 - FEM analyses

Result of the first phase

The stresses in the cross beams are nearby 150[Mpa] but some cross beam is under sized.

The longitudinal beam is over sized.

The maximal stress is 347[MPa].


WP5 - FEM analyses

The second phase

Conception: - standard I 120 cross beams IPE and HEB series- uniquely welded longitudinal beam with holed ridge

Mesh: - fine tetra mesh

Loads and supports: - pressures on the correct location of sub-systems, gravity, one bonded DOF

Weight: 1959 [kg]


WP5 - FEM analyses

Result of the second phase

The HEB I beams are proper, IPE beams are over sized.

Local stress maximums are by the welded joints.

The longitudinal beam is adequate.


WP5 - FEM analyses

The last phase

Conception: - the IPE beams have been exchanged to rectangular tubes- ribs and node plates with large fillet have been used

Mesh: - fine tetra mesh

Loads and supports: - pressures on the correct location of sub-systems, gravity, one bonded DOF

Weight: 1762 [kg]


WP5 - FEM analyses

Result of the last phase

The stress is correct everywhere in the structure.

Due to the ribs the stiffness is better.

The maximal stress is 170 [MPa].

Calculations with non flat seat.


WP5 - FEM analyses

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WP5 - FEM analyses

MAST diagnostics

The challenge:

Thermal analysis for MAST Beam Emission Spectroscopy In-vessel Optics - the optics has to operate on 150 °C in vacuum environment - it is important to know what heater must be use and how long the heating going to last - to check the 750 W electric heater and thermal insulation

The model of diagnostics - cylindrical vacuum vessel and mirror and lens support elements


WP5 - FEM analyses

The FEM model I.

Geometry:- Vacuum vessel + heater + thermal insulation

Materials:- vacumm vessel: A300 stainless steel: thermal conductivity: 15 W/mK

specific heat: 500 J/kgK

- thermal insulation: fiberglass: thermal conductivity: 0,032 W/mKspecific heat: 670 J/kgK


WP5 - FEM analyses

The FEM model II.

Mesh:- solid model has been built- tetra mesh has been applied


WP5 - FEM analyses

Steady state analysis

Heat and convection:

- Internal heat generation in the heater: 750W- Convection on the outer surface of thermal insulation


WP5 - FEM analyses

Calculation of convection

- thermal conductance of the environment (air): λ

- acceleration due to gravity: g

- thermal expansion of the environment (air): β

3

1

135,0

a

tg

Convection depends on:

- temperature difference: Δt

- kinematic viscosity : ν

- thermal diffusivity: a


WP5 - FEM analyses

Results of steady state calculation

The maximum temperature is 436 °C on the cylindrical surface of the vacuum vessel.The temperature of support elements of mirrors is nearby 370 °C.

The heater with 750 W power is enough but this simulation doesn’t give answer for the transient processions.


WP5 - FEM analyses

Transient analysis

Heat , convection and radiation:

- internal heat generation in the heater: 2x750W (double heater)- convection on the outer surface of thermal insulation- radiation between the surfaces

Radiaton depends on:

- surfaces: F

- emission factor: ε- temperatures: T- Stefan-Boltzmann ratio: σ

Relative emission factor:

1

11

1

22

1

1

2,1

FF

Heat flow:)( 4

2412,11 TTFQ


WP5 - FEM analyses

Results of transient calculation

After 14400 sec the temperature of support elements of mirrors is nearby 150 °C.

The heating time is too long with 750 W heating power. Two heaters must be used.This analysis was based some estimations, so the real laboratory test will give important feed-back about the validation.


WP5 - FEM analyses

Results of transient calculation

Thank you!

ottó bede tbm consortium meeting, brasimone 16.10.2006. 1 wp5 - fem analyses iter ppe training...

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