From: 11/28/01 7:20 PM Subject: NTX magnet mtg 11/28/01To: David N Beck ?DNBeck@lbl.gov?, David L Vanecek ?DLVanecek@lbl.gov?, "Simon S. Yu" ?SSYu@lbl.gov?, Gary Ritchie ?GRitchie@lbl.gov?, Craig Peters ?C_Peters@lbl.gov? Please review for correctness please -Derek NTX magnet meeting and other progress 11/28/01. D. Beck, G. Ritchie, D. Shuman, D. Vanecek, S. Yu present 1. Stretched wire samples were present by G. Ritchie indicating that 400-450 # per wire is needed to yield the wire sufficiently to pull out all kinks. This corresponds to 3/8" permanent elongation over a 16" gauge length or 2.3%. Wire dia. should shrink by 1.2% or .002". Samples appeared to be very straight and uniform. The winding/stretching machine is capable of generating 590 lb for 16 conductor runs, so we are in good shape here. 2. Arc bender (D. Vanecek): A sample of stretched wire was "roller" bent over a 6.00" radius cylinder. The wire formed a very uniform arc, even though clamped in the middle and rolled to each side, which was encouraging. The resulting (inner) radius after springback was measured at 7.18" +/- .05. This is an increase of 19.8% . Desired centerline radius is 17.32 cm/2.54 = 6.819". Thus the bending radius should be: (6.819-.092)/1.20=5.615" (11.23" dia). This should include allowance for compression of a 1/16" rubber sheet (say .05"). Target pipe radius is then 5.56". Tube should be 1/8" thick minimum for stability, but a slightly smaller bending radius may turn out to be necessary, so assume final wall thickness would be 1/4-3/8" with O.R. at 5.56". Thus, we are probably looking at using a 10.5" ID pipe that may be 11 inches or more in O.D. 3. Potting mold (D. Beck): A. It appears a rolled and welded tube may be necessary to achieve the desired diameter for the outer tube, as there do not appear to be aluminum tubes available in this size. Perhaps we can skip the welding? Probably not but its worth asking. B. The gasket will be designed for .01-.015" crush and width will be reduced where contacted by the outer cylinder to assure that gasket is not put into an "incompressible" mode. C. Due to machining and sealing problems, the casting extension will be formed by a molded silicone rubber female mold. It will be molded around a form that is machined to the dimensions of the actual casting extension, something that is much easier to machine, (hand) radius, and polish. The exterior walls for molding the mold will also serve to hold the mold against (and seal to) the endplate and outer cylinder. They can be layered with tape afterward to "shrink the volume" in order to provide sealing pressure to the mold. These plates are easily disassembled after potting to where the silicone rubber female mold can be easily pulled off the casting extension without breaking it. Longitudinal knife cuts in the female mold can be cut from the conductor holes out to the endplate to allow the mold to be easily pulled off the conductors. D. After some discussion, it was felt that using a nylon or other tube in a compression fitting that inserts through the end plate would provide the safest release from the casting sprue, by allowing the threaded fitting to be removed (after sawing off the compression fitting and sprue. The endplate can then be removed leaving a short section of casting sprue enclosed by a short section of nylon tubing, both of which can be easily sawn off. An alternative is to use a nylon hose barb fitting that is reamed to a taper on the ID. This might allow the fitting to be unscrewed without damaging the sprue, after the hose barb section is cut off. If this method gives substantially more ID for epoxy flow, it should be explored. D. Beck will solicit G. Ritchie's opinion on this. My guess is that 3/4" clear bore is minimum flow diameter. E. Gary will design a test potting mold for groove evaluation that has the same external clearance over the conductors. We should attempt to achieve the same fluid level speed as in the real magnet casting. E.g. if it takes an hour to fill the magnet, it should take a little less than an hour to fill the slightly shorter test piece. An inlet valve or hose constrictor can be used to slow down the flow. This is more controllable than trying to use a proportionally smaller hose inlet. 4. Magnet Lamination Dwg. (D. Vanecek, D. Shuman) A. Radii on all corners will be set to .06 for smoother cutting. B. Vendor will do a 4 way successive rotate material load when cutting. We will add a note to the drawing, increase the quantity to 5000 sheets, and get a requote. Vendor can also stack and assemble, which makes shipping much easier and frees up our techs. We should make an assembly drawing and add this into the requote. D. Shuman will write some wording for this. We can use simple stainless threaded rod (wrapped in mylar tape or with plastic sleeve over it to avoid shorting laminations) and since leads do not come near bolts, we can use standard SS nuts and washers (silver plate to avoid galling). --------------------------------------------------------------------- Derek Shuman ?DBShuman@lbl.gov? Mechanical Engineer Lawrence Berkeley National Laboratory Derek Shuman Mechanical Engineer ?DBShuman@lbl.gov? Lawrence Berkeley National Laboratory HTML Mail Mailstop 47-112 1 Cyclotron Rd. Fax: 510-486-5392 Berkeley Work: 510-486-4662 CA Conference Software Address 94720 Default Directory Server Additional Information: Last Name Shuman First Name Derek Version 2.1