ATLAS ATLAS Pixel Detector Support Structure Status and

ATLAS ATLAS Pixel Detector Support Structure Status and

ATLAS ATLAS Pixel Detector Support Structure Status and Future Developments February 19, 1999 W. Miller HYTEC LBNL Pixel Support Study 1 W.O. Miller HYTEC ATLAS Meeting Topics Review frame design status Recent FEA results and plans Discuss trade-off of sandwich core materials, carbon foam versus honeycomb in terms of performance definite cost impact Discuss prototypes for testing and test objectives Frame components Frame sub-assembly LBNL Pixel Support Study 2 W.O. Miller HYTEC ATLAS FEA Studies Work Completed Description Nearing completion Objectives FEA of ATLAS Pixel Support Frame

Approach Element types a. Shell4L b. Beams Issues 1. Overall frame analysis-w/o cutouts a. Sag b. Natural freq. a. Must include cones b. Must include joints c. Must include core d. Must include barrel effects 2. Overall frame analysisw/cutouts a. Sag b. Natural freq. a. Must include cones b. Must include joint contacts c. Must include core d. Must include barrel effects a. Shell4L b. Beams a. Judge effect of cut-outs b. Not a full model of joint interactions 3. Panel analysis-two adjacent panels as a minimum a. Load transfer b. Stresses a. Must include tube, panel corner, and panel sandwich a. Solid b. Shell4 c. Beam

a. Interaction within joint b. Panel without and with cut-outs 4. Joint analysis-in form of strip a. Load transfer b. Stresses a. Must include core and attachment of joint to facings a. Solid b. Shell4 a. Single corner block reactions 5. Prototype panel a. Predict static behavior b. Predict natural freq. of single unsupported panel a. Include joints, and core b. Free suspension c. Correlate results with experiment a. Solid b. Shell4 c. Beam a. Predict load transfer of joint with appropriate model of boundary conditions b. Predict effect of cut-outs LBNL Pixel Support Study 3 W.O. Miller HYTEC a. Judge effect of 8 point connection b. Model SCT interaction c. Not adequate model of joint interactions ATLAS

Frame Concept Flat Panel Frame Assembly Disk Regions-2 Central Region-1 End cones-2 Frame cutouts Frame corner connections LBNL Pixel Support Study 4 W.O. Miller HYTEC ATLAS Frame Size Current Studies Based on 250mm Outer Radius LBNL Pixel Support Study 5 W.O. Miller HYTEC ATLAS Frame Issues Solution to Dynamic and Static Stiffness Problems confronting developing a reasonable solution Minimum mass and radiation length requirement must be preserved Envelope more or less fixed limits options for solving dynamic stiffness issue To avoid over constraining detector that causes undesirable strains the lateral restraint of detector must be limited to two points occurs at the extreme ends of the frame lateral reactions to acceleration type loads produce purely radial reaction, direction of lowest stiffness due to load concentration Frame studies focusing on: Frame construction details to achieve 70 to 100 Hz natural frequency in lateral direction Gravitational sag less than 10m LBNL Pixel Support Study 6 W.O. Miller HYTEC

ATLAS FEA Results Example Frame Without Cutouts, No Corner Effects (Both XN50 and Higher Modulus Fiber Option) Notice that substantial stiffness comes from using end rings increased core stiffness produces ~7% effect, with XN50 LBNL Pixel Support Study 7 W.O. Miller HYTEC ATLAS Flat Panel Frame Static Solution with High Modulus Fiber (Typical of XN80, P120, or K13C2U) Model parameters Facings high modulus fibers, e.g., XN80, P120, and K13C2U Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness between 25mm spacing (0.6mm) Total mass of structure and pixel detector 38.38kg Loading 1G vertical Peak deflection 6.07m, more or less uniform along length LBNL Pixel Support Study 8 W.O. Miller HYTEC

ATLAS Flat Panel Frame Static Solution with High Modulus Fiber Including Corner Effects (Typical of XN80, P120, or K13C2U) Model parameters Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness between 25mm spacing (0.6mm) Total mass of structure and pixel detector 38.39kg Frame sections Loading 1G vertical Peak deflection 7.28m at midsection Load transfer at corners only LBNL Pixel Support Study 9 W.O. Miller HYTEC ATLAS Flat Panel Frame Solutions with High Modulus Fiber (Typical of XN80, P120, or K13C2U)

Model parameters Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness between 25mm spacing (0.6mm) Centerframe light weighted Solution static and dynamic Peak deflection 10.2m at midsection 1st mode 46.66Hz LBNL Pixel Support Study 10 W.O. Miller HYTEC Dynamic: 46.66 Hz Static: 10.2m ATLAS Flat Panel Frame FEA Comparison Between Structures (For Light Weighting In Center Panel Only) Frame materials kg/mm2 Cone materials

kg/mm2 Result Special modifications P120 w/End rings, and frame section connections at 8 points only P120 w/End rings, and frame section connections at 8 points only P120 w/End rings, and frame section connections at 8 points only, centerframe lightweighted P120 w/End rings, and frame section connections at 8 points only, centerframe lightweighted Sol. type Static Loading 1G Vertical Mass 38.39 Model Flat panel Facing 1.69 104 Core 68.1 Facing 1.69 104 Core

68.1 7.28 m Dynamic none 38.39 Flat panel 1.69 104 68.1 1.69 104 68.1 49.53Hz Static 1G Vertical 37.46 Flat panel 1.69 104 68.1 1.69 104 68.1 10.2 m Static 1G Vertical 37.46 Flat panel 1.69 104

68.1 1.69 104 68.1 46.66Hz Frame modifications needed to meet design goals LBNL Pixel Support Study 11 W.O. Miller HYTEC ATLAS Flat Panel Frame Solutions with High Modulus Fiber With All Cutouts Included (Typical of XN80, P120, or K13C2U) Model parameters Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness between 25mm spacing (0.6mm) Entire frame light weighted, total mass 36.9 kg, including detector elements Solution static

Peak sag of outer barrel, ~13m Peak sag overall, ~16.3m LBNL Pixel Support Study 12 W.O. Miller HYTEC ATLAS Flat Panel Frame Solutions with High Modulus Fiber (Typical of XN80, P120, or K13C2U) Model parameters Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness between 25mm spacing (0.6mm) Entire frame light weighted, total mass 36.9 kg, including detector elements Dynamic solution fundamental mode, 38.03 Hz LBNL Pixel Support Study 13 W.O. Miller HYTEC ATLAS

Flat Panel Frame Solutions with High Modulus Fiber Light-weighted Frame (Typical of XN80, P120, or K13C2U) Frame materials kg/mm2 Cone materials kg/mm2 Result Special modifications P120 w/End rings, and frame section connections at 8 points only, light weighted frame, 0.6mm facings end section P120 w/End rings, and frame section connections at 8 points only, light weighted frame, 0.6mm facings end section XN50 w/End rings, and frame section connections at 8 points only, light weighted frame, 0.3mm facings end section Sol. type Static Loading 1G Vertical Mass 36.9 Model Flat panel Facing

1.69 104 Core 68.1 Facing 1.69 104 Core 68.1 16.3 m Dynamic none 36.9 Flat panel 1.69 104 68.1 1.69 104 68.1 38.03Hz Dynamic none 36.9 Flat panel 1.054 104 68.1 1.054 104 68.1 30.99Hz

LBNL Pixel Support Study 14 W.O. Miller HYTEC ATLAS Flat Panel Frame Proposed End Reinforcement (Added after Disk Installation) Tubular end truss Demountable Does not block passage of services to any great extent Tubes are 10mm OD with a 0.6mm wall, composite construction similar to longitudinal members Tubular members tie into longitudinal tubes LBNL Pixel Support Study 15 W.O. Miller HYTEC ATLAS Flat Panel Frame End Tubular Frame Connection Geometry of end piece Concept depicted is an illustration Details of end piece need to be worked out Construction feature will

incorporate some lightweighting Pin connection will have zero clearance feature to remove play LBNL Pixel Support Study 16 W.O. Miller HYTEC ATLAS Flat Panel Frame Solutions with High Modulus Fiber With End Reinforcement (Typical of XN80, P120, or K13C2U) Model parameters Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness in disk region 4-10 mm dia. corner end beams reinforcements, 0.6mm wall Entire frame light weighted, total mass 37.53 kg, including detector elements Static solution Gravity sag, ~10.43m LBNL Pixel Support Study 17 W.O. Miller HYTEC

ATLAS (Typical of XN80, P120, or K13C2U) Model parameters Flat Panel Frame Solutions with High Modulus Fiber With End Reinforcement Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness in disk region 4-10 mm dia. corner end beams reinforcements, 0.6mm wall Entire frame light weighted, total mass 37.5 kg, including detector elements Dynamic solution fundamental mode, 77.5 Hz LBNL Pixel Support Study 18 W.O. Miller HYTEC ATLAS Flat Panel Frame Solutions with XN50 Laminates With End Reinforcement

(illustrate effect of lower modulus laminate) Model parameters Transverse connection at individual frame sections limited to 8 corner points Core 68.1kg/mm2 (97000psi, Hexcel 3/16 core size) 2 radial end plates, separated by 25 mm, bounded by sandwich facings. Double facing thickness in disk region 4-10 mm dia. corner end beams reinforcements, 0.6mm wall Entire frame light weighted, total mass 37.53 kg, including detector elements LBNL Pixel Support Study 19 W.O. Miller HYTEC Gravity sag increased to 16.4m ATLAS Flat Panel Frame FEA Summary for Light Weighted Structure (End Flat Panel Structure 0.6mm facings) Frame materials kg/mm2 Cone materials kg/mm2 Result Special modifications P120 w/End rings,

and frame section connections at 8 points only, end tubular truss P120 w/End rings, and frame section connections at 8 points only, end tubular truss XN50 throughout, except high modulus tubes, end tubular truss XN50 throughout, except high modulus tubes, end tubular truss XN50 throughout, except high modulus tubes, end tubular truss, all laminates 0.6mm Sol. type Static Loading 1G Vertical Mass 37.53 Model Flat panel Facing 1.69 104 Core 68.1 Facing 1.69 104 Core 68.1 10.0 m

Dynamic none 37.53 Flat panel 1.69 104 68.1 1.69 104 68.1 77.5Hz Dynamic none 37.53 Flat panel 1.054 104 68.1 1.054 104 68.1 66.46 Static 1G Vertical 37.53 Flat Panel 1.054 104 68.1 1.054 104

68.1 16.4 m Dynamic none 38.50 Flat Panel 1.054 104 68.1 1.054 104 68.1 67.58 LBNL Pixel Support Study 20 W.O. Miller HYTEC ATLAS Flat Panel Frame Summary Remarks on FEA Reinforcements to the very ends of the frame produced positive results in raising the first vibration mode--with kinematic mounts 77.5 Hz for frame with ultra-high modulus composites Drops to 66.46 Hz for XN50, and 0.6mm laminate facings at end sections gravity sag increases from 10 to 16.4 m Eliminating the end reinforcements-with XN50 composite Gravity sag increases from 16.4 to 17.7 m, small effect Resonance drops to 36.7 Hz if we eliminate the reinforcements Resonance would decrease further if we use 0.3mm facings on the end sections---30.99Hz

Clear benefit to reinforcements at frame ends Increased facing thickness on ends is beneficial, as is the use of higher modulus laminates. LBNL Pixel Support Study 21 W.O. Miller HYTEC ATLAS Pixel Support A Concept for the SCT/Pixel Mounting Interface Desirable attributes for mount kinematic to extent practical Four point support 40mmX10mmX3mm SCT mounting channel 1 point XYZ 1 point XY 2 points Y All support points are adjustable vertically Pixel frame reinforced locally to resist lateral loads Issues Need to be assured that SCT channel design is fixed in geometry and stable

Look into pixel frame reinforcements and mount materials LBNL Pixel Support Study 22 W.O. Miller HYTEC (must be replaced with end plates) ATLAS Pixel Support Restraint at Corners Vary lock Mount concept Vertical adjustment for leveling detector Conical seat and V-groove track at opposite end position detector laterally Restrains X and Z, and rotation about vertical axis Vertical adjustment cone Simple flat contact permits movement in X and Z Considerations SCT support dimensional accuracy

to what extent can we rely on location of channel? Must we shim? Section views LBNL Pixel Support Study 23 W.O. Miller HYTEC flat ATLAS Disk Support A Concept For Disk Ring support Mount considerations To avoid excessively tight frame assembly tolerances, we machine and locate precision inserts Bushings are bored after bonding this fixes the azimuthal and Z location for V-groove receivers, within 10m, possibly better Three V-groove blocks are positioned and bonded to bushings fixture used in bonding the V-groove receivers. positional tolerance can be improved by using bond clearances to an advantage if necessary three precisely located balls on the

fixture locate the V-grooves radially, and rotationally LBNL Pixel Support Study 24 W.O. Miller HYTEC Disk support ring mounts ATLAS Disk Support Disk Support Ring Retention Assembly sequence Disk assembly inserted into frame Spherical balls on mounting ring are placed onto three V-grooves Spring keeper inserted from outside to restrain spherical ball in V-groove Spring keeper is guided by the machined bushing bonded in the frame structure and fixed in place on the outside of the frame sandwich ring V-groove Considerations Required spring force to resist movement of disk from extraneous forces caused by services Material selection

spherical ball spring keeper LBNL Pixel Support Study 25 W.O. Miller HYTEC ATLAS Disk Support Disk Ring Position Adjustment Adjustment features R- disk position is obtained by precise location of three point ball support in three V-grooves Final positioning of disk provided by adjustment screw (fine thread) Adjustment screw provides pure axial motion, as well as tip/tilt Considerations Material selection of individual components use composite materials to extent practical to what extent metallic (Be) elements are desired is unclear at this time Demonstrate zero backlash at component level LBNL Pixel Support Study 26

W.O. Miller HYTEC adjustment screw ATLAS Frame Prototype Objective: Test Frame and Support Interactions Prototype test considerations Frame performance is strongly influenced by the stiffness in the end sections Local stiffness of the frame dependent on frame internal reinforcements Testing with the end section will investigate adequacy of this reinforcement, as well as the general performance of the lightweight structure Test of interface connection of the central frame will also be covered LBNL Pixel Support Study 27 W.O. Miller HYTEC For test remove SCT mount ATLAS Frame Costs Process of Establishing Fabrication Cost Estimate History

1st cost estimate covered a comparison between tubular frame and flat panel Lower projected cost favored the flat panel Conclude that even with refinements to both designs that this conclusion would remain unchanged Flat panel costing Proceeded to obtain additional cost information with modified drawing set--solicited bids from 3 vendors Vendors were advised we were still refining the structural aspects and design changes must be anticipated Our objectives were to: Break down costs for NRE, tooling materials, and fabrication labor LBNL Pixel Support Study 28 W.O. Miller HYTEC ATLAS Analysis: Must complete frame FEA to evaluate overall effect of frame light weighting on performance, and support point reinforcement Need to focus on panel joint designs and SCT support interactions with FEA FEA of disk structure to include effects of mount Prototype frame Where are We? Need to decide on: end section material thickness, fiber choice, and core material Complete preliminary construction drawings, joint connections

Costing Solicited pricing information from 3 vendors to common definition Met with 3 vendors and discussed their proposal Selected lowest bidder and requested formal prototype quote Fixed cost quote was based on performing effort in 3 phases Prepared to go ahead with this effort-some discussion still pending LBNL Pixel Support Study 29 W.O. Miller HYTEC ATLAS Design Data What is Needed to Finalize Frame Design Solidify Pixel/SCT interface to complete frame design and analysis Insertion rail design envelop in sufficient detail frame attachments, method of transfer from rail to SCT, etc. Confirmation on SCT/Pixel mount interface- channel design? structural robustness dimensions, positional reference? material Refinement to our proposed Pixel to SCT mount Factor design into frame prototype testing Coolant line, manifold design, and cable routing Develop understanding of possible extraneous loads on disk assembly Recommend early prototype tests of tubing/manifolds to validate design of coolant system Heat shield effects?? LBNL Pixel Support Study 30 W.O. Miller HYTEC ATLAS Milestones

Outer Frame Development Decision on prototype core material------------------Decision on fiber material---------------------------------FEA of panel cut-outs complete------------------------Release drawings for LBNL mock-up-----------------Order pre-preg material------------------------------------Order core material------------------------------------------FEA of reinforced corner (1st mode problem)-------TVH with new environmental enclosure---------------1st sandwich panel-------------------------------------------Evaluation of 1st panel without/with cutouts--------Full scale prototype complete----------------------------Preliminary stiffness tests complete-------------------- LBNL Pixel Support Study 31 W.O. Miller HYTEC 1/30/99 2/19/99 2/28/99 1/30/99 2/22/99 2/22/99 3/30/99 3/01/99 5/15/99 5/30/99 9/15/99 10/15/99 ATLAS Frame Costs High Modulus Laminates (Cost on Bulk Basis) Uncured Pre-preg Pricing Fiber Bryte YLA Hexcel 1 Technologies (Fiberite) Resin EX1515 RS-3

954-3 15Msi Modulus Quasi-isotropic laminate XN50 10# $530/# 10# $823/# 10# $750/# 50# $530/# 50# $418/# 25# $470/# M55J 10# $450/# 10# $807/# 50# $450/# 50# $406/# 26Msi Modulus Quasi-isotropic laminate K13C2U 10# $1175/# 10# $1407/# 50# $1175/# 50# $848/# 1 Indicated set-up charge of $1500. One should anticipate others will have similar charge ALLCOMP proposes P30 fiber carbonized/heat treated to equivalent 22 Msi, resin impregnated, as replacement to above resin based composites. At 25#, cost per lb is ~$500/ # LBNL Pixel Support Study 32 W.O. Miller HYTEC ATLAS Frame Costs Preliminary Cost Summary

Item Composite Horizons 1,3 1 Allcomp $57,349 $58,721 $2,678 $2,678 $24,840 $24,840 Advanced 1 Composites $58,882 $74,960 $14,668 $11,420 $10,789 $10,789 $164,428 Prototype End Section $38,920 1 XN50/Cyanate ester and honeycomb core 2 XN50/Cyanate ester and carbon foam, add $3000 for densification 3 Early bid response to drawings with less detail 4 Includes all tooling required to build end and central section 5 XN50/carbon foam core Central Panel Section End Sections Central Corner Blocks End Corner Blocks Large Flange Mounting Disk Small Flange Mounting Disk

Total LBNL Pixel Support Study 33 W.O. Miller HYTEC PCI $69,330 $15,857 $15,857 Allcomp 2 $41,281 $42,653 $2,478 $2,478 $19,809 $19,809 Advanced 5 Composites $52,362 $63,600 $9,260 $7,676 $9,698 $9,698 Composite 5 Horizons $95,010 $75,205 $9381 $4966 $36,291 $21,023 $181,508 $126,030 $152,294

$241,876 $57,880 $30,816 $45,368 $48,943 ATLAS Mass Summary Sample Mass Breakdown for Frame Study Item Outer center frame Outer End Frame End tubular members Longitudinal tubes End cone structure Inner cone ring Outer barrel shell Frame mass-kg 1.219 1.986 0.085 0.20 0.30 0.12 0.46 Added mass-kg 23.24 9.92 Total masskg 1.219 25.226 0.085 0.20 0.30 10.04 0.46

%RL per frame member 0.23 0.428 0.37 - total 4.37 33.16 37.53 Solution for high modulus fiber with end frame and end beams at 0.6mm wall, center frame sandwich facing at 0.3mm LBNL Pixel Support Study 34 W.O. Miller HYTEC

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