Figure 1 NSTX Upper Umbrella Assembly Upgrade Design: Version 3

1
Figure 1 NSTX Upper Umbrella Assembly Upgrade
Design Version 3
2
304 SS Support
G10 Support
Figure 2 Single Segment Strap Assembly Version
3 with G10/ 304 SS Supports
3
Figure 3 Single Segment Strap Assembly Center
Strap Only
4
Rout 5.688
38 Laminations - .060 thk .005 gap Matl
Copper Wtfull 37.4 lb (Wtarch 20.4 lb)
Rin 3.160
7.5
Bpol .3 T
5
I 130 kA
Uvert thermal .3 in
Btor 1 T
Urad thermal .018 in
2.523
2
Figure 4 Single Laminated Strap Assembly with
Applied Fields and Current
5
Calculated EMAG Loads
Fop
Out-of-Plane Load (z-direction)
I
R
Fop 2IBpolR Fop 2 x 130,000 A/ 38 x .3 T x
5.688/39.37 m Fop 296.4 N 66.6 lbf per
lamination
Bpol
In-Plane Load (y-direction)
pressip
Fip/ L IBtor Fip/ L 130,000 A/ 38 x 1 T per
lamination Fip/ L 3,421 N/ m x .2248 lbf/ N x
1 m/ 39.37 in Fip/ L 19.53 lbf/ in pressip
(Fip/ L)/ w pressip 19.53 lbf/in / 2
in pressip 9.77 lbf/ in2 (applied to inside
cylindrical faces)
x x x x x x x x x x x x x x x x x x
I
w
Btor
6
Force 66.6 lbf
Ux .018 in Uy .3 in Uz 0
Press 9.7 psi
Fixed
3 Elements thru Thickness
Figure 5A Single Lamination FEA Model Mesh and
Boundary Conditions
7
Figure 5B Single Lamination Linear Results von
Mises Stress Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
8
Figure 5C Single Lamination Linear Results von
Mises Stress Loads Thermal Displacements Only
9
Figure 5D Single Lamination Linear Results von
Mises Stress Loads In-Plane (Pressure) Load Only
10
Figure 5E Single Lamination Linear Results von
Mises Stress Loads Out-of-Plane (Force) Load Only
11
Large deflection On
Figure 5F Single Lamination Nonlinear Results
von Mises Stress Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
12
Large deflection On
Figure 5G Single Lamination Nonlinear Results
Z-Deformations Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
13
Large deflection On
Figure 5H Single Lamination Nonlinear Results
Z-Deformations_Front Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
14
shoop PR/ t 9.77 psi x 5.688 in/ .060
in 924 psi
Large deflection On
Figure 5J Single Lamination Nonlinear Results
von Mises Stress Loads Emag Pressure (In Plane)
Only
15
1st Mode Load Multiplier 58.4
1st Mode Load Multiplier 58.4
3rd Mode Load Multiplier 117.6
(Nonlinear 1st Mode Load Multiplier 50)
Large deflection Off
2nd Mode Load Multiplier 73.0
Figure 5K Single Lamination Pre-Stressed Linear
Buckling Results Load multiplier LMF applies to
all Emag loads and thermal displacements
16
Y
LMF 14
0
80
Large deflection On
Figure 5L Single Lamination Nonlinear Buckling
Y-Deformation at Onset (1) Load multiplier factor
LMF applies only Out-of-Plane Emag load
17
Y
LMF 26
0
80
Large deflection On
Figure 5M Single Lamination Nonlinear Buckling
Y-Deformation at Onset (2) Load multiplier factor
LMF applies only to Out-of-Plane Emag load
18
Conclusions

• Buckling due mostly to out-of-plane load.
  In-plane load (pressure outward) reduces
  buckling thermal displacements slightly increase
  buckling.
• Good agreement between linear and nonlinear
  buckling results with load multiplier factor
  applied to both Emag loads and to thermal
  displacements.
• Load multiplier factor over 14 for nonlinear
  analysis with constant in-plane load and
  increasing out-of-plane load (conservative).

19
3 Elements / Lamination
Figure 6A 3 Lamination FEA Model Mesh
20
Large deflection On Frictional contact (COF
.4)
Figure 6B 3 Lamination Nonlinear Results von
Mises Stress Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
21
Large deflection On Frictional contact (COF
.4)
Figure 6C 3 Lamination Nonlinear Results
Z-Deformations Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
22
Large deflection On Frictional contact (COF
.4)
Figure 6D 3 Lamination Nonlinear Results
Z-Deformations_Front Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
23
Large deflection On Frictional contact (COF
.4)
Figure 6E 3 Lamination Nonlinear Results
Contact Status Loads Combined Thermal
Displacements, Emag Press. (In Plane) and Forces
(OOP)
24
3rd Mode Load Multiplier 61.8
1st Mode Load Multiplier 58.2
Large deflection Off Frictional contact (COF
.4)
2nd Mode Load Multiplier 60.7
Figure 6F 3 Lamination Results Linear Buckling
Mode Multiplier Load Multiplier factor LMF
applies to all Emag loads and thermal
displacements
25
Figure 7A Single Laminated Strap Assembly FEA
Model Bonded and Frictionless Contact Areas
26
3 elements/ lamination
Nodes 850423 Elements 152895
Figure 7B Single Laminated Strap Assembly FEA
Model Mesh
27
Large deflection Off Frictional contact (COF
0)
Fig. 7C Laminated Strap Assembly FEA Results -
Thermal Displacements Only von Mises Stress
28
Large deflection Off Frictional contact (COF
0)
Fig. 7D Laminated Strap Assembly FEA Results
Thermal Displacements Only Total Deformation
29
By .3T Bz 1 T
ux .018 uy .30
I 130 kA
JS
FLorentz
Non-Linear Large Deflection
Non-Linear Large Deflection
Heat Gen
Tnodes
Fig. 8A Upper Flex Strap ANSYS Multiphysics
Analysis Work Flow Diagram
30
Figure 8B Single Segment_Center Strap Assembly
Mesh
31
0 V
130,000 A
Fig. 9C Single Segment_Center Strap Electric
Model Boundary Conditions
32
Figure 8D Single Segment_Center Strap Electric
Model Results Voltage
33
Fig. 8E Single Segment_Center Strap Electric
Model Results Current Density
34
Fig. 8F Single Segment_Center Strap Electric
Model Results Joule Heat