MICE Target Mechanical Design

1
MICE Target Mechanical Design

• Contents
• Status of modelling and drawing
• Work being undertaken at RAL on shaft and bearing
  prototypes
• Procedure for shaft manufacture to ensure
  straightness
• QA
• Procedure for alignment of bearings in core
• Manufacturing database
• Cut-off date
• Assembly location (discussion)
• Stator

2
MICE Target Mechanical Design

• Status of drawings
• All modelling complete bar few last minute
  changes (prototyping) see later
• Shaft piece parts and assemblies finished, ready
  for checking
• Engineering check (N Sage provisional)
• Tecvac OK for coating
• W/S OK for manufacturing
• Weld contractor OK for joining (also for jigging)

3
MICE Target Mechanical Design

• Status of drawings
• Bearings almost ready for checking
• Engineering check (N Sage provisional)
• Tecvac OK for coating
• W/S OK for manufacturing
• Core drawings to be finished (AL)
• Overall assembly drawing (JT)
• Parts list
• Peripheral parts to be drawn (TJ)

4
MICE Target Mechanical Design

• Prototype work at RAL
• Shaft
• Conventionally turned top section accurate size
  but not straight
• Use centreless grinding technique (size,
  geometry, finish) shaft design changed
• Cutting 1 flat bends shaft (as expected!)
• Use very small cuts (stress zone depth of cut)
• Flat on both sides 3 stage production
• Socket prototype
• Taper socket with shallow angle to centre and
  align top and bottom sections (preferred by weld
  contractor)

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MICE Target Mechanical Design

• Prototype work at RAL
• Bearings
• Can be bored accurately but best with pre-ream
• Polishing showing bell-mouthing
• Location in housing using taper or close fit

About 1mm square
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MICE Target Mechanical Design

• Recent changes
• Shaft
• Double flat
• Taper joint
• Bearings
• Thickened base bearing
• Start part with features for machining
• Taper OD for location (parallel option too)
• Core Assembly
• Decreased vacuum tube length to allow taper
  location of bearings

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MICE Target Mechanical Design

• Shaft Procedure (up to 4 shafts)
• Rough m/c straighten stock materials
• Rough turned as necessary
• Stress relieve heat treatment
• vacuum oven
• 650degC 30 minutes
• Max rate heat cool to minimise grain growth
• Review oven cycle from print-out
• Final machine upper shaft
• Centreless grind to size
• Return to RAL for Metrology
• Machine on features on upper shaft
• Polish bearing regions(?) then Metrology to
  determine Ra Rz etc

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MICE Target Mechanical Design

• Shaft Procedure...
• Pre-weld assembly
• Upper shaft press on rough machined socket
• Lower shaft fit stop
• Weld on socket stop
• Undertaken in chuck in EB (Electron Beam) welder
• Rapid weld in precise location minimises heat
  (added to low thermal conductivity of Ti
  minimal HAZ)
• Procedure variables and QA schedule agreed with
  contractor
• Final machine socket ends of upper and lower
  shaft
• Machine to fit on taper
• Partner pieces identified

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MICE Target Mechanical Design

• Shaft Procedure...
• Press fit (with ?T)
• Involve metrology to ensure geometric location
  between bearing sections
• Weld both together
• Requires jig with bearings and compliant couple
  to powered chuck in EB welder
• 2nd Stress relieve heat treatment
• Vertical orientation (under tension?)
• Metrology
• Relative location of 2x bearing sections

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MICE Target Mechanical Design

• Shaft Procedure...
• DLC Coating
• Clean
• Coat
• Tecvac to advise on QA
• Metrology
• Final check on dimensions and geometry of bearing
  sections
• Where manufactured outside CofC required
• Transportation
• Transportation boxes required (2 off with
  capacity for 4 shafts each ( despatch
  flexibility)

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MICE Target Mechanical Design

• QA
• Materials
• Certificates
• Element analysis (Bodycote)
• Size geometry
• Dimensional measurements (RAL Metrology)
• Surface Finish
• Surface trace (RAL Metrology)
• DLC coating (Tecvac to advise)
• Adhesion test
• Wear test on swatch
• Print out of cycle

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MICE Target Mechanical Design

• QA...
• Welding
• NDT method on shaft (e.g. X-ray)
• Tests on pre- post-production samples
  undertaken immediately before/after shaft weld
• Section micrograph
• Tensile test (qualification of procedure?)
• Request definition of quality weld
• Heat Treatment
• Cycle data from vacuum oven
• Copy of certificate of calibration of vacuum oven
• Swatch testing

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MICE Target Mechanical Design

• QA
• Recording information
• Traveller document linked to specific shafts
• Method of identifying particular shaft
• Sign off at each stage with sign off criteria
• Prototyping
• Enables definition of what is achievable on
  drawing, quicker sign off

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MICE Target Mechanical Design

• Bearing - Core Procedure
• Bearing production
• Machine start part
• Send off for wire cutting of wedge (Di-Spark or
  ICL?)
• Inspect fit upon return
• Add features to clamp wedge
• Add dowels
• Add bores (incl. polish) and turn taper and part
  off (all in one)
• Highly accurate location of bore to OD
• Metrology
• Add reverse features
• DLC coat

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MICE Target Mechanical Design

• Bearing - Core Procedure
• Core production
• Produce core cap part (1130) with precision fit
  but not bearing recess - Metrology
• m/c features of main core (1128) on general lathe
  part off - Metrology
• Add fixing holes to flange
• Fit precision lathe with drilled flange and face
  off
• Fit m/c core and clock concentric
• Machine fit for cap
• Add cap and machine bearing recess (use molyslip
  or similar!)
• Remove, dowel on mill remove cap
• Turn around and clock concentric
• Add bearing recess

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MICE Target Mechanical Design

• Bearing - Core Procedure
• Core production Alignment features
• Best alignment
• Precision lathe for fine tolerance work (sole
  operator Eamonn Capocci)
• Bearing ID / OD machined w/o changing position in
  chuck
• Bearing holes machined in assembled parts on same
  dedicated jig using same reference datums
• Taper fits on bearings dowels to give
  consistent repeatable alignment
• Dowelled cap on core body for accurate reassembly

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MICE Target Mechanical Design

• Manufacturing database
• General assembly of MICE Target
• Parts list used as BOM
• Decide responsibility for
• Manufacture
• QA
• Sign off etc
• Individual item (critical) or batch log
• Logs...materials certs, processes, when,
  where/who, inspection, sign off
• Held by responsible

18
Schedule for cut-off date
(V2)
No contingency