LCLS Undulator Bellows Module

Internal Design Review

Soon-Hong Lee

Jan. 6, 2006
Chamber & Bellows IDR

Contents
Layout
General Requirements
Specifications
Conceptual Designs
Materials for Bellows Module
FE Stress Analysis
Mechanical Failure Test
Conclusions

Jan. 6, 2006
Chamber & Bellows IDR

Layout
Short Break Diagnostic Section

Jan. 6, 2006
Chamber & Bellows IDR

General Requirements
Bellows motion requirements
Baking temperature at ~200 C
Fabrication tolerance of chamber, BPM, Quad.
Longitudinal cradle motion constraint = 3.0 mm
Total axial travel 5.0 mm

Adjacent two undulators are tilted and/or in parallel

Quad center manual adjustment range = 2.0 mm
Total lateral offset 2.0 mm

From www.flexhose.com

Jan. 6, 2006
Chamber & Bellows IDR

Adjacent two undulators are tilted symmetrically

Angular stroke for bellows module = 2 tan1 (height
change/length between bellows module)
Height change = 2 mm (~2.5) + 2 mm (~2.5) =
10 mm 2 x tan1 (10/3800) = 0.3
Undulator segment pitch tolerance (rms) = 14 rad
Total angular rotation 0.5
4

General Requirements
Mechanical Concept of Bellows Module
Consider axial travels/constraints for easy installation and maintenance
Consider lateral offset with flexible contact fingers and static stub
Consider maintenance cycle and material fatigue life
Consider mechanical restraints to prevent damages for bellows and fingers

RF Connections
Provide a sliding surface with good lubricity and good electric conductivity
RF fingers, spring fingers, and stub mechanism
RF seal ring or spring gasket across flange joints

0.4 ~ 0.5 mils silver plating on the shield fingers

0.2 ~ 0.3 mils rhodium plating on the stub

Jan. 6, 2006
Chamber & Bellows IDR

Specifications
Flexibility

Life
Vacuum

Allow 0.5 of Angular Stroke (Pitch and Yaw)

Allow 2.0 mm of Lateral Stroke (X & Y axes)
Allow 5.0 mm of Axial Stroke (Z axis)
At least 2,000 cycles
1 x 10 7 Torr

Low Beam Impedance

Electric continuity by RF fingers and RF seal ring or spring gasket

across flange joint

Space Constraints

Minimize beam directional overall length of module (Z-axis)

Axial constraint mechanism for easy installation and maintenance

Thermal Loads
Structural Loads
Plating Requirements

Jan. 6, 2006
Chamber & Bellows IDR

Bake at 200 C and Operation Heating

Contact Resistance Heating
Fatigue stress due to flexible strokes across the module
Gravity, vacuum force, and contact force
0.4 ~ 0.5 mils Silver plating on the RF-shielding fingers
0.2 ~ 0.3 mils Rhodium plating on the Stub tube/Spring fingers

Bellows Module
EVAC flanges with
chain clamps for
space limitation and
easy maintenance

Removable tie rods

for restraints to
prevent damages

Welded Bellows
(200-125-3-EE)

RF-connections

Axial travel: 16~60 mm

lateral offset: 4.3 mm
angular offset: 50

Jan. 6, 2006
Chamber & Bellows IDR

Bellows Module - Exploded

RF Fingers (BeCu 174)

with Ag-plating

Stub (OFE Cu) &

Spring Fingers (BeCu)
with Rd-plating

RF seal ring or spring gasket

Jan. 6, 2006
Chamber & Bellows IDR

Materials for RF Fingers and Stub

Flange
Jan. 6, 2006
Chamber & Bellows IDR

Heat Treatment
Stub Tube Needafter
Fingers
forming

Fingers

RF Finger Stress Analysis

3 mm at tip

Jan. 6, 2006
Chamber & Bellows IDR

10

RF Finger Stress Analysis

324.8 MPa at root >

Fatigue strength of
BeCu (276MPa)

Jan. 6, 2006
Chamber & Bellows IDR

11

Design Parameters
To investigate maximum stress at root
contact types (point contact or surface contact)
# of RF-fingers
# of Spring-fingers
shape of fingers to reduce the overlap damage
thickness and length of fingers

RF-finger root

Stub
Jan. 6, 2006
Chamber & Bellows IDR

Spring finger

RF-finger tip
12

FEA Case Study

+ 2mm
+ 5 mm

- 2mm

RF Fingers

Use Pro/Mechanica - Contact Analysis

- Surfaces of fingers & stub are contacted
- Applied 2 mm (Y) for lateral offset, 5 mm (Z) for axial travel
Criteria
- Maximum Displacement < 8.0 mm
- Maximum Stress < 276 MPa
(based on fatigue strength of BeCu Alloy 174)
Spring Finger
Maximum
Displacement

Maximum
Stress

Z-travel
( 5 mm )

3.85 mm

225 MPa

Contracted

3.82 mm

397 MPa

Contracted

3.79 mm

226 MPa

Contracted

2.87 mm

144 MPa

Extended

3.13 mm

281 MPa

Contracted

18

10

40

3.04 mm

304 MPa

Contracted

15

22

10

40

0.30 mm

3.38 mm

553 MPa

Contracted

36

18

40

0.15 mm

3.84 mm

423 MPa

Contracted

8, 9

18

0.15 mm

6.10 mm

221 MPa

No Spring
fingers

Case

Contact

No. of
Fingers

Root
angle

Tip
angle

No. of
Fingers

18

18

36

16

3-1

16

20

3-2

16

20

18

18

18

1
2

Point
Contact

5
6

Surface
Contact

Jan. 6, 2006
Chamber & Bellows IDR

Finger
angle

Thickness

45
0.15mm

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Case 1

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Chamber & Bellows IDR

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Case 3-1

Jan. 6, 2006
Chamber & Bellows IDR

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Case 3-2

Jan. 6, 2006
Chamber & Bellows IDR

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Case 8

Jan. 6, 2006
Chamber & Bellows IDR

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Case 9

Jan. 6, 2006
Chamber & Bellows IDR

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RF Fingers

0.15 mm thick
53.5 mm long
16 fingers

Jan. 6, 2006
Chamber & Bellows IDR

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Spring Fingers

0.15 mm thick
29.5 mm long
8 fingers

Jan. 6, 2006
Chamber & Bellows IDR

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Bellows Module Assembly

Jan. 6, 2006
Chamber & Bellows IDR

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Mechanical Failure Test

Object of failure test is to prove the part in the following conditions
1.

2,000 cycle actuation

2.

5.0 mm axial travel distance

3.

2.0 mm lateral offset movement

4.

0.5 of angular stroke

5.

Ag- & Rd- plating thickness

Materials

Size

Price

OFE Cu Tube

O.D. x 0.0625 THK x 1.5 LG

OFE Cu Rod

5/8 O.D. x 1.5 LG

Fixtures

OFE Cu Plate

5/16 (or 1/4) x 12 x 72

RFfingers /
Springfingers

BeCu 174-HT

Thickness: 0.15 mm
Width: 35 mm
Length: 55 mm

Stub

Bellows

BeCu 25-1/2HT

Copper and Brass Sales

1lb/ free
sample

GlidCop A-15

Stainless Steel
347

Jan. 6, 2006
Chamber & Bellows IDR

Vendors

Brush Wellman, Inc.

(1 lb free, $500 min. lot charge)
Spot Welding Consultant, Inc.

P/N: 200-125-3-EE
Lateral offset: 0.17 (4.3 mm)
Angular offset: 50
@ installed length of 1.59

22

$460.00 /
min. 5 lb

J. L. Anthony & Company

$ 271.00
/Ea

Standard Bellows Company

Conclusions
Established design specifications based on physics
requirements, maintenance, and installation etc.
Conceptual design and drawings are completed.
Based on FE analysis (contact analysis) by use of
Pro/Mechanica, max. stress on fingers is expected to
have 226MPa which shows below fatigue strength
(276 MPa) of BeCu Alloy 174.
Lubricity and mechanical failure tests are planned to
investigate the Rd- & Ag-plating thickness and the
performance of RF- & Spring-fingers.

Jan. 6, 2006
Chamber & Bellows IDR

23

RF Fingers and Stub Plating

Bellows Testing

Jim Morgan

Jan. 6, 2006
Chamber & Bellows IDR

24

RF Fingers and Stub

Plating and Test Requirements
Plating Requirements
Maintain electric continuity and provide lubricity across the sliding joint ( RF
fingers and Stub) during operations
Optimize plating performance
Avoid galling
Minimize loss of plating
Avoid loss of plating adhesion (flaking)
Testing Parameters for Bellows Assembly and Sliding Joint
Test at 10-7 torr
Allow visual inspection of sliding joint during the test
2000 cycle test
5mm axial travel (static and dynamic)
2mm lateral offset (static and dynamic)
0.5 angular offset

Jan. 6, 2006
Chamber & Bellows IDR

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Approach
1. Plate RF Fingers and Stub with Rd and Ag according to
specifications developed for the bellows for the PEP- II
High Energy Ring*
2. Test fingers as assembled inside the bellows to insure
acceptable performance at operating conditions for 2000
cycles
3. Change coating thicknesses if required
4. Optimize performance as budget and schedule allow
*Curt Besler, Jeffery Berg High Current RF Shield for PEP-II Vacuum System Expansion
Joint LLNL
M.E. Nordby, N. Kurita Bellows Design for PEP-II High Energy Ring Arc Chambers SLAC

Jan. 6, 2006
Chamber & Bellows IDR

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Plating Materials and Initial Thickness

RF Fingers 0.4 to 0.5 mils Ag
Stub 0.2 to 0.3 mils Rd
Plating thickness can be changed to optimize performance.
Other possible materials for increased lubricity at the joint
include:
Dicronite impregnated Tungsten Disulfide
Nanolube nested nanoshpere structure Tungsten
Disulfide

Jan. 6, 2006
Chamber & Bellows IDR

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Section Thru Test Fixture

Set-up for dynamic axial Testing

Jan. 6, 2006
Chamber & Bellows IDR

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Enlarged View Test Fixture

Enlarged view

Jan. 6, 2006
Chamber & Bellows IDR

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Bellows Prototype Schedule

Activity ID
UN43_00242
UN43_00243
UN43_00241
UN43_00245
UN43_00244
UN43_00246
UN43_00247
UN43_00248
UN43_00201
UN43_00070
UN43_00080
UN43_00090
UN43_00100
UN43_00120
UN43_00130
UN43_00140
UN43_00150
UN43_00160
UN43_00180
UN43_00190
UN43_00200
UN43_00220
UN43_00230
UN43_00240

Jan. 6, 2006
Chamber & Bellows IDR

Activity description
Study of Lubrication Coating
Proto Mech. Anal.
Proto Prelimin Design
Test Tooling Design
Evaluation of Lubrication Coating
Proto Review
Proto Final Design
Write Bellow Fab Spec
Test Equipment Fab & Assy
Bid Package-Ag Plated RF Finger Prtp Bel Mod
Bid Package-Rh Plated Stub Prtp Bel Mod
Bid Package-Tubes Prtp Bel Mod
Bid Package- Prtp Bellows Module
Bid Process Prtp Bel Mod
Procure Ag Plated RF Finger Prtp Bel Mod
Procure Rh Plated Stub Prtp Bel Mod
Procure Tubes Prtp Bel Mod
Procure Bellows Prtp Bel Mod
Prototype Bel Mod Award Complete
RCV: Bellows Prtp Bel Mod
Quality Assurance Prtp Bel Mod
Measurement and Test Prtp Bel Mod
Review and Report Prtp Bel Mod
Prototype Bel Mod Testing Complete

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Early start
05/02/05A
06/15/05A
07/22/05A
11/01/05*
11/22/05*
1/13/2006
1/31/2006
2/14/2006
2/21/2006
3/2/2006
3/2/2006
3/2/2006
3/2/2006
3/7/2006
4/11/2006
4/11/2006
4/11/2006
4/11/2006
4/13/2006
5/25/2006
6/2/2006
6/16/2006

Early finish
11/30/2005
11/30/2005
11/30/2005
11/30/2005
1/12/2006
1/30/2006
2/20/2006
3/1/2006
4/3/2006
3/6/2006
3/6/2006
3/6/2006
3/6/2006
4/10/2006
4/12/2006
4/12/2006
4/12/2006
4/12/2006
4/12/2006
5/24/2006
6/1/2006
6/15/2006
6/22/2006
6/22/2006

Bellows Prototype Costs

Material costs from current loaded schedule

Jan. 6, 2006
Chamber & Bellows IDR

Bellows

$ 1,500

Test Equipment

$ 4,000

Evaluation of plating

$ 3,000

Rh plate stub

Ag plate fingers

$ 3,000

Fabrication of small parts

$ 600

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900