M construction and Al foam studies at AUTh

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μM construction and Al foam studies at AUTh P. Charalampous, S. Kompogiannis, G. Maliaris,

μM construction and Al foam studies at AUTh P. Charalampous, S. Kompogiannis, G. Maliaris, N. Michailidis, D. Sampsonidis, E. Smyrnaios, F. Stergioudi, I. Tsiafis and C. Lampoudis μM Mechanical Workshop April 2014, CERN Aristotle University of Thessaloniki μM Mechanical Workshop 14 -4 -2014 CERN 1

Contents q Material info (Al honeycomb/foam) q Small size panel construction q 3 P

Contents q Material info (Al honeycomb/foam) q Small size panel construction q 3 P bending test (process/results) q FEM simulation (Al foam case study) q Status and next steps Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 2

Steps and Goals Construct small size panels using different materials in order to study:

Steps and Goals Construct small size panels using different materials in order to study: “strength” properties of the product panel compare achieved planarity (larger panels) evaluate the use of materials (and time!) Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 3

Small size panels PCB skin sandwich with: q Al honecomb (1 cm thick) •

Small size panels PCB skin sandwich with: q Al honecomb (1 cm thick) • 19. 1 mm cell size • 6. 4 mm cell size q Al foam (1 cm thick home made sample) 130 mm x 80 mm Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 4

Construction…before braking Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 5

Construction…before braking Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 5

3 P bending: process Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4

3 P bending: process Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 6

3 P bending: reality demo Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14

3 P bending: reality demo Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 7

3 P bending: results case: 130 mm x 80 mm panels Aristotle University of

3 P bending: results case: 130 mm x 80 mm panels Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 8

FEM study: Al – foam • Study performed for the ¼ of the panel

FEM study: Al – foam • Study performed for the ¼ of the panel to reduce simulation time. • Case study for load of 500 N. • Highly detailed simulated porosity (increased complexity). • Results in good agreement with experiment. N. Michailidis, E. Smyrnaios, G. Maliaris, F. Stergioudi, A. Tsouknidas, Mechanical response and FEM modeling of porous Al under static and dynamic loads, Advanced Engineering Materials, 16(3), pp. 289 -294, 2014. Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 9

FEM studies: results Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014

FEM studies: results Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 10

Potential benefits of Al – foam • Can be machined to precise dimensions using

Potential benefits of Al – foam • Can be machined to precise dimensions using all available methods for conventional parts (e. g. turning, milling, sawing). • Superior strength properties compared to Al honeycomb. • Less time consuming during gluing stage of assembly. • Improved planarity of the product panel. • Possibility to eliminate the Al frame use – calculations are needed. Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 11 ! !

Status and foreseen steps ü Panel construction using Al-honeycomb completed (use of Al-foam pending).

Status and foreseen steps ü Panel construction using Al-honeycomb completed (use of Al-foam pending). ü Planarity control of both panels to be done with the CMM machine. ü Use of home made Al-foam ü The Al foam alternative has to be evaluated at CERN experience is building up Aristotle University of Thessaloniki μM Mechanical Workshop, CERN 14 -4 -2014 12