Professional Documents
Culture Documents
PREPARED BY:
Name Enrollment No.
Mr. AVADHESH H. VYAS (150090709018)
Subject : Dissertation Mid Semester Review,
M.E., 4th Semester, Machine Design,
GTU, Gujarat.
GUIDED BY:
Industrial : Academic:
MR. JAYDEEP JOSHI & PROF. RITESH PATEL,
MR. ASHISH YADAV, Assistant professor,
ITER India, CKPCET,
Gandhinagar, Gujarat, Surat, Gujarat,
India- 382025 India 395007.
2
OUTLINES
Introduction
Problem Identification
Literature Review
Research gap
Methodology
Work plan
References
3
Introduction
The institute owns two operational tokomaks (a machine for controlling thermonuclear
IPR is playing major scientific and technical role in Indian partnership in the international
Through the participation of the country in ITER, the developed technologies are being
4
Introduction
Nuclear Fusion Reaction:
Hydrogen atoms are collide at very high speed and produces the heavier element, helium.
At higher temperature, electrons are separated from nuclei and gas becomes hot and
Plasma provides the environment in which light elements can fuse and produce large
amount of energy.
5
Introduction
The temperatures inside the tokamak must reach ten times the temperature at the core of
the Sun in order to reach plasma state for fusion reaction to occur.
- Two heating and current drive (H&CD) NB injectors: used for heating of plasma
6
Introduction
Diagnostic Neutral Beam (DNB) Injector :
The DNB system injects H0 beam at 100 keV radial to the ITER plasma as a beam for
active charge exchange recombination spectroscopy.
This technique is used mainly to measure the helium ash density in the core plasma region,
monitoring the light emitted from the helium atom in an excited state following charge
exchange with the beam.
As neutral beam in this system is used for diagnosis purpose so it is called DNB
(Diagnostic Neutral Beam).
DNB Beam source (Beam source used in DNB injector) which produces neutral beam is
developed and it will be tested by ITER India.
7
Introduction
Indian Test Facility (INTF):
The Indian Test Facility (INTF) is a serious effort from INDIA to test DNB and to explore
in the R&D, one of the most important challenges in ITER.
Configuration of facility will be identical to the DNB facility for ITER, only some
simplification in design of vessel and other components is adopted.
8
Introduction
INTF injector facility is a vacuum vessel having internal components and duct for
providing 20.665 m transmission length.
INTF has negative Hydrogen Ion source of dimensions ~ 1.6m*0.6m, beam energy of
100kev & 60A of extracted & accelerated current. Beam has to travel 20.665 m with
compatible beamline components.
9
Introduction
INTF Vacuum vessel is designed in cylindrical shape having length of 9 m with diameter
of 4.5 m and has a detachable top-lid for mounting as well as removal of internal
components.
INTF vacuum vessel is of 180 m3 volume and capable of providing Ultra High Vacuum
Environment for the beam operation. As negative ions are easy to accelerate , negative ions
are firstly produce later it will be neutralized to get high energy neutral beam in vessel.
10
Introduction
High Voltage Bushing (HVB):
The high-voltage Bushing (HVB) is an important component of the beam injector (BI).
The 100 kV High voltage Bushing is one of the most important and technologically
challenging component of the INTF vessel.
Vacuum
Vessel
11
Introduction
The High Voltage Bushing (HVB) or HV Feedthrough has undergone considerable
simplification, taking into account the fact that the ITER design had to address this
component as a part of the primary vacuum boundary and radiative environment.
Interface between the transmission line and Beam Source, which constitutes all HV
electric and cooling water line connection for Beam Source (except grounded grid)
between them.
The vacuum interface is through a dish head provided in the HV bushing where all the
feedthrough lines are mounted.
Dish head would provide the structural support to the feedthrough lines as well as it works
as a vacuum isolation between vacuum vessel and the HV bushing.
12
Introduction
The main purpose of HVB is therefore (i) to carry the requirements of source and
accelerator like high current busbars, RF transmission lines, water cooling services, gas
feed and diagnostic lines and (ii) to form a part of primary safety barrier and vacuum
confinement in ITER
13
Introduction
Problem Identification
There is a need of joining process of all the incoming and outgoing feedlines with the
Space around the pipes are so less that it is almost impossible to make it weld from out
The criticality of the pipe alignment is too high so it is not possible to weld it with HV
bushing Dished head top cover plate at remote location and then to move to desired
place.
14
Design Parameters
considered:
Pipe ID:
For FS cooling, EG cooling &
Chamber cooling : 47.55 mm
For PG cooling and RF cooling
: 22.15 mm
Movement Mechanism (Kinematic
design) :
360 Degree
Pipe considered for present development Current and Gas flow controller
15
Problem Identify
Objectives of the work
16
Literature Review
Review on INTF vessel and DNB
Sr. Journal/
Author Topic Comment
no. Thesis
An Indian test
Fusion facility to This paper presents introduction about INTF as a facility to
M.J.
Engineering characterize test DNB beam source. It describes BS,BLC, high voltage
1 Singh
and Design, diagnostic bushing, diagnostic system, magnetic shielding, pumping
et al
86. 2011. neutral beam system, power supply etc used in the facility.
for ITER
Sr. Journal/
Author Topic Comment
no. Thesis
Design and
analysis of This paper presents explanation about HV feedthrough
Korean
Sejal 100-kV designed to connect all the feedlines from HV desk to beam
Physical
1 Shah et feedthrough source along with other brittle component mount on it.
Society,
al for the Indian Design requirement according to Electrical, Structural and
2014.
test Facility vacuum point of view is explained.
(INTF)
18
Literature
Sr. Journal/
Author Topic Comment
no. Thesis
Optimization of
International They Investigate the effect of TIG welding
Process Parameters for
Raghuv Journal of parameter such as welding speed, current,
TIG welding of 304L
2 ir singh Mechanical current and flux for the depth of penetration
Stainless Steel using
et al Science and Civil for 304l SS. Result speaks that Flux has the
Response Surface
Engineering, 2013. most significant effect on weld penetration.
Methodology.
International
A Review on This paper highlight the parametric
Naitik Journal of
Parametric optimization of GTAW. It is proved that
3 S. patel Computational
Optimization of TIG GTAW is better then other welding in most
et al Engineering
Welding. critical welding requirement.
Research, 2014.
The influence of
technological This paper elaborate the Arc welding
Matusi
conditions on the parameters and emission of welding fume for
4 ak J et Metalurgija, 2010.
emission of welding SS. They conclude that fume emission is quite
al
fume due to welding higher and mainly depends on current.
of stainless steels
20
Literature
Sr. Journal/
Author Topic Comment
no. Thesis
Evaluation of
This paper informs the Analysis of GTAW for
Mechanical Properties
Arunku pipe welding. The effect of shielding gas flow
of Dissimilar Metal
5 mar et ITERA, 2012. over the weld pool and weld geometry is
Tube Welded Joints
al explains. Contribution of Tungsten electrode
Using Inert Gas
is highlighted.
Welding. Evaluation.
International
Bharga This paper emphasis the study of effect
Journal of Optimizing and
v C. different input parameter for GTAW process
7 Engineering analysis of parameter
patel et on weld quality. This was carried out by
Research & for pipe welding.
al experimental method.
Technology, 2013.
21
Literature
Review on Comparison of GTAW over other
welding process
Sr. Journal/
Author Topic Comment
no. Thesis
In this paper Comparison of Ti-5Al-5V-5Mo-
Comparison of Ti- 3Cr Welds Performed by Laser Beam,
5Al-5V-5Mo-3Cr Electron Beam and Gas Tungsten Arc
T.
Procedia Welds Performed by Welding. The weld joints were performed by
1 Prasang
Engineering, 2013. Laser Beam, Electron LBW, EBW and GTAW. The weld profiles
a et al
Beam and Gas due to LBW and EBW showed an hour glass-
Tungsten Arc Welding like appearance, while those from GTAW had
a common V-liked shape.
Comparative study on
In this paper Comparative study on transverse
transverse shrinkage,
shrinkage, mechanical and metallurgical
mechanical and
properties of aluminum weld joints prepared
metallurgical
A. Arun by gas tungsten arc and gas metal arc welding
Defense properties of AA2219
2 kumar processes. Based on the mechanical and
Technology aluminum weld joints
et al metallurgical properties it is inferred that
prepared by gas
GTAW process is used to improve the
tungsten arc and gas
aforementioned characteristics of weld joints
metal arc welding
in comparison to GMAW process.
processes.
22
Literature
Research Gap
Key Issue:
The High Voltage Bushing Dished end top plate is
considered under the PIC ( Protection Important
class) component and also forms the first
confinement Vacuum Boundary. Therefore
followings are the basic points to be taken care,
(1) There must be full weld penetration
(2) It must fulfill 100% volumetric Inspection
Reliable welding configuration/solution to fulfill the above requirement is yet not identified
The presentation shows some efforts in developing the configuration and corresponding
welding technique along with hardware development to realize the required welding
characteristics
23
Motivation
Possible methods to fulfill the requirements:
Option 1 :
Fillet welding :
24
Motivation
Option 2 :
Orbital TIG welding :
In orbital TIG welding method, the welding head rotates around a fixed vertical or
horizontal pipe. Available
Min. Max. size
head available
size of between
Orbit pipes
welding
200 +mm 66.9 mm
25
Motivation
Because of the design constraints and other related interfaces, it is assessed that space is
limited around the pipes and therefore it is not feasible to weld in the required
configuration by Orbital TIG welding and also not feasible by manual TIG welding
26
Motivation
Option 3 :
Manual welding :
Limitations:
(1) This could be a full penetration fillet weld No butt weld
27
Motivation
Option 4 :
HV bushing
Welding from Inside : Dish end top
plate
Pipe
(1) Full penetration butt weld
Internal bore
welding
29
Summary of prior work done in this area:
30
IBW concept
Methodology
The 100 kV High voltage Bushing is one of the most important and technologically
challenging of the beam injector (BI). It mainly forms a vacuum interface while
connecting all the feedlines to the BS. It also provides the isolation to the 100-kV high
voltage.
Considering the plate size of HVB, the space was one of the major constraints during
welding of HVB plate to feedlines. Due to its alignment and space requirement, it was
difficult to make it weld from outside at remote location.
Full penetration and space availability around the pipes are two major constraints
approach to the core of the problem. Following is the side view of the arrangement of
pipes on to the Plate.
31
Approach for development of torch :
32
Selection of welding process:
Many different energy sources can be used for welding,
including a gas flame, an electric arc, a laser, an electron
beam, friction, and ultrasound.
It can be done in many different environments, including
open air, underwater and in space.
Welding Processes:
33
Methodology
Automatic welding :
The major components are the manipulator or the mechanical unit and the controller,
which acts as the robot's "brain.
34
Methodology
Justification for selection of GTAW :
Following are the enlisted advantages of Gas Tungsten Arc Welding (GTAW) over other
process of welding, which leads to concentrate the GTAW towards the center of attention
for the present welding work.
It works on almost all types of metals with higher melting points. The process provides
more precise control of the weld than any other arc welding process.
For metals of varying thickness including very thin metals.
It creates strong joints and produces top quality welds in almost all metals and alloys used
by industry. It gives high level of visibility when working due to low levels of smoke.
TIG welding also has reduced distortion in the weld joint because of the concentrated heat
source. It ensures Minimal finishing required after welding.
The heat source and the addition of filler metal can be separately controlled and because
the electrode is non-consumable, it can be used without the addition of filler metal.
35
Methodology
GTAW Welding:
37
Methodology
GTAW Torch:
It holds the non-consumable electrode, assures the transfer of current to the electrode and
the flow of shielding gas to the weld pool.
Torches up to 200 A - gas-cooled
200 A to 500 A - water-cooled
38
Methodology
GTAW Shielding gases:
This Gas Tungsten Arc Welding process uses following two kind of gases as a Shielding
gas around weld to separate from surrounding air and atmosphere.
Argon (Ar)
Helium (He)
This gases can be used in Pure form or mixture of it depends on the working condition
and requirement. Separate cylinder is used along with regulator indicator on it for flow
and pressure regulation.
39
Methodology
Detail Study of GTAW torch:
40
Methodology
Nozzles :
It directs the flow of shielding gas around the electrode, the arc and the molten weld pool.
Standard nozzles are 6.5 mm diameter for aircooled torches and 10.0 mm diameter for
watercooled torches.
41
Methodology
Collet and Collet Body:
The collet body screws into the torch body. It is replaceable and is changed to
accommodate various size tungsten and their respective collets.
The welding electrode is held in the torch by the collet. The collet is usually made of
copper or a copper alloy.
Handle
It is used for primarily
passing the electrical
supply to the collet body
as well as to pass the
shielding gas from pipe
end to front of the
nozzle.
42
Approach
The selection of the correct type and diameter of tungsten electrode is extremely
important to performing a successful gas tungsten arc weld.
43
Approach
Other points taken under consideration :
44
Approach
IBW torch First conceptual design :
Improvements envisaged:
(1) No water supply required as welding current is less then 200 amp hence gas
cooled required.
(2) To separate the current to flow from collet tip to motor body there is a need of
insulating separator.
45
Approach
IBW torch second conceptual design :
Improvements envisaged :
(1) Pressurized shielding gas flow is required in closed medium having only one exit.
(2) Welding current is striking at the shortest contact point so fixing tungsten
electrode with two bolt from top is not appropriate.
(3) Gas flow through previous pipe entering shielding chamber is not finalized yet so
size of holes are not defined.
46
Appraoch
Model of IBW torch test setup with nozzle:
47
Approach
7 8 15
1
9
12
16
3
13
14
4 5 6 10
17 11
48
Approach
Flange
support Flange
insulator
Insulator
Stepper motor
Job
End cap
49
Approach
50
Approach
Front Middle Back
section section section
51
Approach
Front section:
52
Approach
Collet body with Nozzle
53
Approach
Shielding chamber
54
Approach
Extension pipe
C/S
55
Approach
Middle section:
56
Approach
Flange
Support Flange support
Insulator
Flange
face
Job Rotating
pipe
Roller
bearing
Flange
Flange cap
base
57
Approach
Flange support
58
Approach
Flange (With bearing)
59
Approach
Rotating pipe
C/S
60
Approach
Back section:
Motor
support disc Motor Support
Insulator
Rotating
pipe
Stepper
Back cap motor
insulator
Back cap
61
Approach
Bottom cap and insulator
Main
Assy.
62
Approach
1 3
68
Approach
Motors for motion transfer:
Bipolar motor
Full step
4 pole
2.5 kgcm Torque
70
Approach
For the specification listed above there are options of selecting the driver such that it can
ensure best output for long run even with modification in future.
For the better modification, update and connection with computer for automatic control,
Microprocessor based stepper motor driver is the best option need to be select for the
Back
71
Approach
Carry out the dry run:
Back
72
Approach
Calculation of welding speed:
For the present work there is a need of the motion which provides rotation to the whole
assembly of torch. As per the Welding machine manufacturing company Miller, there is a
chart as well as online speed calculator to figured out the desired welding speed for the
present work.
73
Appraoch
74
Appraoch
Check for welding parameters:
Welding voltage
Welding speed
Arc Length
Joint preparation
Pre welding :
Fit up and fixture
Tungsten positioning
Gap between tungsten and pipe (arcing distance)
Gas flow rate (preflow- shielding- purging-post flow)
During welding :
Weld pool characteristics
Speed, welding current, voltage
Post welding :
Profiling
Destructive testing :
Mechanical testing
Tensile testing
Bend test
Hardness testing
RT
Back
77
Approach
Recommendation for HVB pipe welding:
Spacer rods
HV bushing
Dish end top
plate
Pipe
78
Approach
Summary
79
Summary
Model of IBW torch test setup without nozzle:
80
Appraoch
81
Appraoch
82
Approach
83
Approach
Future work plan
86
Work plan
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Reference
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