Novel Approaches in Characterization and Modelling of Fabrication Processes for SRF Components

Abstract

In the past years, Finite Element Methods have been increasingly applied at CERN, with the aim of modelling fabrication processes for SRF components. Currently, many large deformation processes such as deep drawing, forging, hydroforming, and spinning, are being simulat-ed. Taking the initial trials out of the workshop via simu-lation has proven very efficient for steering fabrication strategy, avoiding unnecessary trials, and helping to re-duce time and costs. This contribution will present a novel approach for studying fabrication process feasibil-ity and failure prediction using numerical tools, based on the Forming Limit Diagram method, developed for OFE copper sheets. This contribution will show the applica-tion of the mentioned method on the study of tubular hydroforming, as an alternative way to produce seamless elliptical RF cavities. Analysis of past hydroforming trials is also discussed, together with the comparison of different fabrication strategies