22 Aug J.T. Hong, S.H. Ahn, H.Y. Jeong, C.Y. Joung Neutron Utilization Technology Division, KAERI

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1 Development of a drilling machine for the instrumentation of thermocouple in a fuel pellet 22 Aug J.T. Hong, S.H. Ahn, H.Y. Jeong, C.Y. Joung Neutron Utilization Technology Division, KAERI

2 Contents 2 Introduction of FTL facility in HANAR Development of a new drilling machine Drilling experiments (optimal condition) Fabrication of a test fuel rod mockup

3 Establishment of HANAR and FTL 3 Feb., 1995 Enhance research equipments March, 2009

4 Fuel Test Loop Facility (1/3) 4 Schematics of FTL

5 Fuel Test Loop Facility (2/3) 5 Fuel & material irradiation test under the same condition with NPP s steady state operating condition Applications Integral Fuel Irradiation Tests Fuel Qualification Tests High Burn-up Fuel Tests Water Chemistry and Corrosion Tests Non-fissile Tests of Pressure Tube Material In-Pile test Section ut-of-pile System(Room#1) ut-of-pile System(Room#2) In-Pile Section Design Pressure : 17.5 MPa Design Temperature : 350 ut-pile System

6 Fuel Test Loop Facility (3/3) 6 Loaded in IR-1 irradiation hole of HANAR Doubly sealed pressure vessel Max. available fuel pin: 3 pieces uter Pressure Vessel utlet Nozzle IPS Head utlet Nozzle Inlet Nozzle Inner Pressure Vessel Flow Divider Insulation Gas Gap Test Fuel Intlet Nozzle Fuel Carrier Head Test Fuel Test Fuels Test Fuel Carrier Leg Fuel Carrier Leg Flow Divider Upward Flow Path Downward Flow Path A A Doubly sealed Pressure vessel A-A uter Pressure Vessel Inner Pressure Vessel

7 Necessity of drilling a hole on a U2 pellet 7 Section view of the fuel rod Thermocouple LVDT Al 2 3 Characteristics of sintered U 2 pellet (1) Specification - Diameter ϕ8.19±0.01mm - Height 9.83mm (2) Material Characteristics - Density 10.19g/cm 3 - Hardness 700Hv (HRC 61) - Yield stress 370MPa (3) Hole drilling : - Diameter 0.7~1.4mm (±0.05) - Depth 0~12mm (±0.1) Characteristics of sintered Al 2 3 U 2 Al 2 3 (1) Material Characteristics - Purity 99.7% - Density 3.92g/cm 3 - Hardness 1480Hv - Yield stress 172MPa

8 Decision of hole diameter 8 Diameter of thermocouple D C-type K-type Diameter 1.2mm 0.5mm General tolerance for assembly including shrinkage during irradiation test : 0.2mm Hole Dia. for C-type T/C Hole Dia. for K-type T/C Ø1.4±0.05 Ø9.6 Ø0.7±0.05 Ø8.192 Ø14.1

9 Temperature ( ) Thermal analysis of a fuel rod 9 Compensation of temperature difference due to the hole in the fuel pellet Modeling of fuel rod mockup Thermocouple Result of thermal analysis Analysis tool ABAQUS 6.11 FE Analysis Axisymmetric Initial condition 25 Boundary condition 305 Heat generation at U 2 pellet mj/sec mm 3 Alumina He gas Distribution of temperature in the fuel rod z U2 pellet Clad r T: mm (Hole radius) He Clad r (mm) C L

10 Previous study of drilling machine 10 [ld study, 1999, Kim. et al, KAERI] Feeding of drill bit Drill tip Drilling time Change of drill bit Horizontal Flat type (Electro-deposited diamond) 3 hours (net) 3 times/hole Frequently change of drill bit due to the severe wear of drill tip during drilling process Long working time : Drilling time + Change drill bit + Adjust tool position Spec out (1.40±0.05) due to large run out (61.5µm) : Diameter of the drill tip (ø1.4) Diameter of drilled hole (ø ø1.523) Need to develop a new drilling machine

11 Selection of drill bit for U 2 pellet 11 Electro-deposited diamond drill bit Electro-deposition part Ewha diamond ltd. Diamond coated drill bit Diamond coating (CVD) GCT Co. ltd. 118 Drill tip Large cutting resistance, severe tool wear Chips are trapped in the drilling hole Tooling time per hole : 3hr (net) Change of drill bit per hole : 3 (average) Drill tip Small cutting resistance, low tool wear Self-remove chips

12 100 Module design of drilling machine 12 Drilling part Step motor Circulation of coolant Cooling drilled part Remove chips High frequency Spindle Ball bearing LM guide (2) Chuck Cutting oil pump micro filter Cutting oil pump XY table Protection cover 120 Prevent chips from being scattered out in all over the machine Gather the coolant to flow into the circulation tube Protect human body from a broken drill bit

13 Design and implemented drilling machine 13 Assembly design of a drilling machine step motor control panel high freq. spindle Step motor Control panel chuck XY table Chiller for spindle spindle Coolant hose chuck Housing flask micro filter cutting oil pump cutting oil chamber Al23 XY table Coolant tank Picture of equipment Vertical movement: LM guide (2), ball bearing (1) Spindle position control: Step motor (unit 0.01mm) Fix chuck on a X-Y table Filter the circulated coolant with a micro-filter Control variable: RPM, drilling depth, feed rate step feed

14 Drilling Experiments with sintered Al Case study to find the optimal control variables Experiment 1 Feed rate : moving speed of spindle while drilling the workpiece Step feed : drilling depth in each step RPM (revolutions per minute) : rotational speed of drill bit - Drilling time with various feed rate and step feed Experiment 2 - Limit of step feed according to the rotational speed Experiment 3 - Maximum number of holes with a drill bit (tool life)

15 Result of Drilling Experiment 1 15 Influence of step feed and feed rate to the tooling time (at rpm) Feed rate does not affect the tooling time As the step feed increases, tooling time is drastically decreased Step feed should be larger than 0.07mm/step Drill 5pellets / fuel rod 1 working day (8 hours = 480min.) 96 min. / hole (including waiting time) Feed rate Step feed 3mm/min 5mm/min 7mm/min 9mm/min 0.02 mm/step - - (243min.) (242min.) 0.03 mm/step 0.05 mm/step 0.07 mm/step 0.09 mm/step 0.11 mm/step 0.12 mm/step 0.13 mm/step 0.14 mm/step X (broken) X (broken) X (broken) (37min.) 0.15 mm/step - - X (broken) - (165min.) (101min.) (74min.) (58min.) (48min.) (45min.) (42min.) (163min.) (99min.) (72min.) (57min.) (47min.) (43min.) (40min.) (163min.) (99min.) (72min.) (56min.) (46min.) (43min.) (40min.) (162min.) (98min.) (71min.) (56min.) (46min.) (42min.) (39min.)

16 0.13 mm/step 0.11 mm/step 0.07 mm/step Result of Drilling Experiment 1 16 Diameters of drilled holes on a sintered alumina (Al 2 3 ) (at rpm) No relation between step feed and feed rate Step feed & feed rate do not affect the precision of drilled hole 3mm/min 5mm/min 7mm/min 9mm/min

17 Limit of step feed (mm/step) Result of Drilling Experiment 2 17 Limit of step feed according to rotational speed Increase step feed by 0.01 until the drill bit is broken Safe drilling is possible between 8000 rpm and rpm Feed rate : 5.0 mm/min Safe drilling range (rpm) Not enough cutting force High friction due to lack of coolant

18 Result of Drilling Experiment 2 18 Picture of drilling in each rotational speed As rpm increases, the more coolant scatters out Feed rate : 5.0 mm/min 8000 rpm rpm rpm Drill bit scatters out coolant

19 18000 rpm rpm 8000 rpm Result of Drilling Experiment 2 19 Diameters of drilled hole at various RPM and step feed As the rotational speed increases, the precision of drilled hole increases Feed rate : 5mm/min 0.03mm/step 0.05mm/step 0.07mm/step 0.09mm/step Max. run out = 8 µm Max. run out = 4.5 µm The spindle shows a good performance above rpm Max. run out = 4 µm

20 Summary of Experiment 1 & 2 20 Feed rate does not affect the tooling time To drill off 5 fuel pellets in a day, step feed larger than 0.07 mm/step Safe drilling is possible 8000 rpm rpm at a high step feed Above rpm, spindle shows a good performance (small run out) ptimal drilling condition : rpm, 0.07 mm/step, 5 mm/min

21 Result of Drilling Experiment 3 21 Check the number of drilling holes with a drill bit Test maximum available drilling holes with a single drill bit At 8 th hole, the neck of a drill bit is broken and stuck in the hole (drill-1: broken at 8 th hole, drill-2: broken at 20 th hole) Drill tip is stuck in the hole

22 Result of Drilling Experiment 3 22 Statistical analysis on the precision of drilled holes Rotational speed : rpm Hole dia.(mm) Ø ave.=1.413mm δø=0.004mm Number of hole Design specification Diameter of drill bit Average diameter of drilled hole Standard deviation of hole diameter Ø 1.40 ± 0.05 mm Ø mm Ø mm mm Max. run out 7µm

23 Result of Drilling Experiment 3 23 Wear of a drill bit as the number of drilled holes increase Wear is initiated from the lip of a drill tip Drill bit shows severe wear after 6 th hole 1 st hole 2 nd hole 3 rd hole th hole 5 th hole 6 th hole 4 5 6

24 Result of Drilling Experiment 3 24 Peeling off of diamond coating layer results in brittle fracture of the drill bit 8 Diamond coating layer is peeled off WC is exposed at the drill tip Friction force is increased during drilling process Brittle fracture occurs at the neck of drill body Need to inspect the drill bit at least after drilling 6 holes

25 Fabrication of a test fuel rod mockup 25 Preparation of components for a test fuel rod Zircaloy Tube compression Ring Thermocouple End Cap Sintered alumina End Cap Seal Tube Nut Guide (SUS 316L) Sleeve Assembly of the components by welding and mechanical joining Spot welding system Laser welding Pin hole spot welding Fiber laser welding system

26 Concluding Remarks 26 Development of a new drilling machine for a nuclear fuel Case experiments in sintered Al 2 3 blocks and find out the optimal drilling condition D A drill bit can drill off at least 7 holes in the sintered Al 2 3 blocks D Applied to the fabrication of a test fuel rod mockup

27 THANK YU FR YUR ATTENTIN

28 Reference Initial position 1 2 Spindle Step feed : depth of drilling in each step Difficult to drilling with a single step Divide total drilling depth with n steps to minimize the damage to the drill bit n Coolant hose Drill bit Fuel pellet Feed rate : moving speed of spindle while drilling the workpiece RPM (revolutions per minute) : rotational speed of drill bit

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