Numerical analysis of the manufacturing processes of a mock-up of the ITER NHF First Wall Panel

Highlights: • Development of a constitutive model with temperature dependent material properties. • Development of numerical techniques to simulate cutting and machining operations. • Application of the constitutive model to the manufacturing process of a mockup. • Experimental test to measure stresses and distortions due to the process. - Abstract: The objective of ITER is to build a new Tokamak, with the goal of demonstrating the scientific and technical feasibility of fusion power. The First Wall Panels are the inner component of the reactor, built with different materials that must support high heat flux levels inside the vacuum vessel. The manufacturing processes of the First Wall are a complex procedure including bending, hipping and cutting procedures which, in general, lead to residual stresses and distortions of the fabricated component. In this work, the analysis of the thermo-mechanical response of a simplified prototype of the ITER NHF First Wall Panel is presented from the numerical point of view. The experimental procedure within each phase of the whole manufacturing process is described. Residual stresses and distortions have been measured and analyzed. The numerical simulation of the manufacturing process includes the description of the main hypothesis, the applied loads and the boundary conditions assumed at every stage of the process. Special attention is paid to the simulation of machining and cutting by means of an ad-hoc element deactivation strategy. The numerical results are compared with the experimental evidence to show the prediction capability and the limitations of the proposed numerical model.