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High-current cables using REBCO tapes can be used to develop high-field dipole magnets. However, the strain accumulated during cable fabrication and coil winding may reduce the critical current of the conductor. Therefore, it is important to properly consider the strain when designing high-field magnets. In this paper, we used structural finite-element analysis (FEA) to predict the strain experienced by a REBCO tape during bending in configurations relevant to the fabrication of high-field accelerator magnets, in particular, the mechanical strain generated during cable fabrication and winding in a canted-cosθ dipole configuration. We considered two different cable options: (A) Flat tape that lay in the mandrel channel and (B) a REBCO tape helically wound around a circular copper core, the typical configuration of the conductor in round core cable (CORC). Strain accumulated during tape winding is studied for different core diameters and winding tilt angles. FEA longitudinal strain results were compared with the simulations for configuration A, where higher strain was observed experimentally. Configuration B was verified indirectly by comparing experimentally measured Ic with the one predicted (based on the longitudinal strain) as a function of the bending diameter. Good agreement was found up to a bending diameter of 30 mm. The presented results will help to understand the impact of bending on REBCO tapes and CORC wires to develop high-field magnets.

Finite-Element Analysis of the Strain Distribution Due to Bending in a REBCO Coated Conductor for Canted Cosine Theta Dipole Magnet Applications