Studies on high-precision machining and assembly of CLIC RF structures

The Compact Linear Collider (CLIC) is currently under development at CERN as a potential multi-TeV e+e– collider. The manufacturing and assembly tolerances for the required RF components are essential for the final efficiency and for the operation of CLIC. The proper function of an accelerating structure is sensitive to mechanical errors in the shape and the alignment of the accelerating cavity. The current tolerances are in the micron range. This raises challenges in the field of mechanical design and demands special manufacturing technologies and processes. Currently the mechanical design of the accelerating structures is based on a disk design. Alternatively, it is possible to create the accelerating assembly from quadrants, which has the potential to be favoured for the mass production due to simplicity and cost. In this case, the functional shape inside of the accelerating structure remains the same and a single assembly uses less parts. This paper focuses on the development work done in design and simulation for prototype accelerating structures and describes its application to series production.