HYDROFORMING PROCESS SHORT DESCRIPTION

DVA1 Meeting at NSF Arlington VA

April 15-16, 2010

Matt Fleming

Contributions from

John Andersen

Process Stations ( letters )

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 2 of 8

A Supply StationB Texture Station ( unsure on this )( not shown )C Cutting StationD Seam Welding StationE Form Prep StationF Forming StationG Back Assembly Station. ( rim & back )H Front Assembly Station.

Stations Tasks ( first )

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 3 of 8

1 Concrete floor foundation.2 Building or cover ( not shown )3 Crane with dual hoists ( maybe 2 cranes )4 Coil feed system5 Cutting machine ( laser plasma or water )6 Seam welding machine & table.7 Welded & prepped reflector blank.8 Forming mold.9 Forming pressure back plate.10 Hold down devices.

Stations Tasks ( second )

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 4 of 8

11 Reflector lift and flip device ( not shown )12 Reflector concave up. ( for weld rim )13 Backing frame.14 Backing spars.15 Other components on back side.16 Reflector & support lifting tool. ( not shown )17 Secondary & other components on front side.

Mold Proposal

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 5 of 8

Forming down into a mold supported from a foundation allows better dimensional control and access to surface maintenance

Mold would be manufactured in segments surface filled and generated on site.

Mold Proposal

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 6 of 8

Edge shape is very critical and carries very high forces.Edge elements require precision machined steel.

Mold Parts

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 7 of 8

Path to Conclusions

Process AnalysisDefine optics size and shapeDefine edge shape and edge holdingConsult with industrial partners with experiencePerform analysis on repeatability ( Ohio State 12m & 15m )Evaluate results express conclusions for SKA antenna

Production Cost Estimate ( revised )Redo preliminary cost estimateSecure review and comments from industrial partners.

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 8 of 8

Very preliminary tooling and process costs on next 2 slides

Process Tasks ( preliminary )

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide A

Tasks Mtrl Labor Time Workers

Raw material & handling. 33 10 2

Metal cutting process. $20 100 60 1

Welding Process. $20 300 60 3

Surface texture process. $80 133 40 2

Blank installaton process. 67 10 4

Forming process. 150 45 2

Part removal process. 133 20 4

Inspection process. $20 100 60 1

Trim deburr. $10 67 20 2

Storage process. $40 50 15 2

Repeat prep & cleanup. 167 20 5

Total forming cost: $190 $1,300 6 hrs

Tooling Cost ( preliminary )

DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide B

Costs based oneducated guesses

Coil equip 15,000

Cutting equip 35,000

Welding equip 45,000

Texture equip 32,000

Press ( no mold ) 500,000

Custom Mold 1,420,000

Lifting fixtures 8,000

Inspection table 7,000

Transport carts 7,500

Storage racks 12,000

Shipping fixtures 26,000

Total forming equip $2,157,500

See separateslide

Really bigguess