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.
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