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, Matt Fleming slide 2 of 8 A Supply Station B Texture Station ( unsure on this )( not shown ) C Cutting Station D Seam Welding Station E Form Prep Station F Forming Station G Back Assembly Station. ( rim & back ) H Front Assembly Station.

Stations Tasks ( first ) DVA1, NSF, Arlington, 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 system 5 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, 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, 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, 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, Matt Fleming slide 7 of 8

Path to Conclusions Process Analysis Define optics size and shape Define edge shape and edge holding Consult with industrial partners with experience Perform analysis on repeatability ( Ohio State 12m & 15m ) Evaluate results express conclusions for SKA antenna Production Cost Estimate ( revised ) Redo preliminary cost estimate Secure review and comments from industrial partners. DVA1, NSF, Arlington, Matt Fleming slide 8 of 8 Very preliminary tooling and process costs on next 2 slides

Process Tasks ( preliminary ) DVA1, NSF, Arlington, Matt Fleming slide A TasksMtrlLaborTimeWorkers Raw material & handling Metal cutting process.$ Welding Process.$ Surface texture process.$ Blank installaton process Forming process Part removal process Inspection process.$ Trim deburr.$ Storage process.$ Repeat prep & cleanup Total forming cost:$190$1,3006hrs

Tooling Cost ( preliminary ) DVA1, NSF, Arlington, Matt Fleming slide B Costs based on educated guesses Coil equip15,000 Cutting equip35,000 Welding equip45,000 Texture equip32,000 Press ( no mold )500,000 Custom Mold1,420,000 Lifting fixtures8,000 Inspection table7,000 Transport carts7,500 Storage racks12,000 Shipping fixtures26,000 Total forming equip$2,157,500 See separate slide Really big guess