2008-03-15 Matt Fleming

Hydroformed ReflectorTime & Materials Cost Estimate

SKA US TDP

Matt Fleming

2008-03-15

2008-03-15 Matt Fleming

Purpose• This presentation is intended to estimate the cost of a hydroformed

reflector system for use on a multi antenna radio telescope array.• The reflector system is composed of several parts and these parts

are different for various candidate technologies.• A typical system includes the reflector surface and some support

system that carries back to the elevation axis and drive attachment points.

• This exercise is structured in a way that will allow other candidate reflector manufacturing processes to be compared.

• It examines the process equipment, materials & tasks attempting to identify costs for each.

• The hydroforming process is well known in the metal forming industry. It uses a fluid, under pressure, to form metal sheet material onto or around a mold or pattern.

• Care has been taken not to disclose any information proprietary to any individual entity engaged in this business.

2008-03-15 Matt Fleming

Elements of Part Costs

• Any manufactured device has the following cost elements that need to appear somewhere in the analysis.– Facility cost ( often covered in labor rate )– Technology development cost.– Tooling or equipment cost ( per process )– Setup & adjustment costs ( per batch )– Material & Labor cost ( per part )– Storage & trasportation costs ( per batch )

2008-03-15 Matt Fleming

Surface Material

Diameter ( material used ) 12.2 meter

Thickness 0.25 inch

Weight ( 0.098 ) 4,439 lbs

Material price 2.40 $ / lb

Blank cost $10,654

Stiffener cost $2,273 614 lbs 0.188

So how thin can we make it ?

2008-03-15 Matt Fleming

FormingTasks 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

2008-03-15 Matt Fleming

Tooling

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

2008-03-15 Matt Fleming

Mold Cost Estimateinputs are in green

cool units

AssumeImproved

design

this is thebig guess

ratio Diameter 6.1 12.0 m 1.97

Height 1.2 2.4 m 1.97

Cost 568,000 1,420,000 $ 2.50

Volume 140 1068 cu-m 7.61

Weight

47,000 188,000 lbs 4.00

Density

335 176 cu-m / lb 0.53

Rate 12.09 7.55 $ / lb 1.60

2008-03-15 Matt Fleming

Hydroformed ReflectorAssy Costs

Units Cost 12m = 452m^2

1 3,550,417 7,848.14

10 375,667 830.41

50 93,467 206.61

500 29,972 66.25

2500 24,328 53.78

5000 23,622 52.22