I) THIS DOCUMENT IS: 

CONTROLLED BY BAC 

PREPARED UNDER 

PREPARED ON 

rnrn!/NG 

FSCM NO. 81205 

Manufacturing Research & Development, Org . 2-2115 

ALL REVISIONS TO THIS DOCUMENT SHALL BE APPROVED 

BY THE ABOVE ORGANIZATION PRIOR TO RELEASE. 

CONTRACT NO. NAS8-35969 

lR&O 

OTHER 

FILED UNDER w* 7DL85 

1-3-EH-15543 DOCUMENT NO. D180-27884-3 MODEL 

TITLE NASA/MSFC LARGE STRETCH PRESS STUDY 

ORIGINAL RELEASE DATE 

ISSUE NO. TO DATE 

ADDITIONAL LIMITATIONS IMPOSED ON THIS DOCUMENT 

WILL BE FOUND ON A SEPARATE LIMITATIONS SHEET. 

M. W. Choate 2-2350 

PREPARED BY w. P. Neal son 2-2105 

G. C. Jay 2-4100 

W. D. Buss 2-41 13 

WECKED BY W. P. Nealso #*L 2-2105 4 April 1985 

SUPERVISED BY 

APPROVED AND BY J* A* Beasley 3&&-2 1 15 4 April 1985 

SIGNATURE ORGN DATE 

DO 6000 2160 REV 9/82 
ABSTRACT 

This document D180-27884-3 dated April 4, 1985, presents the final report for 

NASA Study Con tract NAS8-35969. 

NASA Study Contract NAS8-35969 consists of the four principal elements as 

outlined in the Large Stretch Press Study, Folder 1, Technical Proposal 

D180-27884-1, submitted by Boei ng Aerospace Company to the National Aeronautics 

and Space Administration, George C. Marshall Space Flight Center on November 7, 

1983. 

Document D180-27884-3 has been prepared in five separate sections to enable 

elemental distribution. 

1.0 INTRODUCTION AND OVERVIEW 

2.1 PHASE I TASK A - Cost Study 

2.2 PHASE I TASK B - User Survey 

2.3 PHASE I1 TASK A - Site Selection Trade Study 

2.4 PHASE I1 TASK B - Press Design Requirements and Procurement Specification 

-iD180-27884-3 
TABLE OF CONTENTS 

Introduction 

PARAGRAPH PAGE 

1 .o 

1.1 

1.2 

1.3 

1.4 

1.5 

1.6 

2.1 

2.2 

0 2.3 

2.4 

Abstract 

Tab1 e of Contents 

Introduction 

Study Tasks 

Period of Performance 

Large Stretch Press Definition 

Parts Processing Information 

External Tank Parts Candidates 

Other Study Objectives 

Appendix A - Phase I Task A 

Appendix B - Phase I Task B 

Appendix C - Phase I1 Task A 

Appendix D - Phase I1 Task B 

Appendix E - NASA S.O.W. 

cost Study 

User Survey 

Site Selection Trade Study 

Press Design/Procurement Sped fication 

1 

ii 

1 

1 

2 

2 

2 

3 

4 

8 

25 

48 

82 

129 

-i iD180- 27884- 3 .. 
NASA LARGE STRETCH PRESS STUDY 

REFERENCE NASA CONTRACT NASS-35969 

1.0 INTRODUCTION 

The purpose of this study was to: 

A. Assess and document the advantages/disadvantages of a government agency 

investment in a large stretch form press on the order of 5000 tons capacity (per 

jaw) 

Develop a procurement specification for the press. 

Provide trade study data that will permit an optimum site location. 

B. 

C. 

1.1 STUDY TASKS 

Tasks were separated into four major elements: 

A. 

8. 

C. 

Cost Study: Develop cost data for projected stretch form process excluding 

material costs, shipping costs and stretch press capitalization/depreciation 

costs. Evaluate cost savings from producing larger External Tank (ET) gore 

segments (up to 150% in width). Parts drawings and current cost data will be 

made available to the successful bidder. 

User Survey: Contact specific design/manufacturing organizations of various 

government (and commercial/industriaI) agencies and identify those agencies 

which have requirements (or potential) for a large stretch press. Determine 

current and future needs assuming a large stretch press was available. 

Site Selection: Explore the feasibility of a government owned, contractor 

operated stretch forming facility conveniently located nearby applicable ancillary equipment. Provide two options: (1) to support existing Space Shuttle 

External Tank (ET) project and (2) optimum site for all NASA/government 

- 

i 

D180-27884-3 
programs (both options may be at the same site). Support recommendations 

with costltrade study data to substantiate recommendations. 

D. Press Design/Procurement Specification: Prepare a specification for the 

design/procurement, installation, performance and inspection of a stretch press 

with a 5000 ton (per jaw) minimum capacity. Press may be of modular design 

with initially lower capacity and capability but must be capable of achieving 

the target 10000 ton ram force with subsequent modular additions. 

See appendix I for detailed scope of work. 

1.2 PERIOD OF PERFORMANCE 

July 1984 to April 1985. 

1.3 LARGE STRETCH PRESS DEFINITION 0 The customers requirements for a large stretch press were established to be for a 

10,000 ton longitudinal and transverse type press with individual jaw force of 5000 

tons, IH" opening and a die table capable of 10,000 tons ram force. The Press is to 

be capable of processing aluminum alloy 2219-T37 plate 1.00" thick x 210" wide x 

430" long. 

1.4 PARTS PROCESSING INFORMATION 

Existing external tank (ET) parts recommended for consideration are the tank gores 

and dome segments which are currently stretch formed from 2219-T37 aluminum 

alloy to contour and extensively chem-milled prior to heat treating to a T37 

condition and final machine. The domecaps were also recommended for consideration. They are spun formed and machined; they are not stretch formed. All detail 

2 

D130-27884-3 
parts fabrication is accomplished in the Los Angeles, CA area. These details are 

then shipped to the NASA-Michoud New Orleans, LA facility for subassembly and 

final assembly. 

This portion of the study evaluates the overall feasibility of the use of a large 

stretch press to fabricate larger ET components that will be presculptured (premachined) prior to stretch forming to reduce detail fabrication costs, assembly 

costs, eliminate chemical milling, and reduce assembly costs. 

1.5 EXTERNAL TANK PARTS CANDIDATES 

There are four major ET subassembly components areas which could potentially 

result in reduced unit part costs and welding assembly and inspection costs by 

increasing individual part sizes. The four major areas are as follows: 

Number Segments 

Nomenclature Existing Proposed 

LO2 Aft ogive 12 8 

LO2 Aft bulkhead 12 8 

LH2 Aft bulkhead 12 8 

LH2 forward bulkhead 12 8 

Existing ET component designs for these major subassemblies will require redesign 

for (1) the larger size of these components and (2) for premachining (presculpturing) 

and stretch forming as the manufacturing process to replace the existing chemical 

milling design. 

3 

D180-27884-3 
The economical offset to the requirement for redesign of these components is that, 

per NASA/MSFC the existing heat treat fixtures and assembly tools can accommodate these larger size components without any major redesign or rework. In 

addition, the amount of reduced weld joint assembly and inspection labor should 

result from using larger parts. 

1.6 OTHER STUDY OBSERVATIONS 

In addition to the baseline study contract some additional observations were 

requested by NASA/MSFC in relation to (a) the effect of increased environmental 

controls on the chemical milling industry and (b) optional manufacturing 

process/design concepts - for E.T. type structures. 

A. Effect of increased environmental controls on the chemical milling industry. 

The spent aluminum solutions consist primarily of sodium carbonate, sodium 

aluminate, sodium hydroxide, sodium sulfide and triethanolamine. None of 

these are particularly toxic. The spent solution also contains smaller amounts 

of copper sulfide, zinc sulfide and traces of chromium and lead. These heavy 

metals preclude sewer disposal. 

A process exists to regenerate aluminum chem-milling solutions, but because of 

inexpensive disposal methods in the USA, only Japan is using the process at the 

present time. Boeing Wichita has treated spent aluminum chem-mill solutions 

in the past, and expects to implement the Japanese method in their facility 

next year at a cost of 1.6 million. 

4 

D180-27884-3 
Spent chem-mill solution is a priority waste because EPA wants to restrict 

landfill disposal of liquids. In the future, chem-mill shops may need to 

centrifuge or dewater the waste some other way prior to landfill disposal of 

sludge. The technology exists to recycle the spent solution continuously with 

less waste generation as mentioned above. The chem-mill industry is not in 

danger of a shut-down due to anticipated EPA requirements. 

B. Optimal manufacturing process/design concepts for E.T. type structures. 

1. Rationale for Alternate Design Concept Selection 

Several very basic considerations of relationships of the E.T. tank detailed 

structural design to resultant cost and weight savings should be evaluated. 

The most significant consideration in terms of determining the size or load 

capability of the stretch press required to fabricate stretch formed parts is the 

area of part cross section normal to the direction of stretching. As a general 

rule the cross section area normal to the direction of stretching should be 

essentially constant along the length of the part in order to provide uniform 

stretching. These considerations also lead to assuming at least a partial premachining of the parts before stretch forming would be beneficial. 

A feature which significantly affects chemical milling fabrication costs is the 

amount of detailed thickness mapping and the number of successive chemmilling operations required to produce a part within dimensional tolerances. 

This consideration provides incentive for finding ways to reduce the initial 

4 

/ 

D180-27884-3 
thickness of the part and minimize the amount of stretching and resultant 

differential thinning in the part. 

In addition a reduction in the number of weld lands by using larger width 

segments could be used to offset a weight increase that might result from 

increasing tolerances on thicknesses by using pre-machining in preference to 

extensive chemical milling. 

2. Discussion of Study Candidates 

a. Reduced number of larger gores. 

This concept will make excellent use of increased stretch forming capabilities 

and will reduce the cost of joining the gores in proportion to the number of 

gores eliminated. It will also make corresponding reductions in resultant weight 

of weld lands without involving a basic tooling concept change. This should be a 

low technical risk choice and require a minimum of engineering/analysis 

support. 

b. Stretch form pre-machined gores. 

This is a particularly appealing approach which would result in essentially no 

change in the final assembly tools and should offer added advantages if 

employed with the existing longitudinal design or for futures a transverse gore 

design concept. Specific advantages are reduced stretch forming loads and the 

elimination of chem milling or a reduction of chem milling to further reduce 

costs and reduce work in process flow times. 

6 

D 180-27 88 4-3 
3. Expected Preliminary Results and Candidate Selection for Further Study 

It is anticipated that optional study candidates could be found that would be 

most desirable for different structural subassemblies of the E.T. and that 

combinations of the concepts studied will be most advantageous. Forming of 

those gore segments with lands suitable for welding in the heavy bosses may 

also prove to be advantageous. A separate research and development study 

could be beneficial to the existing E.T. program and future programs. 

7 

D130-27884-3 
APPENDIX A 

LARGE STRETCH PRESS STUDY 

NASA STUDY CONTRACT NASS-35969 

COST STUDY 

PHASE I TASK A 

APRIL 1, 1985 

8 

D 180-27884-3 
2.1.0 

2.1.1 

2.1.2 

2.1.3 

TABLE OF CONTENTS 

PARAGRAPH 

Title Page 

Table of Contents 

List of Figures 

Overview 

Boeing Simulated Type I1 Labor Standards 

Simulated Parts Cost Analysis 

Additional Cost Considerations 

PAGE 

8 

9 

10 

11 

13 

18 

22 

9 

D189-27884-3 
FIGURE 

NUMBER 

LIST OF FIGURES 

Cost Study - Phase 1 Task A 

- PAGE 

2.1-1 Dollar Cost Comparison Problems 12 

2.1.1-1 Labor Standards Summary Comparison 17 

2.1.2-1 

2.1.2-2 

Skin Mill LH2 Forward Dome Gore Estimate 

Skin Mill Lox Aft Dome Gore Estimate 

19 

20 

2.1.2-3 Skin Mill LH2 Aft Dome Cap Estimate 21 

2.1.2-4 Comparative Analysis Dollar Actuals vs. Simulated Analysis Cost 23 

10 

D180-27884-3 
2.1 PART COST COMPARISONS 

PHASE1 TASKA 

2.1.0 OVERVIEW 

The Boeing Technical Proposal Response document DI 80-27884-1 (p. 54) requested 

that "detail manufacturing plans (shop orders) for gores, ogives, and domes, and 

related cost data, are required for the successful performance of this program." 

After contract award current customer (full-up) dollar cost data was received for 

the cost study task, which while not conducive to detail manufacturing process cost 

analysis was used for comparative purposes. See figure 2.1-1 for cost comparison 

problems using gross dollar data which due to its subcontractor location, local labor 

rate and charging practice creates variations that are not directly comparative. As 

a preferred option, cost data, was requested in terms of actual manhours or labor 

standard hours as related to the manufacturing processes for any one of a number of 

potential candidate parts for stretch forming. This information was also not 

available and as a result two different approaches were made to simulate the 

current parts costs. 

(A.) Boeing type I1 labor standards data based on part cost by size and complexity 

was simulated. 

(B.) A Boeing estimate for manhour data was made for three select candidate parts. 

Our approaches to simulate parts costs by either method did clearly indicate a cost 

advantage by changing the existing manufacturing process from chemical milling to 

skin milling and from raw material pre-forming to precision stretch forming of 

premachined (prescuiptured) panels. 

11 

DI 80-27884-3 
Direct cost 

Labor cost 

Overhead cost 

*Operating facility 

*Capital equipment 

*Facilities and buildings 

Plate 

maintenance 

Raw materials 

Cost comparison 

problems 

Contractor 

facility 

Location 

wnr i t ive 

Expense 

Expense 

Expense 

GFP 

Government 

facility 

Location 

sensitive 

GFP or ? 

GFP or? 

GFP or ? 

GFP 

Figure 2.1-1 Dollar Data Cost Comparison Troblems 

12 

D180-27884-3 
It must be emphasized that while our simulations did indicate a cost savings on an 

individual parts basis they were inhibited by the unavailability of proprietary 

manufacturing process plans, actual labor manhours, or labor standards data. In 

addition there are some other major cost savings factors to be considered. Of major 

cost savings significance would have been the availability of External Tank (ET) 

final assembly information as the use of larger components. can reduce the final 

assembly, parts handling, setup, welding, and inspection COSXS. This data should be 

evaluated by NASA/MSFC as it could be a significant savings. The scope of this 

cost study was also limited, in that it did not encompass any long range futures 

provisioning for design growth of a new generation larger diameter external tank, 

Space Station, or other large space vehicles requirements for ogival segments. The 

design growth potential for larger width gore segments and reduced assembly costs 

and flow times are additional justification for a large stretch press as technologically there is no other process available for the economical fabrication of larger 

parts. 

2.1.1 BOEING SIMULATED TYPE II LABOR STANDARDS ANALYSIS 

Summary dollar cost data provided by the customer was used as a guideline to 

determine what were the cost drivers to the current ET detail parts. The dome-cap 

spinning/premachining, and the extensive chemical milling for the gore segments are 

the cost drivers for these detail components. Boeing proceeded with the development of baseline cost data using current ET parts drawings and type I1 labor 

standards as defined in Military Standard (MIL-STD) 1567. 

MIL-STD-1567 establishes certain requirements which must be met for a 

contractor's work measurement system to be considered acceptable. These requirements are intended to permit maximum contractor flexibility in the application of 

13 

D 180-27884-3 
the standard rather than providing rigid methodology by which work measurement 

should be accomplished. The contractor's work measurement program must be 

documented and include the elements described as follows: 

a. 

b. 

C. 

d. 

e. 

work measurement plan and supporting procedures 

clear designation of the organization and personnel 

responsible for executing the system 

plan to establish and maintain engineered labor 

standards of a known accuracy 

plan of continued improved work methods in connection 

with the established labor standards 

plan for the use of labor standards as an imput to 

budgeting, estimating, production, planning, and touch 

labor performance evaluation 

The work measurement system uses engineered labor standards in most phases of 

manufacturing operation. A labor standard describes the time allowed for a 

normally skilled operator following a prescribed method, working at a normal all-day 

level of effort, to complete a defined task with acceptable quality. An engineered 

standard is one established using a recognized technique, such as time study, work 

sampling, standard data, or a predetermined time system, to derive at lease 90 

percent of the total time associated with the labor effort covered by the standard. 

In order to confirm the conclusion drawn from the NASA full up dollar cost data, 

Boeing labor standards data which is compliant with MIL-STD 1567 was used for 

comparison of processing by stretch forming, and chemical milling against 

processing by N/C skin-milling and then/stretch forming parts. ,4 comparison was 

14 

Dl80-27884-3 
made between each of the two processes based on part standard by size, and part 

standard by complexity. Setup and run times were analyzed separately for each 

process. Data is in labor standard minutes for aluminum sheet (plate) material. 

As a general overview labor standards in minutes for setup of a stretch formed part 

of a given size can increase up to 300% depending on the complexity of the part. 

Complexity is based in terms of the number of separate floor-to-floor operations to 

complete the process (punch, drill, saw, trim, etc.). The run times for a stretch 

formed part remain relatively constant. Labor standard for chemical milled part 

setup time of a given size part can however increase up to 200% and depending on 

the complexity of the part run times can increase over 300%. 

The existing design of the ET parts evaluated, when combined with the limited 

commonality of parts within most major or structural areas, prohibits economical 

lot size manufacture by any other process other than extremely time extensive 

chem milling. 

In the proposed process (N/C skin mill and precision stretch forming), NC skin 

milling (pre machining) set up costs are relatively insensitive to the size or 

complexity of the part and the run times are relatively constant. The set up times 

for stretch forming a premachined E.T. part are however assumed to be more 

complex and as a result they are over 30% longer than those for forming unmachined 

plate as was done (105 min. v/s 134 min.) but the run times are the same. 

Of significance is the fact that when using a large aircraft skin mill, multiple parts 

can be produced with a one time setup cost and a multiple run time based on the 

quantity of the same parts on the skin mill bed. In the case of the LOX Forward 

15 

D180-27884-3 
Ogive Gore, at least 6 ogives can be machined in sequence and the average part cost 

is 555 minutes (setup 149 minutes + 6 parts x 539 minutes each (3180) = 555 

minutes). The same productivity efficiencies are applicable for a large production 

stretch press with finite yield point controls and air bearing die conversion systems 

which enhance lot size production. See Figure 2.1.1 -1, Summary Comparison (Labor 

Standards) for details. 

Labor standards per se indicate that there is a cost savings in changing the 

fabrication process from chemical milling to premachining by large aircraft skin 

mills. There are however additional savings of work in process flow times that 

provide further justification for the procurement of a large stretch press. 

From a technology standpoint the only economical process for the precision forming 

of large presculptured E.T. p!ate components is a large modern production stretch 

press. Only the latest design presses are capable if the finite yield point control and 

low end tonnage control that is required for large pre-machined, high value, parts. 

In addition only the latest design presses can accommodate air bearing die change 

over systems which increase productivity. There are only two large production 

stretch presses in the United States that are in the 1,500 ton (750 tonljaw) range. 

Neither of these presses are of either adequate size or capacity to support the 

existing or proposed E.T. rate requirements nor the anticipated increase in plate 

width. 

Per our user survey (Phase I, Task 8) there is positive industrial interest and 

application for a large stretch press in either the 5,000 or 10,000 ton range as a 

nationa1 asset. 

16 

D180-27884-3 
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17 
2.1.2 SIMULATED PARTS COST ANALYSIS: CHEM MILL VERSUS SKIN MILL 

A comparison of selective high cost E.T. parts using a simulated parts cost analysis 

shows skin milling to be significantly less expensive than the costs for chemical 

milling. An estimate was made for the LH2 aft dome cap, the LOX aft dome gore, 

and the LH2 forward dome gore. It appears that the dome caps which are 

manufactured by a combination of machining and chemical milling would cost 

significantly less if they were premachined and then stretch formed presuming there 

are no technology problems with this process. 

The detail estimates are made based on the following ground rules. 

(A.) All parts are machined in a flat condition whether chemical milled or skin 

milled (premachined). 

(B.) Current 2219137 raw material is baseline. 

(C.) There are no significant metal forming technology problems involved in the 

stretch forming of premachined components. 

Parametric data was developed from Boeing estimating data and is related to the 

estimated square feet of the part requiring a given operation. This data is then 

summarized to the estimated total hours and a hypothetical constant dollar rate per 

hour is used to develop an estimated part cost. 

Figure 2.1.2-1 through 2.1.2-3 were developed using labor standards and run times 

for large aircraft skin mills which could be used for premachining the candidate 

parts in lieu of the existing chemical milling process for metal removal. 

The increase of the width of the existing gore segments (Le., from 12 to 8) does not 

appear to result in any significant individual part cost reduction based on our 

simulated cost analysis however the reduced assembly costs appear to be signifizan:. 

18 

D180-27884-3 
'e SKIN MILL 

LH2 CAP AFT DOME 

809-1459-0991 SET UP - RUN 

INSPECT AND IDENTIFY 

MILL EDGE TO CLEAN UP 

MILL TAPER SIDE ONE 

156 x 156 / 100 / 60 = 4.056 

MILL POCKETS WITH 5. OR (2) 

PLACES 

144 x 144 / 50 / 60 = 6.912 

MILL STEP WITH 6.12R (2) 

NOTE: 56.0 & 45.0 DIA HOLES 

MACHINED AFTER FORMING 

DEBURR 

INSPECT 

HANDLING TIME 

CLEAN 

'@ WRAP & IDENTIFY 

TOTAL SET UP DIVIDE BY 6 

PARTS PER LOT 

TOTAL MANHOURS 

RATE PER HOUR 

TOTAL DOLLARS 

1.50 

.675 

.250 

1.50 4.056 

.75 6.912 

.50 .600 

4.25 

2.1.2-1 Skin Mill LH2 Forward Dome Gore Estimate 

2.405 

.165 

,200 

.338 

.150 

.708 

16.454 

$ 3,291.80 

$ 200.00 

19 

D180-27884-3 
<KIN MILL :I) LOX AFT DOME 

809-12664001 SET UP - RUN 

INSPECT AND IDENTIFY 

MILL EDGE TO CLEAN UP 

MILL TAPER SIDE ONE 

96 x 217 / 100 / 60 = 3.472 

MILL 9 POCKETS AT 90% OF 

SIDE 

MILL TAPER OPPOSITE SIDE 

MILL 9 POCKETS AT 90% OF 

SI DE 

DEBURR 

INSPECT 

HANDLING TIME 

CLEAN 

'@ WRAP & IDENTIFY 

TOTAL SET UP DIVIDE BY 6 

PARTS PER LOT 

TOTAL MAN HOURS 

RATE PER HOUR 

TOTAL DOLLARS 

1.50 

1.50 

.50 

1.50 

.675 

.250 

3.472 

3.472 

3.472 

.50 3.125 

5.50 

2.1.2-2 Skin Mill Lox Aft Dome Gore Estimate 

.723 

.594 

.200 

.289 

.150 

.916 

16.808 

$ 3,361.60 

$ 200.00 

20 

D180-27884-3 
SKIN MILL 0 LH2 FWD DOME GORE 

809-14164993 SET UP RUN 

~~ 

INSPECT AND IDENTIFY 

MILL EDGE TO CLEAN UP 

MILL TAPER SIDE ONE 

96 x 217 / 100 / 60 = 3.472 

MILL 2 POCKETS AT 95% OF 

SIDEMILL TAPER OPPOSITE SIDE 

AND 2 POCKETS 3.472 +3.298 

DEBURR 

INSPECT 

HANDLING TIME 

CLEAN 

WRAP h IDENTIFY 

TOTAL SET UP DIVIDE BY 6 

PARTS PER LOT 

TOTAL MANHOURS 

RATE PER HOUR 

TOTAL DOLLARS 

1 SO 

.675 

.250 

1.50 3.472 

.50 3.298 

2.00 6.770 

.963 

.132 

.200 

.385 

.150 

5.50 .916 

17.028 

$ 3,405.60 

$ 200.00 

2.1.2-3 Skin Mill LH2 Aft Dome Cap Estimate 

21 

D180-27884-3 
Based on the two separate efforts by Boeing to simulate ET parts cost data there is 

a clear indication based on the data simulation that there is a significant individual 

parts cost advantage to justify the change of existing processes. See figure 2.1.2-4 

for a comparison of chemical milling current program costs vs NIC skin milling 

parametric costs for selected components. The requirement for a large stretch 

press is dictated (1) by the change of manufacturing process from chemical milling 

to skin milling and (2) the technological requirement for a large stretch press to 

form these existing E.T. precision parts which does not exist in industry today. In 

addition any future increase in plate size edicts a change in process due to the 

limitations on highway transportation systems (see Phase 11 Task A for substantiating analysis). 

Based on parametric cost estimates the cost savings for the change of manufacturing process which dictates the use of a large stretch press would pay the total cost 

for a 5000 ton large stretch press in less than 100 external tank units. 

There are, however, other program cost and schedule considerations which, while 

outside the scope of this cost study, are significant for further cost reductions and 

product iv ity imp rove men ts. 

2.1.3 ADDITIONAL COST STUDY CONSIDERATIONS 

A. The increase of existing ET gore segment size while requiring a redesign of the 

parts would result in at least a 30% reduction of final assembly handling and 

setup costs, welding costs, and inspection costs. 

All component redesigns are structurally localized into select major assembly 

structural areas and would not affect ET final assembly. 

The existing NASA tooling can accommodate larger gore segments without 

major rework. 

8. 

C. 

22 

D180-27884-3 
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23 

D180-27884-3 
D. The major advantage of skin milling (premachining) and large stretch press 

forming is the ability of these combined processes to drastically reduce the 

existing lengthy process flow times currently required for chemical milling. 

Premachining and stretch forming enables larger lot size production which 

permits reduced setup costs. 

E. 

F. Premachining and stretch forming permits rate acceleration and/or surge 

capability that the existing chemical milling process cannot provide. 

G. Any future design growth for larger external tanks or other larger space 

vehicles cannot be accommodated without change in the manufacturing process 

and a large stretch press with waterway access. 

24 

D180-27884-3 
APPENDIX B 

LARGE STRETCH PRESS STUDY 

NASA SNDY CONTRACT NAS8-35969 

USER SURVEY 

PHASE1 TASKB 

APRIL 1, 1985 

25 

D 180-27884-3 
PARAGRAPH 

2.2.0 

2.2.1 

2.2.2 

2.2.3 

TABLE OF CONTENTS 

USER SURVEY 

PHASE1 TASKB 

TITLE PAGE 

TABLE OF CONTENTS 

LIST OF FIGURES 

SURVEY FORMAT 

SURVEY CONTACTS 

SURVEY DISTRIBUTION 

SURVEY RESULTS 

APPENDIX 2.B-1 

APPENDIX 2.B-2 

PAGE 

25 

26 

27 

28 

29 

29 

30 

34 

41 

26 

D180-27884-3 
LIST OF FIGURES 

USER SURVEY 

PHASE1 TASKB 

FIGURE NUMBER TITLE PAGE 

2.4-1 SUMMARY OF SURVEY RESULTS 31 

2.4-2 ANALYSIS OF GOVERNMENT AGENCY RESPONSES 32 

2.4-3 SUMMARY OF RESPONSE DATA 33 

27 

D180-27884-3 
USER SURVEY 

PHASE1 TASKB 

2.2.0 SURVEY FORMAT 

The survey format was designed to encompass all of the large stretch press study 

areas in relation to: 

A. 

B. 

C. 

D. 

E. 

F. 

C. 

H. 

I. 

J. 

Baseline external tank (ET) requirements (Exhibit A--NASA Scope of 

Work). 

ET proposed requirements for this capability. 

Other potential product line requirements. 

Location options. 

Ownership/operational preference (government owned/contractor operated, 

etc.). 

Other size and material type requirements. 

Other potential production requirements (rate, lot size, etc.). 

Estimate of parts requirements in f ive-year increments. 

Press specification options - extrusion jaws; bed, die, jaw, etc. size 

requirements. 

Other comments. 

The survey format as developed was pre-tested by coordination, in-house with 

applicable technical personnel, and then coordinated with the three prime U.S. 

stretch press equipment manufacturers prior to distribution. A copy of the 

survey form is in Appendix 2.B-1. 

28 

D180-27884-3 
2.2.1 SURVEY CONTACTS 

a The development of the survey contact list required an extensive effort. 

Existing contacts within the Aerospace Industries Association were utilized in a 

selective basis. Seventeen surveys were sent to members of this group. 

Government agency listings were prepared on the basis of auditing the Federal 

Register and listings provided by the Boeing Washington, DC office. These 

listings were supplemented by other government agencies which had either 

conducted or participated in similar surveys. In some cases, multiple surveys 

were sent to a given agency to insure coverage. Twenty-nine surveys were sent 

to government agencies. 

Commercial/industrial companies involved in industrial, construction, 

shipbuilding, power generation, nuclear construction, and external tank 

component fabrication were developed through research of periodicals, etc. 

Seventeen surveys were sent to these companies. 

In addition, each equipment manufacturer was sent extra copies of the survey for 

distribution to any of their existing or potential U.S. customers not previously 

covered by the Boeing survey. 

2.2.2 SURVEY DISTRIBUTION 

Of the 63 survey forms sent out, only one was returned due to an address error. 

Survey distribution was made incrementally starting on July 26, 1984 through 

August 29, 1984, with responses being received from August 22, 1984 through 

October 10, 1984. A copy of the survey mail listing is in Appendix 2.8-2. 

29 

D 180-27884-3 
Per NASA/MSFC request on November 15, 1984, a follow-on survey was 

conducted of 28 addressees that did not respond to the initial survey. This 

resurvey was distributed on December 7, 1984 with responses received by 

January 11, 1985. 

2.2.3 SURVEY RESULTS 

The survey results are summarized in FIGURE 2.4-1, with a detailed analysis of 

the government agency responses in FIGURE 2.4-2. 

Of the 63 survey forms mailed, over 59 percent responded. Of those responding, 

14 percent had potential requirements which could utilize a large stretch press 

based on the survey questionnaire criteria. 

Of those that responded with potential requirements only one had a requirement 

for a 10,000 ton (5,000 ton per jaw) stretch press. The predominate responses 

were for a press no larger than 5,000 tons (2,500 tons per jaw). The response 

data has been summarized in FIGURE 2.4-3. This data has been included in our 

other study tasks (Cost Analysis, Site Analysis and Equipment Specification) as 

additive to the baseline external tank requirements for other potential product 

line applications. 

30 

D180-27884-3 
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32 
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APPENDIX 2.51 

SURVEY FORM 

34 

D180-27884-3 
12/7/84 

LARGE STRETCH PRESS SURVEY FORM 

The National Aeronautics and Space Administration (NASA) George C. Marshall 

Space Flight Center (MSFC) has contracted with Boeing Aerospace Manufacturing Technology to conduct a feasibility study for a large stretch press facility. 

The objective of this study is to: 

assess and document the advantages/di sadvantages of a government agency investment in a large stretch press on the order of 10000 ton capacity. 

*develop a procurement specification for the press. 

.provide trade study data that will permit optimum site selection. 

Stretch forming offers several potential benefits such as low tooling costs, 

quick changeover, low distortion and minimal springback, reduced manufacturing 

costs with improvement in component quality, reduced raw material costs, 

improved tensile strength, reduced welding due to increased part size, and 

near net shape parts. 

Current stretch form presses are in the 1000-ton range. indicates that an investment in a large 10000-ton stretch form press would be 

cost effective for several applications if implementation is made in a timely 

manner. NASA indicates there are potential manufacturing cost savings and 

improvements in component quality in the stretch forming of larger tank 

bulkhead gore segments, ogive’ gore segments, and dome caps for the Space Shuttle External Tank. The capability of a large stretch press would permit the fabrication of larger gore segments and other hardware with less welding and assembly costs. 

Some examples of U.S. Government agency programs with potential applications for large stretch formed parts include military space vehicles, submarines, 

shipbuilding, nuclear, and ordnance vehicles. Examples of commercial 

appl ications include 1 arge storage tanks, pressure vessel s, antenna dishes, 

solar collectors, rail car and large automotive vehicles. 

A large stretch press could be economically justified on the basis of other 

current U.S. Government and commercial industrial hardware that is being 

produced by other means because a large capacity stretch press is not 

available. Additional long-term justification can also be developed from 

future hardware, which could be designed for stretch forming assuming a large stretch press was available. 

product lines is a key element of this survey. 

Individual commercial company data submittals from this survey will be handled 

as proprietary (confidential ) information and not disseminated on other than a 

summary basis. Survey responses will be handled on a no-obligation/no- commitment basis in terms of individual agency or company responses. 

NASA/MSFC data 

0 

Your assistance in identifying these potential 

35 

D180-27884-3 
2 

Survey participants will be provided a summary report of the marketing survey 

results as requested. The Boeing Company has no business involvement in this 

survey other than the conduct of this study. 

in this survey is requested as a national interest. 

Your assistance in participating 

PLEASE RETURN THE SURVU ON OR BEFORE FRIDAY, JANUARY 11, 1985. 

Mr. W. P. Nealson 

Boeing Aerospace Company 

Sea ttl e, WA 981 24- 2499 

(206) 656-9524 or 656-9607 

P.O. BOX 3999, M/S 6K-43 

8405A 

36 

D180-27884-3 
12/7/84 p 

LARGE STRETCH PRESS SURVEY 

Base1 i ne Equipment Requi rement: 

*Longitudinal stretch-wrap type press with articulating jaws 

Modular design with ultimate capabil ity of 10000 ton ram (die) force and 

5000tons per jaw 

.Baseline material application--stretch forming 2219-T37 aluminum plate 

frame maximum of 1.00'' thick x 270" wide x 480" long 

1. Do you presently use large (750 to 1000 ton) stretch press plate or sheet 

formed parts? Yes ( 1 No ( 1 

2. Could you use a large (10000 ton) stretch press if available? 

Yes ( 1 No ( 1 Specify if less than 10000 ton 

a. When could you use such a capability? 1988/1990 .( 

1990/1995 ( I 

1995/2001 ( 1 

b. List potential product line applications: 

IF THE ANSWERS TO QUESTIONS 1 AND 2 ARE NO, PLEASE RETURN THIS QUESTIONNAIRE 

FOR DATA RESPONSE INFORMATION. 

3. What would be the most advantageous location for such a facility? 

a. Name/Area Ci ty/State 

b. Name/Area City /S tate 

c. Name/Area Ci ty/State 

37 

D180-27884-3 
4. Site operational preference: 

a. Government owned, contractor operated facility ( 1 

b. Contractor owned facility, government owned press ( 

c. Consortium government and industry owned and funded ( 1 

5. What other size and type of material would be of potential use over the 

base1 ine material requirement? 

Material Size 

Mater i a1 Type Temper LxWxT 

a. 

b. 

C. 

d. 

6. If specific material data is not available, please describe potential 

applications and year for a product line; i.e., aluminum sail boat hull 

sections 15' wide x 24' long (1990). 

a. 

b. 

C. 

d. 

38 

D180-27884-3 
3 

7. What are your potential production requirements: e a. Number of parts per year ( ) Batch lots 

Lot size 

( ) Continuous production 

Quanti ty/mon t h 

( 1 Other (explain) 

b. Possible number of parts in five-year increments: 

- Year Material Type (Use material type code from Question 5 

to indicate potential mix. 1 

1990 

1995 

2000 

2005 

8. In terms of press specifications: 

a. Would you require the capability to adapt the sheet metal jaw system 

to an extrusion jaw system? 

Yes ( 1 No ( ) If yes, describe: 

39 

D180-27884-3 
4 

Inches 

b. 

C. 

d. 

e. 

What would be your maximum bed length requirement? 

What would be your maximum die table length and width 

requi rement? 

What would be your maximum jaw width requirement? 

What would be your maximum curved jaw chord height 

requirement? 

9. Please add any additional comnents: 

Response by: 

Name Telephone Number 

Company Name 

Company Address 

@ City, State, Zip Code 

40 

D180-27884-3 
APPENDIX 2.52 

SURVEY MAILING LIST 

41 

D180-27884-3 
Revised 2/11 /85 

Code: * = Responded 

*R = Responded/ 

Resulted 

Requested 

NASA LARGE STRETCH PRESS SURVEY CONTACTS 

Equi pmen t Manu f ac tu rers 

L & F Industries* 

21 10 Bel grave Avenue 

Huntington Park, CA 90255 

ATTN: Mr. L. Grey/Mr. J. Frank 

( 21 3) 588-2231 

LOIRE* 

Murdock Inc. 

15800 South Avalon Blvd. 

Compton, CA 90220 

ATTN: Mr. D. Thorlackson 

(21 3) 770-0220 

Cyril Bath* 

1610 Airport Road 

Monroe, NC 28110 

ATTN: Mr. R. McFarland 

(704) 289-8531 

Verson All -Steel Press Company 

1355 East 93rd Street 

Chicago, IL 60619 

ATTN: Mr. Chuck Rezack 

ALCOA* 

Honeywell Center, Suite 846 

600 108th Avenue NE 

Bel 1 evue , WA 98009 

ATTN: Mr. D. Schneider 

P.O. BOX C-96000 

(206) 453-8999 

Raw Material Suppliers 

Kaiser A1 umi num and Chemical 

P.O. Box C97310 

Bel 1 evue , WA 98009 

ATTN: Mr. W. J. Hines 

( 206) 455-5466 

Reynolds Metal s Company* 

15446 Bel-Red Road, Suite 300 

Redmond, WA 98052 

AlTN: Mr. G. Harper 

Commercial /Industrial 

Roc kwel 1 International 

HVCO Government Products 

21 35 West Maple Road 

Troy, MI 48084 

(31 3) 435-1 000 

Standard Manufacturing Company 

Combat Mobility Division 

4012 West Illinois Avenue 

e P.O. Box 21 03000 Dallas, TX 75211 

(21 4) 337-891 1 

LTV Aerospace and Defense Company 

A.M. General Division 

14250 Plymouth Road 

Detroit, MI 48232 

(31 3) 493-3300 

Mr. Tom Dean 

Market Development Division 

Lukens Steel Company 

Coatsville, PA 19320 

(21 5) 383-2527 

42 

D180-27884-3 
Commercial /Industrial (Continued) 

Babcock and Wilcox Mr. Chris Hyvonen* 

Uti 1 i ty Power Generati on Division Marketing Director 

P.O. Box 1260 

Lynchburg, VA 24505 

(804) 385-3558 

Power Group 

Morrison Knudsen Plaza 

Boise, ID 83729 

( 208 ) 386 -5000 

Mr. R. W. Barret, Vice President* Mr. R. A. Buthmann, Director 

Busi ness P1 anni ng and Marketi ng 

UNC Naval Products United Nuclear Corporation 

Division of United Nuclear Corp. 

179 Gallivan Lane 

Unc asv i 1 1 e, CT 06382 

(203) 838-1511 ext. 2527 

Government Marketing 

1735 I Street NW, Suite 618 

Washington, DC 20006 

P.O. Box 984 (703) 827-8032 

Mr. Russ Bradford 

Aircraft Hydro Forming Inc. 

131 East Gardenia Street 

P.O. Box 2170 

Gardenia, CA 92042 

. Vice President, Sales 

(213) 532-1810 

e Todd Shipyards One State Street Plaza 

New York, NY 10004 

(21 2) 668-4700 

Newport News Shi pbui 1 ding 

Tenneco 

Newport News, VA 23607 

Mr. Robert McFarland 

Aeroc h em 

1885 Batavia Street 

Orange, CA 92667 

(714) 637-4401 

Mr. L. P. Haumschilt* 

National Steel and Shipbuil ding 

P.O. Box 85278 

San Diego, CA 92138 

(619) 696-7800 

Mr. William Herchenrider* 

Fansteel Precision Sheet Metal 

5235 West 104th Street 

Los Angeles, CA 90045 

(21 3) 670-1 030 

Mr. Frank L. Raezer* 

Pennsylvania Shipbuilding Company 

P.O. Box 442 

Chester, PA 19016 

(21 5) 449-21 60 

Bath Iron Works Corporation 

Bath, ME 04530 

Mr. Forbert McClell and* 

FMC Corporation 

Marine and Rail Equipment 

2700 NW Front Avenue 

P.O. Box 3616 

Portland, OR 97208 

(503) 288-9281 ext. 665 

43 

D180-27884-3 
United States Government Agencies * United Staes Air Force 

Mr. A. Adair, AFWL-MLTM 

Department of Air Force 

Wright Aeronautice Lab 

Wright Patterson AFB 

Dayton, OH 45433 

(513) 255-4623 

Dr. Charles Williams Jr. 

Deputy for Advanced Technology 

Deputy Assistant Secretary for Systems 

U.S. Air Force 

The Pentagon, Room 4D961 

Washington, DC 20330 

Mr. J. Williamson, AFWAL-MLTW Mr. H. Johnson , AFWL-MLT 

Department of Air Force 

Wright Aeronautics Lab 

Wright Patterson AFB 

Dayton, OH 45433 -6533 Dayton, OH 45433 

Department of Air Force 

Wright Aeronautics Lab 

Wright Patterson AFB 

(51 3) 255-2232 

United Stats Armv 

USAIBEA* AVSCOM* 

U.S. Army Industrial Base Engineering 

ATTN: DRXIB-MM/Mr. Gordon B. Ney ATTN: AMSAV-PEC/Mr. Joe Pratcher 

Rock Island, IL 61299 4300 Goodf el 1 ow B1 vd. 

( 309 ) 794-51 1 3 St. Louis, MO 63120-1798 

U.S. Army Aviation Systems Comnand 

(31 4) 263-3079/3080 

0 MICOM* 

U.S. Am Missile Command 

TACOM* 

U.S. Army Tank Automotive Command 

ATTN: AhSMI-RST/Mr. Tom Shaw ATTN: AhSTA-RCKM/Ms. Janet S. Dentel 

Redstone Arsenal, AL 35898-5270 East 11 Mile 

( 205) 876-2604 Warren, MI 48090 

(31 3) 574-871 8 

Amoretta M. Hoeber T ROSCOM* 

Research, Development, and Systems U.S. Army Troop Support Command 

U.S. Army ATTN: AMSTR-PT/Mr. Richard Green 

The Pentagon, Room 2E672 

Washington, DC 20310 St. Louis, MO 63120 

4300 Goodf el 1 ow B1 vd. 

(31 4) 263-3353 

Department of Comnerce 

Mr. D. Bruce Merrifield Mr. Robert D. Wilson, Director 

Productivity, Technology, and Office of Strategic Resources 

I nnovati on Herbert Hoover Buil ding, Room 461 6 

Herbert Hoover Building, Room 4824 14th Street and Constitution Avenue NW 

14th Street and Constitution Avenue NW Washington, DC 20230 

Washington, DC 20230 

Mr. Egil s Mil bergs*R Mr. Leon Douglas, Director 

Deputy Assistant Secretary President's Commission on 

Industrial Competitiveness Herbert Hoover Building, Room 7864 

746 Jackson Place 14th Street and Constitution Avenue NW 

Washington, DC 20503 Washington, DC 20230 

Office of Planning, Technical 

Assistance, Research, and Evaluation 

(202) 377-1581 44 

0180-27884-3 
United States Government Agencies (Continued) 

@ Department of Transportation 

Rear Admiral Kenneth G. Wiman, Chief* 

Off ice of Engineering 

U.S. Coast Guard (G-E/62) 

Coast Guard Headquarters, Room 5314 

2100 Second Street SW 

Washington, DC 20593 

(202) 426-11 27 

Mr. Walter S. Luffsey* 

Assoc. Admin. for Aviation Standards 

Feder a1 Av i a ti on Admi ni strati on 

800 Independence Avenue SW 

Washington, DC 20591 

Department of Energy 

Mr. Kenneth Vagts, Director* 

Office of Planning and Resources 

Forres tal Buil ding, Room 2H-087 

1000 IndeDendence Avenue SW 

Washington, DC 20585 

Dr. A1 vin W. Trivel piece, Director* 

Office of Energy Research 

Forrestal Buil ding, Room 78-058 

1000 Independence Avenue SW 

Washington, DC 20585 

Deoartment of Aaricul ture 

Mr. Ray F. Voelkel* 

Acting Deputy Administrator 

Program Planning and Development 

P.O. Box 2415 

Washington, DC 20013 

Deoartment of Defense 

Mr. Richard E. Hay, Director* 

Office of Eng. and Highway Opns RAD 

Room T-306 

Federal Highway Administration 

Turner Fai rbank Highway Research Center 

6300 Georgetown Pike 

McLean, VA 22101 

(703) 285-2001 

Mr. Donald R. Trill ing* 

Commercial Space Transportation 

10th Floor 

400 Seventh Street SW 

Washington, DC 20590 

(202) 426-5770 

Mr. William P. Collins, Undersecretary* 

Forrestal Building, Room 7B-260 

1000 Independence Avenue SW 

Washington, DC 20585 

Mr. Maurice J. Katz, Acting Director* 

Military Application DP222.2GTN 

Washington, DC 

Dr. Richard DeLauer, Undersecretary 

Research and Engineering 

The Pentagon, Room 3E1006 

Washi ngton, DC 20301 

Mr. Richard E. Donnely, Director*R 

Industrial Resources 

Office of the Undersecretary of Defense 

Research and Engineering (AM) 

The Pentagon 

Washington, DC 20301-3060 

(202) 695-7458 

45 

D180-27884-3 
Mr. John Melonas* 

Marshall Space Flight Center, AL 35812 

NASA/MSFC-GMFTC 

Bldg. 47-11 M/S EH-44 

( 205 ) 453-1 520 

United States Navy 

Mr, P. M. Palermo 

Naval Sea Systems Command 

Washington, DC 20362 

S EA- 05B 

Mr. B. S. Safier, Director* 

Navy Material Comnand 

Industrial Resources Detachment 

Building 75-2 Naval Base 

Philadelphia, PA 19112 

(21 5) 897-6682 

Dr. Herbert Rabin 

Deputy Assi stan t Secretary 

The Pentagon, Room 4D-745 

Washington, DC 20350 

AIA Methods Processor and Equipment (MPE) MTAG 

0 Mr. J. R. Harris* Mr. J. M. Gumfory, Manager* Aerojet Mfg. Spl. Tech. Sys. Co. Airframe Technology Aeroj et-General Corpora tion Boeing Mi 1 i tary Ai rpl ane Company 

Bldg. 2002, Dept. 1140 M/S 76-85, Org. 3-7252 

P.O. Box 13222 3801 South Oliver 

Sacramento, CA 95613 Wichita, KS 67210 

(91 6) 355-1 000 (31 6) 526-3451 

Mr. B. E. Kaminski, Manager Mr. J. H. McCollum* 

Manufacturing Technology Convai r Division 

Gener a1 Dynamics Corpora tion Forth Worth Division 

P.O. BOX 80847 , MZ 91 -4709 General Dynamics Corporation 

San Diego, CA 92138 P.O. Box 748, MZ 6251-McCollum 

Fort Worth, TX 76101 

Deputy Program Manager AMs 

Flexible Machining Systems 

(81 7) 777-51 80 

Mr. Reed E. Yount, Manager 

Technology Mod Projects 

Mail Drop A-273 

General Electric Company 

Interstate Highway 75 

Evendale, OH 45215 

(51 3) 243-6203 

Mr. William Lamberta, Director* 

Manufacturing and Metal s Engineering 

Grumnan Aerospace Corporation 

1111 Stewart Avenue 

Bethpage, NY 11714 

MS 818-02 

(51 6) 575-7220 

46 

D180-27884-3 
AIA Methods Processor and Equipment (MPE) MTAG (Continued) 

0 Mr. Georse M. Vickers. SuDervisor* 

Machine6 and Equipment Design 

Lockheed California Company 

Dept. 39-35, Bldg. 85, Plant A-1 

P.O. Box 551 

Burbank, CA 91520 

(21 3) 847-5211 

Mr. E. J. Gann* 

Chief Manufacturing Engineer 

Lockheed Georgia Company 

Dept. 4-10, Zone 77 

80 South Cobb Drive 

Marietta, GA 30063 

(404) 424-4259 

Mr. Cleve F. Claxton 

Denver Division 

Martin Marietta Aerospace 

MS F9970 

P.O. Box 179 

Denver, CO 80201 

( 303 ) 977 -4094 

Mr. R. J. Owens, Manager* 

I ndus trial Engi neeri ng/Facil i ti es 

Autonetics Strategic Systems Div. 

Rockwell International Corporation 

P.O. Box 4192 M/S AC43 

3370 Miraloma Avenue 

Anaheim, CA 92803 

Mr. R. Kenneth Schell, Manager* 0 Manufacturing Prod./Sup. Sys. 

Shuttle Orbiter Division 

Roc kwell International Corpora ti on 

12214 Lakewood Blvd. 

Mail Code SODAA04, D/361 

Downey, CA 90241 

(213) 922-5242 or 922-4504 

(71 4) 632-2986 

Mr. Will iam Johnson, Chief 

Producibil ity Standards 

Dougl as Ai rcraft Company 

McDonnell Dougl as Corporation 

Dept. Cl-E71 M/C 35-40 

3855 Lakewood Blvd. 

Long Beach, CA 

(21 3) 593-3428 

Mr. H. E. Woodward* 

Systems Technology Manager 

Manufacturing Research and Development 

Boeing Commercial Airplane Company 

P.O. Box 3707, M/S 5H-07, Org. A-2021 

Seattle, WA 98124 

(206) 931 -31 73 

Mr. H. W. Fields, Manager* 

Mfg Tech Fab/Proc Eqpmt Div 

Northrop Corporati on 

Aircraft Division 

D5072/61 One Northrop Avenue 

Hawthorne, CA 90250 

(21 3) 970-3497 

Mr. L. Odor, Project Manager* 

North American Aircraft Operations 

Rockwell International Corporation 

Dept. 831 

4300 East Fifth Avenue, P.O. Box 1259 

Columbus, OH 43216 

(614) 239-2477 

Mr. Edward T. Argo, Manager* 

Development Operations 

Pratt and Whitney Aircraft Division 

United Technologies Corporation 

400 Mai n Street 

East Hartford, CT 06108 

(203) 565-5566 

Mr. C. W. Webster 

Chief Industrial Engineer 

Aerostructures Division 

AVCO Corporation 

Manufacturing Engineering Group 

P.O. Box 210 

Nashville, TN 37202 

(61 5) 361 -2000 

47 

D180-27884-3 
APPENDIX C 

LARGE STRETCH PRESS STUDY 

NASA STUDY CONTRACT NAS8-35969 

SITE SELECTION TRADE STUDY 

PHASEII TASKA 

APRIL 1, 1985 

48 

D180-27884-3 
TABLE OF CONTENTS 

SITE SELECTION 

PHASEII TASKA 

PARAGRAPH 

2.3.0 

2.3.1 

2.3.2 

2.3.3 

2.3.4 

2.3.5 

2.3.6 

2.3.7 

TITLE PAGE 

TABLE OF CONTENTS 

LIST OF FIGURES 

INTRODUCTION 

OBJECTIVE 

ASSUMPTIONS 

BACKGROUND 

APPROACH 

ANALYSIS 

CONCLUSIONS 

RECOMMENDATIONS 

PAGE 

48 

49 

50 

51 

51 

51 

52 

54 

55 

70 

76 

49 

D180-27884-3 
LIST OF FIGURES 

SITE SELECTION 

PHASEII TASKA 

FIGURE NUMBER TITLE PAGE 

2.3.5-1 

2.3.5-2 

2.3.5-3 

2.3.5-4 

2.3.5-5 

2.3.5-6 

2.3.6- 1 

- 2.3.6-2 

2.3.7-1 

2.3.7-2 

2.3.7-3 

2.3.7-4 

TRUCK AND RAIL TRANSPORTATION 

TENNESSEE RIVER AND INLAND WATER SYSTEM 

SITE LOCATION CANDIDATES 

NATIONWIDE CONSTRUCTION COST INDEX 

BUSINESS CLIMATES STUDY CRITERIA 

BUSINESS CLIMATES STUDY 

TRUCK TRAVEL TIME 

TRUCK FREIGHT COST INDEX 

RAILROAD RATE STRUCTURE 

SOUTHWEST REGION SUPPORT CAPABILITY 

MIDWEST REGION SUPPORT CAPABILITY 

SOUTHEAST REGION SUPPORT CAPABILITY 

56 

57- 

61 

65 

66 

67 

74 

75 

78 

79 

80 

81 

50 

D180-27884-3 
2.3 SITE SELECTION TRADE STUDY 

PHASEII TASKA 

2.3.0 INTRODUCTION 

Huntsville, AL is the optimum site for location of the proposed 10,000 ton 

stretch press. This site is for both the support of the External Tank Project and 

for supporting all NASA/Government Programs. 

2.3.1 OBJECTIVE 

The objective of this study is to conduct a parametric analysis to select the most 

cost effective location for a large 10,000 ton stretch press. 

A. 

8. 

Option I, optimum site to support the External Tank Project. 

Option 11, optimum site for supporting all N ASA/Government Programs. 

2.3.2 ASSUMPTIONS 

Several assumptions have been made to structure and frame the analytic effort. 

A. The operational period for the large stretch press has not been specifically 

defined at this time. We assume that it will commence in the 1990 

timef rame. 

The current Space Transportation System (STS) Program schedules reflect 

a 234 flight manifest through 1994 at a peak rate of 24 flights per year. 

We have assumed that shuttle operations will continue for an undefined 

period beyond 1994 and may increase in peak rate above 24 flights per 

year. 

Kennedy Space Center (KSC) will continue to be the major launch facility 

B. 

C. 

51 

D 180-27884-3 
D. 

E. 

F. 

for the STS Program. 

secondary launch facility. 

The external tank will remain a single source production program located 

at the Michoud Facility near New Orleans, LA. 

Should a West Coast Second Source Facility be constructed for the 

External Tank Program, then transportation costs identified in this study 

will be invalid. 

A Government Owned and Contractor Operated (COCO) plant is assumed 

to be the proposed method of operation. 

The Vandenberg Launch Site (VLS) will remain a 

2.3.3 BACKGROUND 

The maximum existing aluminum plate sizes capable of being produced today are 

as follows: 

- SIZE VENDOR 

210" x 1320" 

120" x 1200" 

103l' x 320" 

Alcoa, Davenport, Iowa 

Reynolds, Chicago, Illinois 

Kaiser, Ravenswood, West Virginia 

The proposed large stretch press would have 210" wide articulated jaws. This 

would provide the capability to form the largest 210" width aluminum plate 

produced by Alcoa in Davenport, Iowa. 

The existing Space Shuttle External Tank Program forward and aft ogive and 

dome gores for the LH2 and LO2 tanks use aluminum plate widths that range 

from 96" to 108". This is well within the existing capability of surface 

transportation by either truck or rail. 

52 

D180-27884-3 
Currently ogive and dome gores are produced in the Los Angeles, CA industrial 

area by a combination of Space Shuttle component manufacturers as follows: 

FANSTEEL PSM 

Fansteel Precision Sheet Metal (PSM) is one of 12 Fansteel Inc. operating 

organizations. Fansteel PSM is a precision sheet metal producer for both 

aircraft and missile exotic sheet metal parts. Over 58 different Space 

Shuttle components are built by PSM. The external tank dome cap, 144" 

diameter, appears to be the largest single diameter part currently 

fabricated by PSM. 

Fansteel PSM spin forms the dome cap from a round plate and after 

machining ships the part to Aero Chem in Orange, CA, about 30 miles one 

way for chem milling. It is then returned to Fansteel for additional 

manufacturing operations prior to shipment by truck to Martin-Marietta 

located at the Michoud Facility near New Orleans, LA. Fansteel PSM 

expressed a desire to be considered as a location for a large stretch press. 

AERO CHEM 

Aero Chem is located at Orange, CA and does all of the chemical milling 

for the external tank components in the Los Angeles region. Aero Chem 

has suggested that a large stretch press be located near their facility. 

Their major concern is with the inter-city transportation constraints posed 

by the larger external tank parts. 

AIRCRAFT HYDROFORM 

Aircraft Hydroform (A/C HF) is a major facility for products requiring 

hydro formed parts. They have presses located at both Gardenia and 

53 

D180-27884-3 
Victoria, CA. A/C HF is the largest user of stretch and forming presses in 

the Los Angeles area. They have stretch press capability up to 1,600 tons. 

Consideration of A/C HF for a proposed location of a large stretch press 

requires relocation to a new plant site. 

2.3.4 APPROACH 

The objective of the Phase I Task B large stretch press survey was to identify the 

potential user market. The physical dimensions of the proposed stretch press to 

handle 1" thick x 210" wide x 480" long aluminum plate was defined on the User 

Survey Form. 

The User Survey Forms were distributed to over 60 various government agencies, 

aluminum suppliers, the Aerospace Industry and other various commercial and 

industrial companies. The governmental agencies included: U. S. Air Force, U. 

S. Army, U. S. Navy, Department of Defense, Department of Transportation and 

Department of Commerce. Other potential customers included: aluminum 

suppliers, the Aerospace Industry, stretch press equipment, design and 

fabricators as well as other commercial industries. 

Response to the survey by NASA, Department of Defense and industry users, up 

to and beyond the year 2000, was for plate sizes within the proposed stretch 

press capabilities as defined in the User Survey. The majority of potential users 

have not identified future width requirements beyond 200". However, whenever 

larger dimension capability becomes available to industry, it is only a matter of 

time before components are designed which will utilize the larger capability. 

54 

D180-27884-3 
The approach used in the Site Selection Survey was to look at the placement of a 

large stretch press in a location that would use its full capability to handle 1" 

thick x 210'' wide x 480" long aluminum plate. 

2.3.5 ANALYSIS 

The capability to form components from 1" thick x 210" wide x 480" long 

aluminum plate requires the analysis of the overall transportation system from 

producer to manufacturer to ultimate user. 

Existing surface transportation by either truck or rail is not feasible for parts 

using 1" thick x 210" wide x 480" long aluminum plate which equates to part sizes 

17.5' wide x 40' long. See FIGURE 2.3.5-1 for surface transportation size 

restrictions. The use of wide load permits and pilot cars makes truck 

transportation over long distances economically impractical. 

A logical method for transportation of 17.5' wide x 40' long aluminum plate over 

long distances becomes feasible only by use of either water routes or air 

transport by Super Guppy. All three large plate producers have water access. 

See FIGURE 2.3.5-2 for the inland waterway system which inter-ties all three 

large plate producers. 

55 

D180-27884-3 
TRUCK AND RAIL TRANSPORTATION 

FIGURE 2.3.5-1 

WIDTH LENGTH HEIGHT GROSS WEIGHT NET PAYLOAD(3) 

Truck(1) 8l-6" 65' 13'-6" 80,000 Ibs. 46,000 Ibs. 

Rail(2) 10'-6'@ 100' 15'-0'' 154,000 Ibs. 100,000 Ibs. 

1. Dimensions listed are overall truck and trailer dimensions rather than net 

payload dimensions. The normal truck bed height is 50" above the road surface 

and Lo-Boy trailer height is 22". Net usable height for payload becomes 9W1 

and I1'-8" respectively using 13W' as a maximum overall height. 

2. Dimensions listed are overall general purpose railcar dimensions rather than net 

payload dimensions. Extra heavy duty and depressed center flatcars for 

extraordinary shipments exist in limited numbers. 

Net Payload is weight available for components transported. A 1" thick x 210" 

wide. x 480" long aluminum plate weighs approximately 10,000 Ibs. each. 

3. 

56 

D 180-27884-3 
57 ' 

D180-27884-3 
PRODUCER LOCATION WATERWAY/RIVER 

Alcoa Davenport, Iowa Mississippi 

Kaiser Ravenswood, WV Ohio 

Reynolds Chicago, IL Illinois 

Use of air transportation by Super Guppy for transporting finished large 

components may be economical from the manufacturer to the user. However, 

shipment by air from the producer of raw material plate to the manufacturer is 

questionable. 

A 1" thick x 210" wide x 480" long aluminum plate weights approximately 10,000 

Ibs. each. Air Bus Industry of France, which owns the current fleet of Guppy and 

Super Guppy aircraft, has minimum net payload capacity for handling large 

volumes of aluminum plate. The TAC Heavy Lift Air Cargo aircraft, the largest 

lift capability existing, has a maximum net payload capacity of 55,000 lbs. This 

equates to a total of 5 aluminum plates 1" thick x 210" wide x 480" long and must 

include the weight of any cargo tie down system in excess of 5,000 Ibs. 

The low value cost per weight of each 10,000 Ib. 1" x 210" x 480" aluminum plate 

makes consideration of air transportation economically unfeasible for any long 

term production programs. 

However, after application of intensive labor and machining or milling operations 

to blank aluminum plates, plus the reduction in weight by these processes, air 

transportation may be feasible. 

58 

D180-27884-3 
For example, Aero Chem located in Orange, CA currently does all of the 

chemical milling for Los Angeles, CA area external tank component 

manufacturers. During a plant tour of their facilities it was stated that over 

63% of the total aluminum plate weight was removed during the chemical milling 

process. Therefore finished aluminum plate weights average only 40% or less of 

the original raw material plate furnished to the fabricator from the producer. 

SITE LOCATION REQUIREMENTS 

The site selection process for the location of a large stretch press must take into 

consideration ancillary equipment and additional facilities besides the stretch 

press. 

Ancillary equipment and additional facilities required to support a stretch press 

operation includes: 

A. 

B. Chemical milling 

C. Mechanical milling 

D. 5 axis machining 

E. Tool fabrication facilities 

F. Storage and handling capability 

Heat treat or aging facilities 

The ideal concept would be for all functions to be at one contiguous location to 

reduce both handling and transportation. In addition, the distance between the 

raw material producer and the manufacturer and then the ultimate user should 

be minimized wherever possible. 

59 

D 180-27884-3 
SITE CANDIDATES 

Several existing and potential sites were considered for evaluation. See FIGURE 

2.3.5-3 for site locations. These include: 

REGION LOCATION 

Southwest Los Angeles, CA 

Midwest Wichita, KA 

Southeast Huntsville, AL 

60 

D180-27884-3 
61 

D18O-27884-3 
SOUTHWEST 

The large number of manufacturing facilities within the southwest region 

makes the Los Angeles Basin a prime candidate for the location of a 

stretch press facility. 

Currently the Space Shuttle Program utilizes the capability of this region 

to manufacture various elements of the Space Shuttle Orbiter, main engine 

and external tank components. 

Site selection candidates include the following: 

FIRM LOCATION 

1. Fansteel PSM Los Angeles, CA 

2. Aero Chem Orange, CA 

3. Aircraft Hydroform Gardenia, CA 

- 

All three southwest region potential sites are within a 30 mile radius of the 

greater Los Angeles area. Today Fansteel PSM, Aero Chem and Aircraft 

Hydroform fabricate components for the Space Shuttle Program. Any 

consideration for locating a large stretch press in this area would benefit 

from the existing experience and capability of the current labor force. 

However, when looking at the capability of the Los Angeles area to form 

parts up to the maximum capability of the proposed large stretch press, 1" 

thick x 210" wide x 480" long, other factors become extremely important. 

Transportation by either truck or rail of large existing 1" thick x 210" wide 

x 480'' long or 17.5' wide x 40' long aluminum plate from the raw material 

62 

D 180-27884-3 
producer to the Los Angeles area is impractical. Shipment by water 

transportation from the producer, see FIGURE 2.3.5-2, via the inland 

waterway, the Gulf of Mexico, Panama Canal and Pacific Ocean is 

possible. 

Although the water route is possible for the shipment of 1" thick x 210'' 

wide x 480" long aluminum plate, transportation time and cost makes the 

Los Angeles, CA area economically non-competitive when other potential 

site locations are considered. 

The installation of a large stretch press within the Los Angeles, CA area 

would require a new site for all three proposed Southwest Area locations. 

In addition, ancillary equipment and support facilities would require either 

extensive renovation or new construction. 

The Nationwide Construction Cost Index, based on the Means Construction 

Cost Data, see FIGURE 2.3.5-4, ranks California as the most costly of all 

potential site locations for new construction. 

The Alexander Grant & Co. study evaluates each state's manufacturing 

Yhsiness Climate". The "Business Climate" refers to a collection of 

factors viewed by manufacturers as important to their business. See 

FIGURE 2.3.5-5 for a listing of these factors. The factors are oriented to 

the cost of doing business. The Alexander Grant & Co. study ranks all 48 

contiguous states against each other based on the values of each of the 23 

measurement factors. This is the fourth annual study. The methodology of 

the study is the same identical approach as used in previous years. 

63 

D180-27884-3 
The Business Climate Study, see FIGURE 2.3.5-6, ranks California 26th out 

of 48 with one being best and 48th worst. 

64 

D 180-27884-3 
STATE 

CALIFORNIA 

WASHINGTON 

OREGON 

LOUISIANA 

MARYLAND 

TEXAS 

FLORIDA 

ALABAMA 

GEORGIA 

MISSISSIPPI 

VIRGINIA 

NORTH CAROLINA 

SOUTH CAROLINA 

NATIONWIDE CONSTRUCTION COST INDEX 

. FIGURE 2.3-5-4 

INDEX 

I .05 

I .oo 

.96 

.88 

.86 

.85 

.83 

.82 

.82 

.82 

.82 

.79 

.77 

DOLLARS IN MILLIONS * 

$57.7 

55.0 

52.8 

48.4 

47.3 

46.7 

45.6 

45.1 

45.1 

45.1 

45.1 

43.4 

42.4 

* Assumes a total construction cost base of $55 million for comparison purposes. 

This includes an estimated rough order of magnitude of $25 million for the 

stretch press and $30 million for the structure to house the stretch press. 

65 

D180-27884-3 
BUSINESS CLIMATES STUDY CRITERIA 

FIGURE 2.3.5-5 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

16 

17 

18 

19 

20 

21 

22 

23 

SOUTHEAST 

Energy Costs (Fuel dc Electric M BTU) $ 3.62 

Wages (Average Hourly) $ 6.60 

Unionization 15.6% 

Workers Compensation Insurance (per $100 of Payroll) $ 2.95 

Location to Market Place (75% of Market) 700 miles 

Value Added (per Dollar of Production Payroll) $ 3.67 

Change in Wages (3 years) 

Taxes (per $1000 Personal Income) $ 105 

Unemployment Compensation (per Covered Worker) $ 213 

Manhours Lost (2 years) .092% 

Maximum Workers Compensation Payment (per week) $ 191 

Expenditure Growth vs Revenue Growth (3 years) 

Vocational Education Enrollment (Percent of Popuiation) 

Unemployment Compensation (per Covered Worker) $ 83 

31% 

1.13% 

2.12% 

High School Educated Adults (Percent over 25 yrs old) 

Environmental Control (Percent of State Expenditure) 

Changes in Taxes (3 years, $1,000 Personal Income) 

Changes in Unionization (2 years) 

Debt (per Capita) 

Population Density (per Square Mile) 

Population Change (3 years in 1,000's) 

Hours Worked (per week) 

Welfare Expenditure (per Capita) 

57.2% 

0.23% 

-7.62% 

-6.29% 

$1,264 

105 

409 

39.8 

$ 152 

Data from Alexander Grant & Company using 1982 Data Base - 4th Study 

WEST 

$ 3.17 

$ 9.49 

29.2% 

$ 6.96 

$ 117 

2,000 miles 

$ 3.68 

34% 

$ 111 

$ 267 

.170% 

$ 228 

1.27% 

3.01% 

75.1% 

0.47% 

-18.71% 

-7.84% 

$2,495 

80.6 

835 

38.7 

$ 255 

* 66 

D180-27884-3 
D180-27884-3 
MIDWEST 

The site candidate is Boeing at Wichita, Kansas. The Boeing Wichita 

Company currently operates 150 ton, 250 ton, 300 ton and 1,500 ton stretch 

form presses. Within the Boeing Company there are 21 sheet metal and 

stretch form facilities of 150 tons or more capacity. The 1,500 ton press 

at Wichita, KA is used in addition to its plate forming capabilities as a 

back-up for stretching extruded aluminum aircraft wing chords. This 

supplements the Boeing Seattle area capability. The 1,500 ton transverse 

and longitudinal press is the largest of its type in the US. Collectively at 

all locations Boeing has the largest number of stretch presses in the world. 

Capability to deliver large 1" thick x 210" wide x 480" long aluminum plate 

by water transportation from the raw material producer to Wichita, KA 

does not exist. Therefore Wichita is not considered a candidate for 

location of the large stretch press. 

The site selection process must, however, consider second source capability 

as a back-up to existing external tank parts fabrication. The existing 

external tank ogive and gore sections for the LH2 and LO2 tanks use 

aluminum plate widths between 96" and 108". This is well within the 

capability of existing truck and rail surface transportation, see FIGURE 

2.33-1. Therefore, consideration of Boeing Wichita as a back-up second 

source facility to existing external tank parts fabricators has merit. 

SOUTHEAST 

Huntsville, AL is located on the banks of the Tennessee River. A stretch 

press location in the vicinity of Huntsville, AL provides a direct water 

68 

D180-27884-3 
route from the three major raw material producers to Huntsville. See 

FIGURE 2.3.5-2. Water shipment from Huntsville, AL to the Michoud 

Facility near New Orleans, LA can also be accomplished via the Tombigbee 

Waterway to Mobile, AL and through the Gulf of Mexico to the external 

tank assembly plant at Michoud, LA. 

The Redstone Arsenal located at Huntsville, AL has existing barge 

facilities that were constructed in support of the Saturn Program. Should 

the Redstone Arsenal be considered as the site location for the proposed 

stretch press, a cost savings by use of existing barge capability would be 

realized. 

The Shop and Assembly Building 4707 or the Machine Shop/Neutral 

Buoyancy Simulator Building 4705 are two potential locations for the 

stretch press facility if located at Redstone Arsenal. Each structure has 

high bay area served by existing cranes. 

BUILDING CRANE HOOK HEXGHT 

4705 10 ton 3 6' 

4707 20 ton 24' 

Consideration should be given to the operation of the proposed stretch 

press as a Government Owned, Contractor Operated (GOCO) Facility. This 

allows private industry the capability to become users of the press 

capacity. 

Other locations in the vicinity of Huntsville, AL are feasible as long as 

access to the Tennessee River is maintained. 

69 

D180-27884-3 
2.3.6 CONCLUSIONS 

The proposed location for a large capacity stretch press, capable of forming 1" 

thick x 210" wide x 480" long aluminum plate, requires water access from the 

three raw material producers. Without direct water access, transportation costs 

become prohibitive when other modes of transportation such as air freight are 

used. 

0 

FIGURE 23.5-2 shows the location of Alcoa at Davenport, Iowa on the 

Mississippi River, Kaiser at Ravenswood, West Virginia on the Ohio River and 

Reynolds near Chicago, IL on the Illinois River. To maintain flexibility of 

receiving aluminum plate from all three producers, a stretch press site location 

should be downstream from the point where all three rivers intersect. This point 

is where the Ohio River meets the Mississippi River between Missouri, Illinois 

and Kentucky. Any site location downstream from this junction can be served 

economically by all three raw material producers. 

The existing external tank fabricators located in the Los Angeles area currently 

use truck transportation. They receive plate from the raw material producers 

and deliver the formed parts to the Michoud Facility near New Orleans, LA. 

However, the existing 8' and 9' plate widths can be produced at many locations in 

close proximity to the Los Angeles Basin. When today's maximum plate sizes are 

considered, 1" thick x 210t1 wide x 480" long, the closest producer is over 2,000 

land miles and 3,000 water miles away from Los Angeles. See FIGURE 2.35-2 

for aluminum plate producer locations. 

As plate sizes increase and exceed the capability of either truck or rail surface 

transportation, then water and air becomes the only modes of transportation 

capable of handling the larger sizes. 

70 

D180-27884-3 
The LOS Angeles area then becomes an economically unfeasible location for the 

stretch press. Placement of a stretch press in a location to handle 1" thick x 

210" wide x 480" long plate excludes Los Angeles from consideration. 

The use of Wichita, KA as a second source back-up capability to the existing Los 

Angeles area fabricators is feasible due to the small sized plate widths that 

range between 8' and 9'. Both truck and rail transportation can be used. 

Consideration of Wichita for location of the large NASA stretch press is 

impractical due to the lack of direct water access. 

A large stretch press location at Huntsville, AL provides capability to receive 

and ship, by direct water access, the largest aluminum plate sizes produced. 

Advantages also exist in the use of truck shipments for smaller sized plate. 

Huntsville is within 500 miles or 1 day truck travel time of all major producers. 

See FIGURE 2.3.6-1. The truck travel time is one day from Huntsville, AL to 

New Orleans versus 4 days truck travel time from Los Angeles to either New 

Orleans or Huntsville. 

Truck freight cost penalties are also incurred when shipping from Los Angeles to 

either New Orleans or Huntsville. Los Angeles averages 2.8 times greater cost 

to New Orleans in comparison from Huntsville to New Orleans. See FIGURE 

2.3.6-2- 

Electrical power, in the southeast, for the operation of the proposed stretch 

press along with power requirements for the ancillary equipment and support 

facilities is substantial. 

71 

D 180-27884-3 
TVA is the largest energy sales producer in the United States with a generating 

capacity in excess of 31,000 MW. TVA provides power to 160 municipal and 

cooperative distributors as well as Federal, Nuclear, Aerospace and military 

installations. The service area covers 80,000 square miles and parts of seven 

states in the southeast region. 

Comparison of typical residential electrical bills places TVA near the bottom of 

the list. 

MAJOR U. S. CITIES JULY - MONTHLY COMPARISON 

New York, NY $ 157 

Chicago, IL 106 

Boston, MA 88 

St. Louis, MO 64 

Los Angeles, CA 58 

TVA Service Area 47 

By the late 1980's, TVA rates should be significantly lower than the nation and 

southeastern regional averages. The large capacity and diversification of 

generation types provides an advantage over other electric utility areas. 

The southeast region has many advantages in comparison to both the midwest 

and southwest regions. 

A. Manufacturing wages are lower at $6.60 in the southeast versus $9.49 in 

the southwest. See FIGURE 2-3.5-5. 

Office skill wages are a 21% savings. 

Management wages are a 10% savings. 

The southeast states are right to work states. 

B. 

C. 

D. 

72 

D 180-27884-3 
E. Within one day's delivery time of 76% of this country's major suppliers and 

population centers. 

F. Provides reduced freight costs. 

G. Excellent business climate. 

€3. Excellent labor market. 

I. 

J. Attractive liveability. 

K. High technology area. 

L. Advantageous cost of living. 

Ample supply of utilities at moderate cost. 

73 

D180-27884-3 
3 

74 

D180-27884-3 

v) 

9 
Y 

D180-27884-3 
2.3.7 RECOMMENDATIONS 

Huntsville, AL is the recommended site for the 10,000 ton stretch press for both 

Option 1 - the Optimum Site recommended for the External Tank Project and 

Option I1 - the Optimum Site recommended for supporting all NASA/Government 

Programs. 

The location at either the Redstone Arsenal or some other site on the Tennessee 

River provides the capability to receive and ship large components by direct 

water access via the inland waterway system. 

The location of Huntsville, AL in direct alignment between the raw material 

producers and the user in Michoud at New Orleans, LA eliminates 4,000 miles of 

truck travel or 6,000 miles of water travel that otherwise would be incurred with 

a Los Angeles area location. 

Sufficient undeveloped land is available within the existing Redstone Arsenal 

boundaries to eliminate the need for land acquisition if other Huntsville area 

sites are found to be impractical for economic reasons. 

The cost penalties incurred by truck to ship from the west coast to Huntsville or 

New Orleans is also true for the railroad rate structure. See FIGURE 2.3.7-1. 

Ancillary equipment capability and additional facilities required to support a 

large stretch press operation include the following: 

A. Heat treat or aging facilities 

B. Chimical milling 

C. Mechanical milling 

76 

D180-27884-3 
D. 5 axis machining 

E. Tool fabrication facilities 

F. Storage and handling capability 

The largest existing support capability for the three different geographical 

regions are as follows: 

REGION LOCATION FIGURE 

Southwest Los Angeles, CA 2.3.7-2 

Midwest Wichita, KA 2.3.7-3 

Southeast Huntsville, AL 2.3.7-4 

As part sizes increase in dimensions to fully utilize the 1" thick x 210" wide x 

480" long capacity of the proposed NASA stretch press and as part sizes exceed 

existing capability of support facilities, then construction of new ancillzry 

equipment and facilities should be undertaken. Consideration could then be 

given, at that future time, with the use of inland water transportation, to locate 

the new larger sized support facilities in closer proximity to the stretch press 

site. 

There is also a potential for developing major external tank sub-assembly 

capability along the inland waterway system to the Michoud Facility near New 

Orleans, LA. 

Industrial diversification would be enhanced. It would also reduce the potential 

for a local natural disaster by dispersing facilities. Space at the Michoud Facility 

could be used for other additional product applications. 

77 

D180-27884-3 
d 

78 

D180-27334-3 
SOUTHWEST REGION SUPPORT CAPABILITY 

FIGURE 2.3.7-2 

CHEMICAL 

 MILLING(^) 

LENGTH 40' 

WIDTH 12' 

HEIGHT 16' 

HEAT 

TREAT(2) 

30' 

4' 

5' 

5 AXIS 

MACHINING(3) 

180' 

13' 

2' 

I. Chemical Milling, Chem Energy Company, San Diego, CA. 

2. Heat Treat, Cal-Doran, Los Angeles, CA or Aerospace Aluminum Heat 

Treating Company, Paramount, CA. 

3. 5 Axis Machining, Rohr Industries, Chula Vista, CA. 

79 

D180-27884-3 
MIDWEST REGION SUPPORT CAPABILITY * 

FIGURE 2.3.7-3 

CHEMICAL 

MILLING 

LENGTH 24' 

WIDTH 4' 

HEIGHT 7' 

HEAT 

TREAT 

2 4' 

8' 

8' 

* Boeing Military Airplane Company, Wichita, KA. 

5 AXIS 

MACHINING 

45' 

12' 

2' 

80 

D 180-27884-3 
SOUTHEAST REGION SUPPORT CAPABEITY 

FIGURE 2-3.7-4 

CHEMICAL 

 MILLING(^) 

LENGTH 50' 

WIDTH 10' 

HEIGHT 15' 

HEAT 

TREA~~) 

48' 

1 9' 

15' 

5 AXIS 

MACHINING(3) 

50' 

6' 

2' 

1. Chemical Milling, Lockheed Georgia, Atlanta, GA. 

AVCO, Nashville, Tennessee 

(C-5 Chem Milling relocated to Texas and California.) 

2. Heat Treat, . Pinson Valley Heat Treating Co., Birmingham, AL. 

3. 5 Axis Machining, Lockheed Georgia, Atlanta, GA. 

AVCO, Nashville, Tennessee 

81 

D180-27884-3 
APPENDIX D 

LARGE STRETCH PRESS STUDY 

NASA STUDY CONTRACT NAS8-35969 

PRES DESIGN/PROCUREMENT SPECIFICATION 

PHASE 11 TASK B 

APRIL I, 1985 

82 

Dl 80-27884-3 
TABLE OF CONTENTS 

Press Design/Spec. - Phase I1 Task B 

PARAGRAPH 

Title Page 

Table of Contents 

2.4.0 Overview 

2.4.1 Background 

2.4.2 Press Size/Cost Considerations 

Appendix 2.B.I 5000 Ton Stretch Press (Spec /I44271 

Appendix 2.B.2 10000 Ton Stretch Press (Spec /I44371 

- PAGE 

82 

83 

84 

85 

86 

89 

109 

83 

Dl 80-27884-3 
2.4 LARGE STRETCH PRESS DESICN/PROCUREMENT SPECIFICATION 

PHASE I1 TASK B 

2.4.0 OVERVIEW 

Two separate specifications were developed by Boeing in conjunction with the 

two major competitive U.S. equipment manufacturers. These manufacturers 

assisted in this study with no cost to this contract. 

Boeing specification number 4427 was developed for a 5,000-ton (2,500 

tons/jaw) stretch press and Boeing specification number 4437 for a 10,000-ton 

(5,000 ton/jaw) stretch press. 

Two separate specifications were developed by Boeing to provision for two 

separate but distinct requirements from the NASA contract NAS 8-35969 

Statement of Work. 

A. Requirement for the use of a stretch press for the fabrication of existing 

size or larger size (up to 150% wider) external tank (ET) premachined 

components. 

Requirement for forming larger 2219 aluminum alloy size plate (1'' thick 

x 210" wide x 480" long). This size material is not only significantly larger 

than existing ET plate requirements but it is also larger than existing U.S. 

aluminum manufacturer currently produce. 

B. 

Our Phase I1 Task B study provisions for both size presses. The next separate 

phase of this study by NASA/MSFC with stretch press manufacturers should be 

84 

D180-27884-3 
for a preliminary design contract based on NASA/MSFC's analysis of their press 

size and optimal feature requirements. The next phase should be a final design 

competition by the manufacturers based on these requirements. 

2.4.1 BACKGROUND 

The Boeing Phase I Task A study indicates that to stretch from existing 

configuration ET components a press in the 3,000-ton (1500 tons/jaw) range is 

more than adequate for the fabrication of larger (wider) ET tank candidate 

parts. Our industrial survey was made initially on the requirement for a 5,000- 

ton (2500 tons/jaw) press based on our analysis of the potential growth of 

stretch formed parts for larger space vehicle requirements, i.e. 67' diameter vs. 

30' existing ET diameter. 

The largest current design production stretch presses are in the 1,500-ton range 

(750 tons/jaw) and these presses are utilized by both us and friendly foreign 

aircraft manufacturers for forming aircraft major body skins in large crown 

sections to reduce detail fabrication parts costs and reduce in process flow 

times. 

The state of the art in stretch press design has changed dramatically in the last 

decade and current designs dramatically improve the flexibility and potential of 

the stretch press. The additive features of smaller insert jaws, insert extrusion 

adaption dies, overhead die table (bulldozer) have improved both application and 

utilization. In addition, new air bearing die handling capability enhances 

changeover with reduced requi:ements for very heavy overhead cranes. 

85 

D 180-27884-3 
2.42 PRESS SIZE/COST CONSIDERATIONS 

Based on our development of the press specifications with both of the prime 

U.S. stretch press manufacturers. The following size considerations are 

applicable: 

A. 10,000-ton press (5,000 tons/jaw) 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

Size Manufacturer C (ROM estimate only) 

65' wide x 120' long x 30' deep x 24' high (above ground) 

Size manufacturer L (ROM estimate only) 

45' wide x 100' long x 30' deep x 24' high 

Approximate weight 5 to 7 million pounds. Boeing estimate $5/lb = 

$25 to $30 million press cost. Weight of largest single fabricated part 

400,000 Ibs. 

Foundation cost approximately $1.2-$1.5 million 

Lead time 3 years 

Hydraulic system 5000 psi 

The requirement for rotation of the press jaws (articulating jaws) is 

not advisable for a 10,000-ton press. There are divergent opinions 

from the two press manufacturers on the requirement for articulating 

jaws-one manufacturer does not recommend them but the other says 

it is feasible but at a much higher cost & addition - to adding 

approximately 20' to the length and width of the press. These 

differences are due to the two different manufacturers design 

concepts. 

No estimate of the cost or size for an overhead crane for die handling 

or material handling was provisioned. 

86 

D180-27884-3 
B. Large stretch press technical comparisons 

The following data as provided by one manufacturer is presented for 

comparative press size purposes: 

1. 10,000 ton press 

Tension cylinders (2) 

Bore 40" dia 

Rod 18" dia Net area each 1002 sq in 

Die table 

Bore 52" dia 

Rod 24" dia Net area each 1671 sq in 

2. 5000 ton press 

Tension cylinders (2) 

Bore 29" dia 

Rod 13" dia Net area each 523 sq in 

Die table 

Bore 3611 dia 

Rod 18" dia Net area, each 764 sq in 

3. Either press size would require waterway access for press assembly 

and installation due to its large component size and weight for 

comparative purposes with larger presses described in paragraph 

2.4.2.A a 1500 ton (750 tons/jaw) press installed in Wichita, Kansas 

was as follows: 

Press Type-1500 ton transverse/longitudinal sheet stretch forming 

machine with power curvable jaws. 

87 

D130-27884-3 
Press site-27' wide, 85' long, 2St deep, 8' high (above ground) 

Weight (approximately) 1 million pounds 

Foundation size (approximately) 30' wide x 90' long x 29' deep 

Hydraulic system-2750 psi/l68 GPM 

Jaw opening 1" 

Functionlstretch forms A/C skins under 1/2 inch thick up to 70" wide x 

30' long 

Cost $4.5 million (approximately) 

Overhead crane-25-ton capacity with spreader bars 

4. As a general rule the larger the press tonnage the higher the lower end 

tonnage control, i.e., a 10 year old 1000 ton press cannot normally control 

lower limits under 100 to 150 tons (10%). Newer press control systems now 

in operation can perform to a 5% lower limit and the latest design control 

systems per the equipment manufacturers can perform as lows as 2%. 

88 

D180-27884-3 
2.403 BOEING SPECIFICATION NUMBER 4427 5OOO-TON STRETCH PRESS 

89 

D 180-27884-3 
SPECIFICATION 

FOR 

5,000 TON TRANSVERSE LONGITUDINAL CURVED JAW SHEET STRETCH 

FORMING MACHINE, COWUTER NUMERICALLY CONTROLLED 

Specification No. 4427 

January 14,1984 

1.0 SCOPE 

1.1 Pur pose 

This specification provides a standard for the procurement, design, 

installation, performance and inspection for the subject equipment. It lists 

minimum requirementsand is not to limit design advances, safety features, 

ease and convenience of operation and maintenance. 

1.2 Intended Use 

The equipment described by this specification is to be utilized for stretch 

forming of ferrous and non-ferrous alloy sheets into complex contoured 

shapes. 

2.0 CODES AND STANDARDS 

Latest revisions shall apply. 

2.1 The Joint Industrial Council (JIC) Electrical Standards, drawings only. 

2.2 The United States of America Standards Institute (USASI). 

2.3 The National Electrical Code (NEC). 

2.4 

2.5 

National Aerospace Standard 930, Stretch Forming Machines-Airf rames. 

Occupational Safety and Health Administration (OSHA). 

2.6 State and Local Electrical and Labor Codes. 

2.7 American Society of Mechanical Engineers (ASME) Boiler and Pressure 

Vessel Code, Section VIII. 

2.8 Electronic Industries Association Standard RS-281, Numerical Control 

Construction Standards - Numerical Machine Tool. 

2.9 Joint Industrial Council (JIC) Hydraulic Standards for Industrial Equipment, 

H-1-1973. 

2.10 Joint Industrial Council (JIC) Pneumatic Standard for Industrial Equipment 

1957. 

3.0 TECHNICAL DATA 

The seller shall be completely responsible for the successful design, fabrication, 

complete installation and testing of the machine. Seller shall provide qualified field 

engineering personnel to supervise the erection and installation of the machine and 

conduct checkout, testing and training. 

90 

D180-27884-3 
Specification No. 4427 

Page -2- 

3.1 Mechanical 

Special design consideration shall be given to machine disassembly to 

permit equipment shipment by most economical method. 

3.1.1 Description 

3.1.1.1 NAS 930 Type I transverse and Type I1 longitudinal combination stretch 

forming machine with power curvable sheet jaws mounted in carriages 

transversely positionable during machine set-up and stretching operation. 

The die table shall be tiltable in vertical plane parallel to the sheet jaws. 

3.1.1.2 The machine shall have a maximum tension tonnage of 2500 tons per jaw 

for a total machine rating of 5000 tons. 

Part sizes ranging from .200 inch to 1.00 inch in thickness, 60 inches to 210 

inches in width, and to 480 inches long. 

3.1.1.3 

3.1.2 Die Table Capacity 

3.1.2.1 Size: Length 

Width 

3.1.2.2 Tonnage: Maximum 

Minimum 

210 inches minimum 

36 inches 

5,000 tons 

Operate under position 

control 

3.1.2.3 Tilt angle 21 50 from horizontal 

3.1.2.4 Stroke Approx. 100 inches 

3.1.2.4.1 Distance between centerline of jaw 

trunion and die table top surface. 

(Jaw horizontal and stroke down.) 

Approx. 80 inches 

3.1.2.5 Table rotation 900 

3.1.2.6 Speeds: Positioning 

Forming 

0 to 20 IPM 

.2 to 8 IPM 

3.1.3 Jaw Capacity 

3.1.3.1 Jaws, curved (Primary): 

3.1.3.1.1 Distance between Jaws: 

Maximum 480 inches 

Minimum (Horizontal) 16 inches 

Minimum (Vertical) (E to E of jaws) 100 inches, with tension . cylinders fully retracted 

3.1.3.1.2 Stroke, each Jaw: 

Minimum, carriage cylinders 

Minimum, tension cylinders 

90 inches 

24 inches 

91 

D180-27884-3 
Specification No. 4427 

Page -3- 

3.1.3.1.3 Length of Jaws, straight: 

Maximum (effective) 

Minimum at Maximum Tonnage 

3.1.3.1.3.1 Curvature, minimum radius 

3.1.3.1.4 Tonnage (per jaw) 

Both directions (IS" curve) 

Maximum 

Mini mum 

Maximum 

Maximum 

3.1.3.1.5 

3.1.3.1.6 Swing: Setup 

Carriage Tonnage (per jaw) (Maximum) 

3.1.3.1.6.1 Horizontal Angulation (Minimum) 

3.1.3.1.6.2 Rotation (Minimum) 

Torque Requirement (Minimum) 

3.1.3.1.6.3 Type: 

3.1.3.1.6.4 Opening (Minimum) 

3.1.3.1.6.5 Positive Stop 

3.1.3.1.7 Speeds 

3.1.3.1.7.1 Positioning speed Range 

3.1.3.1.7.2 Forming Speed (full tonnage) 

3.1.3.2 Jaws, curved (Auxiliary): 

210 inches 

160 inches 

80 inches down 

320 inches up 

2500 tons (over min. 

160 inches) 

100 tons or less (tension 

cylinder) 

100 tons (per segment 

outboard of center 160") 

282 tons (per segment 

in center 160") 

2500 tons 

Infinitely adjustable 

from horizontal through 

vertical with tangency 

con tr 01s. 

5150 

600,000 in. lbs. 

Hydraulic actuated, 

direct acting, adjustable 

power curvable. 

2% inches 

Hydraulic lock at all 

positions of jaw swing 

range. 

0 IPM to 20 IPM 

.2 IPM to 8 IPM 

92 

D180-27884-3 
Specification No. 4427 

Page -4- 

3.1.3.2.1 Distance between jaws: 

Maxim um 300 inches 

Mini mum (Horizon tal) 0 inches 

Minimum (Vertical) (E to E of jaws) 100 inches 

3.1.3.2.2 Stroke, each jaw (Minimum) 90 inches 

3.1.3.2.2.1 Stroke, tension cylinders (Minimum) 24 inches 

3.1.3.2.3 Length of jaws, straight (Maximum) 72 inches 

3.1.3.2.3.1 Curvature, minimum radius 

(In both directions 9" curve) 

3.1.3.2.4 Tonnage (per jaw) (under repeated use) 

Maximum 

Mini mum 

Maximum (per segment) 

30 inches up 

30 inches down 

400 tons 

100 tons or less 

45 tons 

3.1.3.2.5 Carriage Tonnage (Per jaw) (Maximum) 2500 tons 

3.1.3.2.6 Swing: Setup Infinitely adjustable 

from horizontal to 

vertical with tangency 

control. 

3.1.3.2.6.1 Horizontal Angulation (Minimum) 21 50 

3.1.3.2.6.2 Rotation (Minimum) 2150 

Torque Requirement (minimum) 200,000 in. Ibs. 

3.1.3.2.6.3 Type: Hydraulic direct acting Hydraulic actuated slid56,000/, per lin. inch ing wedge taperlock, adclamping force justable power curvable 

3.1.3.2.6.4 Opening (Minimum) .625 inches 

3.1.3.2.6.5 Positive Stop Hydraulic lock at all 

positions of jaw swing 

range. 

3.1.3.2.7 Speeds 

3.1.3.2.7.1 Positioning speed Range 

3.1.3.2.7.2 Forming Speed (full tonnage) 

0 IPM to 20 IPM 

.3 IPM to 8 IPM 

3.1.4 Die Table 

3.1.4.1 The machine shall be designed and constructed to allow rated tonnage at 

rated speeds for all forming motions. Maximum tonnage shall be available 

at 5 IPM. 

93 

-3 D180- 27884-3 
Specification No. 4427 

Page -5- 

3.1.4.2 

3.1.4.3 

3.1.4.4 

3.1.4.5 

3.1.4.6 

3.1.4.7 

3.1.4.8 

3.1.4.8.1 

3.1.4.8.2 

3.1.4.9 

3.1.5 

3.1.5.1 

3.1.5.2 

3.1.5.3 

3.1 S.4 

Four removable die table extensions for increasing the table width to 14 

feet. 

The die table shall be provided with a forged steel die support tube to allow 

the maximum longitudinal - horizontal loads to the table surface with the 

table in the maximum up position. 

Furnish hard chrome plated rods complete with wipers to prevent the entry 

of dirt and contamination into the die table cylinders. 

The die table shall be actuated by hydraulic cylinders, micro-processor 

con trolled. 

At the specified tilt angle (2150) the die table shall hold the die stationary 

under all loading conditions within the tonnage range of the machine. 

The die table shall be capable of raising or lowering, both loaded and 

unloaded, throughout its stroke maintaining any preadjusted tilt angle. 

Die mounting provisions along and on either side of the die table transverse 

centerline shall provide as follows: 

A standard 1s-inch T-slot along centerline. 

Two rows of threaded mounting holes along each edge of the table, spaced 

at 9-inch intervals. Each hole shall be fitted with a removable hardened 

insert, threaded 1"- 8 NC and fixed in place to prevent rotation. All holes 

shall be numbered with 1/2-inch high characters metal stamped adjacent to 

the holes, buyer to provide the numbering plan. 

Four (4) pressure sensors, for control at very low tonnages, to permit 

"snugging" of the workpiece to the die prior to commencing the forming 

cycle shall be provided. 

- Jaws (Primary and Auxiliary) 

Primary jaws shall be direct acting, hydraulic actuated type with multiple 

cylinders. The hydraulic cylinders shall be honed to a 16 RMS finish for 

maximum seal life and minimum frictional resistance. Auxiliary jaws may 

be sliding wedge type. 

Controls for jaw opening and closing shall be mounted on the jaws. These 

controls shall be in addition to controls contained in the main control 

console. 

The primary jaws shall be designed and constructed to carry full machine 

tonnage over a 160-inch span at the center of the jaw length without 

additional or special surface preparation. 

Jaws shall be counter balanced about the horizontal axis of the swing with 

tangency control to maintain tangency of pull-off during forming. A means 

of maintaining a selected position and providing powered swing for set-up 

shall be provided, regardless of part guage (sheet and extrusion). 

94 

D180-27884-3 
Specification No. 4427 

Page -6- 

3.1. 

3.1.5.6 

3.1.5.7 

3.1.5.8 

3.1.5.9 

3.1.5.10 

3.1.5.11 

3.1.6 

3.1.7 

3.1.8 

3.1.9 

The jaws shall be manufactured and assemblec 

prevent oil leakage. 

to precise tolerance to 

The jaws shall be segmented, power curvable type, equipped with hydraulic 

curving cylinders and adjustable stops to limit curvature infinitely between 

straight and a curvature of 80-inch radius to the primary jaws and a 

curvature of 30-inch radius for the auxiliary jaws. (Capable of curvature in 

both directions 5" curve.) 

Jaw carriages are to be provided with wear strips on moving surfaces. The 

machine main rails shall be equipped to minimize friction under heavy 

loads. The machine main rail ways are to be hardened steel machined and 

polished on the bearing faces. 

The relative movements of the jaws and table shall be such that the tension 

load in the workpiece is maintained at the prescribed level throughout the 

entire forming cyde. These movements shall effect a smooth "wrapping" 

of the workpiece around the die to provide a duplication of the motion 

experienced with a stretch-wrap press. 

The jaws shall be individually programmable to provide independent and 

variable (to provide variable elongation) tension cylinder motion during the 

forming cycle to effect the proper wrap of the workpieces around 

asymmetrical dies. 

Repositioning of jaw carriages from one keyway to another, on the main 

frame, shall be power positioned to the desired keyway. 

Keys to be power assisted for disengagement and reengagement at the 

desi red keyway . Automatic Elongation Control 

An available device for the automatic, progressive, and positive regulation 

of elongation during the entire forming process through tension control, 

jaw movement, or a combination of the two controls. 

Pre-Elongation Control 

Adjustable stroke limiting devices which allow the work pieces, regardless 

of variations in length, to be elongated a predetermined amount prior to 

the forming process. 

Final Elongation 

Adjustable, automatic stroke limiting devices to allow elongation at 

forming cycle completion to be stopped at a predetermined point anywhere 

within the full stroke range of the forming device involved. 

Yield Point Detector 

A device attached to the press which will sense yield of parts that can be 

pulled in the extrusion jaws with a minimum of a 75-ton capability, provide 

a visual indication of the yield condition and after the condition is 

attained, initiate the forming cycle. 

95 

D180-27884-3 
Specification No. 4427 

Page -7- 

3.1.10 Sheet Jaws 

Devices with gripping surfaces in a fixed plane for holding work pieces during stretch forming process. 

3.2 Control 

3.2.1 The control shall be a "Computer Numerical Control" (CNC), 

microprocessor based system, with capacity for operating in the following 

modes and with the capability for separate tutorial input. 

a. 

b. 

d. 

e. 

f. 

g* 

h. 

C. 

Manual - Pressure form mode (see paragraph 3.2.12) 

Record 

Auto Form 

Memory 

Edit 

Interface Troubles hooting 

Self Testing (Diagnostic) 

Yield Point Detection 

Manual Data Input Calculator (Keyboard) with full alpha numeric Cathode 

Ray Tube Display (CRT) shall be mounted in the control, convenient to the 

operator. 

3.2.2 The control shall include manual, automatic (forms an entire part requiring 

only loading and unloading assistance from the operator) and a mode where 

a part is produced by entering values, and all parameters are recorded by 

the microprocessor in order to reproduce the same part in automatic mode. 

3.2.2.1 An automatic operation shall be initiated by a single pushbutton. 

3.2.3 The control shall include a means to record, on tape cassette, entire sets of 

commands and data to reproduce a part at a later date (playback). 

3.2.3.1 The cassette tape shall be industry standard, digital quality type. 

3.2.3.2 

3.2.3.2.1 

3.2.3.3 

Programs on tape shall be searchable via recorded part numbers. 

Any limitations on the alpha-numeric part number shall be noted. 

A means shall be provided, such as a directory list, displayed on a CRT, of 

programs on a particular tape as an aid in selecting the proper tape and 

program. 

Parameters stored on tape shall include but not be limited to pre-stretch, 

jaws and die table paths, post-stretch and wrap speed, etc. 

3.2.3.4 

3.2.3.4.1 Recorded wrap speed shall not be adjustable by the operator during 

production operation. 

The control shall include an edit mode to correct or adjust stored programs 

and tables. 

3.2.4 

96 

D180-27884-3 
Specification No. 4427 

Page -8- 

3.2.5 

3.2.5.1 

3.2.5.2 

3.2.5.3 

3.2.5.4 

3.2.6 

3.2.7 

3.2.7.1 

3.2.7.2 

3.2.7.3 

3.2.8 

3.2.8.1 

3.2.9 

3.2.9.1 

3.2.10 

3.2.10.1 

The control shall include a CRT display, mounted in a console located 

convenient to the operator in his normal work position and protected from 

damage during loading, unloading and wrapping operations. 

The CRT shall display all stored data required for reference while wrapping 

a part or during setup. , 

The CRT shall display the position of the jaws, die table, and bulldozer. 

The CRT shall display the tables of axis limits, dwells and sequencing; 

available through keyboard recall. 

The CRT shall automatically display machine maintenance data such as 

hydraulic low level, over-temperature and dirty filter conditions, etc. 

The control shall detect and perform an orderly halt at any attempt to 

exceed fixed or programmable axis or jaw limits. 

All feedback units shall be direct driven (Le., direct coupling , gearing, 

rack and pinion, etc. utilizing anti-backlash devices. If direct acting units 

are impractical at certain locations, cable pulls in a straight line may be 

pro posed. 

Feedback units shall be protected from damage during normal loading, 

unloading and production operation. 

Feedback units shall be protected from entry of dust and debris. 

Yield point detector shall incorporate force and distance measuring devices 

mounted on the machine. The detector shall monitor force and distance 

and effectively look at the stress-strain curve for each part Yield shall be 

determined by detecting an offset from the straight line portion of this 

curve. 

The control shall include an alpha numeric keyboard by which instructions 

for forming a part can be entered into the control system and employed by 

the microprocessor to produce a part in automatic mode. 

Information entered through the keyboard must be able to be displayed on 

the CRT to provide the operator with reference data and instrucitons 

required to produce a part. 

All operator's controls, gauges, indicators and regulating devices shall be 

mounted in a console and in locations compatible with good functionability 

and visibility. 

A11 controls, gauges, switches, etc. shall be identified as to function. 

Identification shall be accomplished by means of engraved, stamped or 

etched nameplates located for maximum visibility. 

The control panel shall include an "emergency stop" button to turn off 

hydraulic and electric power. 

The control panel shall include an "all stop" button to stop all linear and 

rotary motion without the loss of memory. 

97 

D180-27884-3 
Specification No. 4427 

Page -9- 

3.2.11 The face of the CRT shall be protected by a durable plexiglass cover to 

prevent damage during movement of dies. 

3.2.12 Manual mode is defined as the standard pressure forming technique of 

stretch forming. 

3.2.13 The control cabinet shall operate in a 500 to 1200F, ambient temperature 

range and up to 95% humidity and shall be equipped with an air 

conditioning device. 

3.2.14 Programmable die table and jaw carriage rates shall be capable of variable 

speeds to be used in the same program. 

3.2.15 A deflection sensing device shall be located on the die table, non-tilting 

axis, to sense excessive deflection due to eccentric loading. 

Upon receiving this signal, an alarm shall alert the operator and the die 

table force shall be reduced, to prevent damage, without changing the jaw 

tonnage. 

3.2.15.1 

3.3 Lubrication 

3.3. I All lubrication systems shall be automatic (failsafe) and shall include all 

piping, hoses, fittings, ejectors, etc. to lubricate all slide ways, gearings, 

etc. 

3.3.2 Instructions regarding procedure, frequency and type of lubricant for all 

filler and lubrication points shall be provided. 

3.3 Systems which collect and reuse lubricating oils shall have oil filtering 

equipment which is easily changed without having to drain the reservoir. 

Clogged filters shall be so indicated by a signal. 

3.3.4 All lubrication reservoirs shall have a low level indicator. 

3.3.5 Suitable low lubrication pressure switches with visual devices shall be 

provided to alert the operator to a low pressure condition. One minute 

after alert of low pressure signal, the machine shall stop. 

3.3.6 Adequate oil reservoir capacity for at least 80 hours of continuous 

lubrication shall be provided. 

3.4 Electrics 

3.4.1 All interconnecting wiring, cables, etc., between machine tool and control 

shall be furnishd and be of plug-in type. 

3.4.2 All electrical components shall be protected from contamination and 

foreign matter, and from damage due to power surges, transients, power 

failures, etc. 

3.4.3 All relays rated at 120 VAC or less shall be of the sealed plug-in type. 

3.4.4 Arc suppressions shall be furnished for all motors, solenoids and relays to 

minimize noise. 

98 

D180-27884-3 
Specification No. 4427 

Page -1 0- 

3.4.5 

3.4.6 

3.4.7 

3.4.8 

3.4.9 

3.4.10 

3.4.1 1 

3.5 

3.5. I 

3.5.2 

3.5.3 

3.5.4 

3.5.5 

3.6 

3.6.1 

3.6.2 

3.6.3 

All motors one-half horsepower and larger shall be dual-wound, 3-phase, 

have magnetic starter and 3-phase overload protection. 

Control circuites shall be 120 volts or less; transformer supplied with 

fused, grounded secondary. 

The complete system shall include protection for and not be limited to 

self-destruction due to overload, loss of feedback, loss of field or input 

phase, power supply fault, accidental motor reversal, over-temperature, 

shorted SCR's, etc. 

The control systems shall be insensitive to any RFI or EM1 either selfinduced or generated by other equipment in its industrial environment. The 

system shall not generate RFI or EM1 which may impair the operation of 

other equipment in its industrial environment. 

Equipment shall be capable of operation from a 480 volt, 3 0, 4 wire 

distribution system, and shall be wired for 480 volts. Three phase motors 

shall be 240/480 volt wired for 480 volts. . 

There shall be a single point of power disconnect. 

All motors, associated controls and enclosure located in the pit area shall 

be suitable to NEMA Standards i.e. NEMA 12 for enclosures and Totally 

Enclosed Fan Cooled (TEFC) for motors. 

Environm ent/Utilities 

Temperature Range 500 - 1200F. 

Humidity Range 5% - 95%. 

Power fluctuations - 510%. 

Shop Air 90 psi Max. 

Water Temperature 600F at 50 psi. 

Construction 

This machine shall be constructed to comply with the requirements of this 

specification and the codes and standards applicable to this type of 

euqipment, NAS930 in particular. 

Provide appropriate safety covers to protect all sliding and rotating 

surfaces, except power unit, from foreign material. Covers used shall be 

readily accessible and removable to allow inspection. 

Rotating and sliding surfaces shall be protected by felt and/or wire 

reinf orced rubber wipers. 

Removable deck and cover plates shall be provided to cover all operational 

and maintenance work areas. Interior platforms shall be designed to 

provide various configurations as required by the machine setup. They 

99 

0180-27884-3 
Specification No. 4427 

Page -11- 

3.6.4 

3.6.5 

3.6.6 

4.0 PAINT 

4.1 

4.1.1 

4.1.2 

4.1.3 

4.2 

shall have adequate locking mechanisms to maintain platform stability. 

Removable handrails shall be provided for setup, maintenance and forming 

purposes. A minimum of three (3) sets of fill in foot walks shall be 

provided between the transverse platforms. 

All welded steel components subject to forming load application or which 

directly or indirectly affect machine accuracy are stress relieved. 

The machine shall be designed and constructed to allow rated tonnage and 

independence of control of all motions at all positions speeds, and tonnage, 

or any combination thereof, during the forming cycles. 

Shock waves, caused by breakage of a part, shall be absorbed without 

damage to machine components, foundation, or operting personnel. 

Complete machine tool and its peripheral equipment shall be painted as 

follows: 

Pittsburgh Paint: 

Item (1) - To be Determined 

Item (2) - To be Determined 

All machines shall be painted in the following manner: 

Tension Cylinders - Item 2 

Die Table - Item 2 

Electrical Panels - Item 2 

Miscellaneous - Item 2 

Jaw Cartridges - Item 1 

OSHA color to remain as required. 

Reference OSHA, Section 1910.144. (OSHA Safety Colors) 

5.0 RELIABILITY 

5.1 Machine shall be operated continuously for eight hours. There shall be no 

failure during this run. 

6.0 QUALIFICATION 

6.1 Seller shall perform suitable measurements and tests to confirm 

compliance to Paragraph 3.1 and other requirements of this specification. 

Seller shall provide test tools, tapes and materials as applicable. In 

addition, Seller shall perform the following tests to prove out required 

capabilities of the equipment. 

6.1.1 Form a sheet metal skin which requires curvature of the sheet metal jaws. 

6.1.2 Form an extruded part requiring the use of the extrusion jzws. 

1 00 

D180-27884-3 
Specification No. 4427 

Page -12- 

6.1.3 

6.1.4 

6.2 

6.3 

6.3.1 

6.3.1.1 

6.4 

7.0 TESTS 

7.1 

7.2 

7.3 

7.4 

7.5 

7.5.1 

7.5.2 

Form a sheet metal part, demonstrating the stretch-draw capability 

requiring the use of the bulldozer. 

Form a sheet metal and extruded part to demonstrate the stretch-wrap 

capability. 

Buyer shall supply dies, extrusion jaw inserts and material for forming 

parts as required by paragrahs 6.1.1, 6.1.2, 6.1.3 and 6.1.4. The selection 

of these parts shall be by mutual agreement of Seller and Buyer. 

Above tests (paragraph 6.1) shall be made by Seller with certified/verified 

results submitted to buyer. 

Test shall include a demonstration of the press at full tonnage at Buyer's 

facilities. 

Due to the size of the equipment, complete assembly and testing will be at 

the Buyer's facility. However, all components, subassemblies etc. will be 

subject t'o inspection and approval by customer prior to shipment to final 

installation site. 

After delivery and completion of installation at the Buyer's plant, Seller's 

representatives will complete all acceptance tests. Final acceptance shall 

take place after all tests are successfully completed and full compliance to 

this specification has been met. 

All strokes, movements, other requirements and physical dimensions as 

specified in Paragraph 3.1 shall be checked to assure that the specified 

requirements are fulfilled. 

Wrap rates shall be checked to assure that maximum and minimum rates 

are attained. 

The die table, tension cylinders, jaw carriages and any other machine 

elements for which a maximum force is specified shall be loaded at a limit 

of travel through the use of appropriate dies and work pieces to assure that 

the rates forces are attained or exceeded. 

The same components specified above shall be loaded to the minimum 

specified tonange at the lmit of travel to ascertain if machine control is 

available at the specified minimum tonnage. 

Either separately or simultaneously, with above tests, the press shall be run 

with each component loaded to full force capacity between the limits of 

travel of each component. Each component shall be inspected and 

evaluated to determine that: 

There is no permanent visual deformation or indication of failure, 

impending failure, or underdesign. 

There is no deflection under full load that would affect satisfactory 

forming. 

101 

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Specification No. 4427 

Page -1 3- 

7.5.3 

7.5.4 

7.5.5 

7.5.6 

7.6 

7.6.1 

7.6.2 

7.6.3 

7.7 

Operation is performed without binding, chattering, or stickiness. 

Unusual sounds do not emanate from the pumping system or from 

structural movement of components. 

No undesirable scuffing, scoring, or abrasion of bearing surfaces result 

from operation of the machine. 

Adequate control of movement is provided. 

A typical part shall be formed to demonstrate the capability of all phases 

of the control system. 

For this test, the Buyer shall provide the applicable stretch form die and 

part material. 

Parts shall be formed by different techniques to test and demonstrate the 

various means by which parts can be produced and means by which 

processing information can be introduced into the machine. This should 

include forming parts manually, by CNC, through keyboard inputs, by tape 

control, and by yield point detection of sectional parts. 

The microprocess control shall be certified by a production part run of ten 

parts consecutively stretch wrapped with deviation of not more than .030 

inch in the free state. 

The Seller shall furnish tapes, material, and fixtures for all machine 

capability tests with the exception of those described in Paragrpah 7.6. 

8.0 ENVIRONMENT/SAFETY 

8.1 Electrical systems or any portion thereof shall conform to NEC, NEMA and 

original manufacturing standards. 

All exposed non-current carrying metal parts that may be energized under 

abnormal conditions shall be grounded. 

8.2 

8.3 All power transmission apparatus shall be guarded for personnel protection 

in accordance with "ANSI B15.1-1972". 

8.4 Proper grounding 120 volt control circuits, protection against elements, 

etc., shall be provided. 

All pinchhip points, sharp edges/corners, hazardous moving elements, etc., 

shall be guarded. 

8.5 

8.6 

8.7 

Safety stops shall be used to limit excess travel of all axes. 

A system shall be provided, mercury, limit excess travel of all axes. 

8.8 Safety devices shall operate an indicator light where applicable. 

8.9 Fail-safe design shall be employed (e+, power failure device). 

102 

D180-27884-3 
Specification No. 4427 

Page -1 4- 

8.10 All components shall be Seller's latest design, affording full safety 

features, ease and convenience of operation and maintenance. 

8.11 The maximum sound pressure levels measured at a distance of 6 feet from 

the equipment shall not exceed 85 db on the sound level meter "A" scale. 

A minimum of three sets of noise level readings shall be submitted where 

each set is taken at a 6 foot distance from each of the four principal 

orthogonal surfaces of the equipment. Each reading shall not exceed 85 db 

on the "A" scale. 

8.11.1 

8.11.2 The test area shall be typical shoplike environment. Specifically, not an 

acoustically treated room. 

8.11.3 The tests shall be made under normal operating conditions, i.e., no load and 

under load. 

8.11.4 The individuals conducting the tests shall have proven capabilty in noise 

measurement and use approved measurement equipment and acceptable 

m eas ur em en t pr ocedur es. 

8.11.5 The ambient noise level in the test area shall be less than 75 db on the "A" 

scale. 

9.0 HYDRAULICS 

9.1 This machine may be used on hot stretch forming operations. Its hydraulic 

system, Le., hoses, filters, seals, joints, etc., shall theref ore be designed 

for use with fire resistant hydraulic fluids approved by factory Mutual 

Engineering Division and Underwriters Laboratories Group 2. Specific 

fluids shall be as per these listed below or equivalent. 

ZLEE Trade Name Manufacturer 

Phosphate Esters, Cellulube Celanese Corporation 

Chlorinated Hydro- 150, 200, 

carbons or other 

synthetic fluids. 

300 & 600 

Pydraulic F9 Monsanto Chemical Company 

Arodor 1248 Monsanto Chemical Company 

and 1254 

Hough to 

safe 11 20 

E. F. Houghton Company 

Shell SFR Shell Oil Company 

Fluid B or C 

Pyr ogard 

4353 or 4355 

Scony Mobile Oil Company 

9.2 Suitable over-temperature signalling devices shall be provided to alert 

operator to an over-normal temperature condition and to allow shutdown of 

machine at end of cycle. 

103 

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Specification No. 4427 

Page -15- 

9.3 

9.4 

9.5 

9.6 

9.7 

9.8 

9.9 

9.10 

9.11 

9.12 

9.13 

9.14 

9.15 

Heat exchangers shall be of stainless steel type capable of maintaining 

fluid temperature below the maximum operating temperature. 

Reservoir shall be non-pressurized type. 

Maximum hydraulic system operating pressure 5000 psi for continuous 

machine operation as separate and removable units. 

All hydraulic cylinders, except jaw actuating cylinders, shall be 

constructed as separate and removable units. 

Plugged "Tees" for pressure gauges shall be provided and suitably located 

to allow for troubleshooting. 

Over-temperature thermal switches, alarms for each hydraulic pump shall 

be provided to alert the operator to an over-temperature condition and 

shut the system down automatically. 

Hydraulic fluid reservoirs shall be equipped with low level alarm system, 

and automatic shutoff of affected pump motor. 

The hydraulic system shall receive 100% filtration. All servo valves are to 

have individual filters at the input port. A bypass shall be provided for all 

filters. 

Reference Paragrphs 9.7, 9.8, and 9.9 faulty indications shall be displayed 

on the CRT. 

A gauge shall be conveniently located, for the operator, that indicates the 

level of fluid in the reservoir. 

A fluid fill tube will be provided at floor level for ease of maintaining 

proper fluid level. 

All hydraulic gauges shall indicate pressure (P.S.1.) and corresponding force 

(tonnage) on the face. 

Pumps are to be sized or system shall be isolated, when satisfied and 

maintained, to allow the maximum pressure settings to remain constant 

when the maximum form rates, as specified, are required. 

10.0 REQUIRED ATTACHMENTS 

The following items are to be quoted as additional options, to be delivered and 

installed with the machine. 

10.1 Extrusion Jaws 

Two (2) 2500-ton extrusion jaws with 18" openings complete with adapters 

shall be furnished for mounting on the standard sheet jaws. The extrusion 

jaws and mounting adapters shall be capable of mounting on the sheet jaws 

without the use of special tools. Provisions shall be included for quick 

disconnect of extrusion jaw hydraulic lines from the main power 'mit of the 

press. Controls for opening, closing, rotation, swing, extension and 

retraction shall be located on the extrusion jaws. 

104 

D180-27884-3 
Specification No. 4427 

Page -1 6- 

1 Distance between jaws: 

10.1.2 

10.2 

10.2.1 

10.2. I. 1 

10.2.1.2 

10.2.1.3 

10.2.2 

10.2.2.1 

10.2.2.2 

10.2.2.3 

10.3 

10.3.1 

Minimum when fully extended 

Rotation about tension cylinder E minimum 

350 inches 

2150 

Torque Requirement (Minimum) 600,000 in. lbs. 

Die Table Extensions 

The two following types of table extensions are desirable for various 

purposes. They should all be capable of supporting rated forming loads, 

including typically unbalanced loads which can be expected. Options should 

be priced by item to facilitate selection. 

Full Width Cover 

The full width cover type of extension is placed on top of the die table and 

consists of one continuous plate extending across width suitable gusseted 

and supported from underneath in overhang areas. Desired sizes are as 

follows: (Approximate Size) 

Item 1: (1) each. 4811 full width x 108" long 

(1) each. 48" full width x 60" long 

(1) each. 60" full width x 108" long 

(1) each. 60" full width x 60" long 

Item 2: 

Item 3: (1) each. 144" full width x 144" long 

Angular Extensions 

This type of extension attaches flush with the top of the die table and may 

support only a portion of the length of the die. Individual segments should 

be capable of being attached at various positions along the entire length of 

the die table. Segment width shall be designed to produce overall die table 

widths as indicated in the following items when one angular extnesion is 

mounted on each side of the die table. 

Item 1: (4) each. Angular extension segments 6" long to produce 48" 

overall table width. 

Item 2: (4) each. Angular extension segments 12" long to produce 72" 

overall table width. 

Item 3: (4) each. Angular extension segments 24" long to produce 84" 

overall table width. 

Provide a leading edge forming capability with bullnose segments. 

If a strongback is required during leading edge forming at full tonnage bull 

nosing (400 tons per jaw), a limit switch shall be added to indicate the 

strongback is in place and to prevent jaw swing. When the stongback is not 

in place, the limit switch shall prevent locking of the jaw swing cylinder. 

105 

D180-27884-3 
Specification No. 4427 

Page -17- 

10.4 

10.4.1 

10.4.1.1 

10.4.1.2 

10.4.1.3 

10.4.1.4 

10.4.1.5 

10.4.1.6 

10.4.1.6.1 

10.4.1.6.2 

10.4.1.6.3 

Vertical Bulldozer (Minimum Requirements) 

The bulldozer shall be a four (4) post, bridged, traveling gantry type and 

shall have the following characteristics: 

Capacity: Maximum 500 Tons 

Platen Size: Length 210 Inches 

Die Mounting Hole Pattern and/or Keyway Locations shall be provided by 

Buyer. 

Stroke: 60 Inches 

Daylight: 138 Inches 

(Bulldozer fully extended and die table fully retracted.) 

Distance between centerline 60 inches of Jaw Trunion and Bulldozer 

bottom surf ace (Jaw horizontal and bulldozer fully extended.) 

Speeds 

Gantry travel from park position 150 I.P.M. to centerline of the die table 

(and back to park position). 

Rapid advance Down (closing) - 100 I.P.M. 

At selected forming Tonnage - 30 I.P.M. (at closing). 

Width 85 Inches 

11.0 SHIPPING INSTRUCTIONS 

11.1 Equipment shall be adequately protected from inclement weather, rust and 

damage during shipping. Electronic equipment shall be shipped by padded 

van, or equivalent. 

11.2 Shipping weight and size of all cartons, crates, skids, etc. shall be furnished 

to Buyer's Purchasing Department prior to receipt of equipment. 

11.3 The quantity of shipping units and/or crates shall appear on each unit 

and/or crate. 

11.4 Seller shall notify Buyer's Purchasing Department of shipment 48 hours 

prior to arrival of equipment at site. 

12.0 MANUALS/DOCUMENTATION 

All data shall be furnished to the Facilities Department via the Purchasing 

Department. Five (5) complete sets of data shall be furnished. One set requried 30 

days prior to machine delivery and additional pre-installation and installation 

instructions and procedures. The remaining sets shall be delivered at time of 

shipment. Each set shall inciude but not be iimited to the following: 

106 

D180- 27884- 3 
Specification No. 4427 

Page -18- 

12.1 Maintenance 

12.1.1 Procedures, drawings, diagrams, schematics, etc., to maintain the 

mechanical, electrical, electronic, hydraulic and pneumatic mechanisms of 

the complete machine tool and all peripheral equipment. 

12.1.2 Preventive maintenance procedures in Buyer's format indicating frequency 

schedule sample. 

12.1.3 Complete listing of all parts by name and number, including a 

recommended spare parts list. 

12.1.4 Plan and elevation views of complete system showing all necessary 

dimensions. 

12.1.5 Installation and instruction data including levelling and alignment 

requirements, location and size of all utilities required. 

12.1.6 Theory of Operation" for maintenance trouble-shooting covering detailed 

operation of the complete system. 

12.2 Operating Procedures 

Procedures, drawings, illustrations to simplify operation of the machine 

tool and all peripheral euqipment. 

1 3.0 INSTALLATION~INSTRUCTIONS 

13.1 Seller shall be completely responsible for the equipment installation, to 

include all required personnel, transportation, rigging and equipment 

(holddowns, pads, levelling screws, etc.) and performing all testing 

procedures. Buyer shall furnish all utilities and a suitable foundation. 

Buyer's personnel shall make all final utilities connections. 

Buyer's cognizant personnel shall be notified to witness only the final test 

procedure. - 

13.2 Training of personnel that is not concurrent with the installation at Buyer's 

facility shall be defined as to where it will take place, the duration and 

type of training and the quantity and type of personnel required. 

14.0 SELLER'S REQUIREMENTS 

14.1 For the successful installation and checkout of the new machine. 

14.2 

14.3 Where this specification causes a deviation from the Seller's standard 

product, quote the standard product in addition to the requirements 

specified herein. 

Seller's personnel shall adhere to Buyer's security and fire regulations. 

14.3.1 Seller shall indicate where the standard product deviates from this 

specification. 

107 

D180-27884-3 
Specification No. 4427 

Page -19- 

14.3.2 Seller shall reply by item number when there is compliancehon-compliance 

with this specification. 

14.4 Seller shall agree that availability of field service on a one-shift and twoshift basis in response to a service request by Buyer during the warranty 

period and also after its expiration shall not exceed 48-hour period. 

Seller shall respond to each paragraph of this specification and inquiry, 

indicating his concurrence or not, and including a brief explanation of his 

intent. 

14.5 

14.6 Seller shall provide an upgraded schedule,.. monthly, from the start to the 

completion of the job. 

108 

D180-27884-3 
2.4.4 BOEING SPECIFICATION NUMBER 4437 10,000-TON STRETCH PRESS 

109 

D180-27884-3 
SPECIFICATION 

FOR 

10,000 TON TRANSVERSE LONGITUDINAL CURVED JAW SHEET STRETCH 

FORMING MACHINE, COMPUTER NUMERICALLY CONTROLLED 

Specification No. 4437 

January 14,1984 

1.0 SCOPE 

1.1 Pur pose 

This specification provides a standard for the procurement, design, 

installation, performance and inspection for the subject equipment. It lists 

minimum requirements and is not to limit design advances, safety features, 

ease and convenience of operation and maintenance. 

1.2 Intended Use 

The equipment described by this specification is to be utilized for stretch 

forming of ferrous and non-ferrous alloy sheets 'into complex contoured 

shapes. 

2.0 CODES AND STANDARDS 

Latest revisions shall apply. 

2.1 The Joint Industrial Council (JIC) Electrical Standards, drawings only. 

2.2 The United States of America Standards Institute (USASI). 

2.3 The National Electrical Code (NEC). 

2.4 National Aerospace Standard 930, Stretch Forming Machines-Airframes. 

2.5 Occupational Safety and Health Administration (OSHA). 

2.6 State and Local Electrical and Labor Codes. 

2.7 American Society of Mechanical Engineers (ASME) Boiler and Pressure 

Vessel Code, Section VIII. 

2.8 Electronic Industries Association Standard RS-281, Numerical Control 

Construction Standards - Numerical Machine Tool. 

2.9 Joint Industrial Council (JIC) Hydraulic Standards for Industrial Equipment, 

H-1-1973. 

2.10 Joint Industrial Council (JIC) Pneumatic Standard for Industrial Equipment 

1957. 

3.0 TECHNICAL DATA 

The seller shall be completely responsible for the successful design, fabrication, 

complete installation and testing of the machine. Seller shall provide qualified field 

engineering personnel to supervise the erection and installation of the machine and 

conduct checkout, testing and training. 

110 

D180-27884-3 
Specification No. 4437 

Page -2- 

3.1 Mechanical 

Special design consideration shall be given to machine disassembly to 

permit equipment shipment by most economical method. 

3.1.1 Description 

3.1.1.1 NAS 930 Type I transverse and Type I1 longitudinal combination stretch 

forming machine with power curvable sheet jaws mounted in carriages 

transversely positionable during machine set-up and stretching operation. 

The die table shall be tiltable in vertical plane parallel to the sheet jaws. 

The machine shall have a maximum tension tonnage of 5,000 tons per jaw 

for a total machine rating of 10,000 tons. 

3.1.1.2 

3.1.1.3 Part sizes ranging from .200 inch to 1.00 inch in thickness, 60 inches to 210 

inches in width, and to 480 inches long. 

3.1.2 Die Table Capacity 

3.1.2.1 Size: Length 

Width 

3.1.2.2 Tonnage: Maximum 

Minimum 

3.1.2.3 Tilt angle: Maximum 

: Minimum 

210 inches minimum 

48 inches minimum 

10,000 tons 

Operate under position 

control 

2150 from horizontal 

2100 from horizontal 

3.1.2.4 Stroke Approx. 144 inches 

3.1.2.4.1 Distance between centerline of jaw 

trunion and die table top surface. 

(Jaw horizontal and stroke down.) 

Approx. 80 inches 

3.1.2.5 Table rotation 900 

3.1.2.6 Speeds: Positioning 

Forming 

0 to 15 IPM 

0 to 7 IPM 

3.1.3 Jaw Capacity 

3.1.3.1 Jaws, curved (Primary): 

3.1.3.1.1 Distance between Jaws: 

Maxim um 480 inches 

M inimum (Horizon tal) 10 inches 

Minimum (Vertical) (E to of jaws) 144 inches, with tension 

cylinders fully retracted 

3.1.3.1.2 Stroke, each Jaw: 

M inimurn, carriage cylinders 

Minimum, tension cylinders 

11 1 

D180-27884-3 

96 inches 

24 inches 
Specification No. 4437 

Page -3- 

3.1.3.1.3 Length of Jaws, straight: 

Maximum (effective) 

Minimum at Maximum Tonnage 

3.1.3.1.3.1 Curvature, minimum radius 

Both directions (,,Y curve) 

NOTE: 3.1.5.6 

3.1.3.1.4 Tonnage (per jaw) 

Maximum 

Minimum 

Maximum 

Maximum 

3.1.3.1.5 

3.1.3.1.6 Swing: Setup 

Carriage Tonnage (per jaw) (Maximum) 

3.1.3.1.6.1 Horizontal Angulation (Minimum) 

3.1.3.1.6.2 Rotation (Minimum) 

Torque Requirement (Minimum) 

3.1.3.1.6.3 Type: 

3.1.3.1.6.4 Opening (Minimum) 

3.1.3.1.6.5 Positive Stop 

3.1.3.1.7 Speeds 

3.1.3.1.7.1 Positioning speed Range 

3.1.3.1.7.2 Forming Speed (full tonnage) 

3.1.3.2 Jaws, curved (Auxiliary): 

210 inches 

160 inches 

120 inches down 

480 inches up 

5,000 tons (over min. 

160 inches) 

200 tons or less 

120 tons (per segment 

outboard of center 160") 

300 tons (per segment 

in center 160") 

5,000 tons 

Infinitely adjustable 

from horizontal through 

vertical with tangency 

controls. 

21 50 

21 50 

850,000 in. Ibs. 

Hydraulic actuated, 

direct acting, adjustable 

power curvable. 

2% inches 

Hydraulic lock at all 

positions of jaw swing 

range. 

0 IPM to 15 IPM 

.2 IPM to 6 IPM 

11 2 

D180-27884-3 
Specification No. 4437 

Page -4- 

3.1.3.2.1 Distance between jaws: 

Maximum 

Minimum (Horizontal) 

Minimum (Vertical) (E to E of jaws) 

3.1.3.2.2 Stroke, each jaw (Minimum) 

3.1.3.2.2.1 Stroke, tension cylinders (Minimum) 

3.1.3.2.3 

3.1.3.2.3.1 Curvature, minimum radius 

Length of jaws, straight (Maximum) 

(In both directions "S" curve) 

3.1.3.2.4 Tonnage (per jaw) (under repeated use) 

Maximum 

Minimum 

Maximum (per segment) 

3.1.3.2.5 Carriage Tonnage (Per jaw) (Maximum) 

3.1.3.2.6 Swing: Setup 

3.1.3.2.6.1 Horizontal Angulation (Minimum) 

3.1.3.2.6.2 Rotation (Minimum) 

Torque Requirement (mini mum) 

3.1.3.2.6.3 Type: Hydraulic direct acting 

56,0008 per lin. inch 

clamping force 

3.1.3.2.6.4 Opening (Minimurn) 

3.1.3.2.6.5 Positive Stop 

3.1.3.2.7 Speeds 

3.1.3.2.7.1 Positioning speed Range 

3.1.3.2.7.2 Forming Speed (full tonnage) 

300 inches 

0 inches 

130 inches 

90 inches 

24 inches 

72 inches 

30 inches 

400 tons 

200 tons or less 

55 tons 

5,000 tons 

Infinitely adjustable 

from horizontal to 

vertical with tangency 

control. 

200,000 in. lbs. 

Hydraulic actuated sliding wedge taperlock, adjustable power curvable 

.625 inches 

Hydraulic lock at all 

positions of jaw swing 

range. 

0 IPM to 15 IPM 

.2 IPM to 6 IPM 

3. I .4 Die Table 

3.1.4.1 The machine shall be designed and constructed to allow rated tonnage at 

rated speeds for all forming motions. Maximum tonnage shall be available 

at 4 IPM. 113 

D180-27884-3 
Specification No. 4437 

Page -5- 

3.1.4.2 Four removable die table extensions for increasing the table width to 14 

feet. 

3.1.4.3 The die table shall be provided with a forged steel die support tube to allow 

the maximum longitudinal - horizontal loads to the table surface with the 

table in the maximum up position. 

Furnish hard chrome plated rods complete with wipers to prevent the entry 

of dirt and contamination into the die table cylinders. 

3.1.4.4 

3.1.4.5 The die table shall be actuated by. hydraulic cylinders, micro-processor 

controlled. 

3.1.4.6 At the specified tilt angle k150) the die table shall hold the die stationary 

under all loading conditions within the tonnage range of the machine. 

The die table' shall be capable of raising or lowering, both loaded and 

unloaded, throughout its stroke maintaining any preadjusted tilt angle. 

Die mounting provisions along and on either side of the die table transverse 

centerline shall provide as follows: 

A standard 1%-inch T-slot along centerline. 

3.1.4.7 

3.1.4.8 

3.1.4.8.1 

3.1.4.8.2 Two rows of threaded mounting holes along each edge of the table, spaced 

at 9-inch intervals. Each hole shall be fitted with a removable hardened 

insert, threaded 1"- 8 NC and fixed in place to prevent rotation. All holes 

shall be numbered with 1/2-inch high characters metal stamped adjacent to 

the holes, buyer to provide the numbering plan. 

Four (4) pressure sensors, for control at very low tonnages, to permit 

"snugging" of the workpiece to the die prior to commencing the forming 

cycle shall be provided. 

3.1.4.9 

3.1.5 - Jaws (Primary and Auxiliary) 

3.1.5.1 All jaws shall be direct acting, hydraulic actuated type with multiple 

cylinders. The hydraulic cylinders shall be honed to a 16 RMS finish for 

maximum seal life and minimum frictional resistance. 

3.1.5.2 Controls for jaw opening and closing shall be mounted on the jaws. These 

controls shall be in addition to controls contained in the main control 

console. 

3.1.5.3 The primary jaws shall be designed and constructed to carry full machine 

tonnage over a 160-inch span at the center of the jaw length without 

additional or special surf ace preparation. 

3.1.5.4 Jaws shall be counter balanced about the horizontal axis of the swing with 

tangency control to maintain tangency of pull-off during forming. A means 

of maintaining a selected position and providing powered swing for set-up 

shall be provided, regardless of part guage (sheet and extrusion). 

3.1.5.5 The jaws shall be manufactured and assembled to precise tolerance to 

prevent oil leakage. 

114 

D180-27884-3 
Specification No. 4437 

Page -6- 

3.1.5.6 

3.1.5.7 

3.1.5.8 

3.1.5.9 

3.1 S. 10 

3.1.5.11 

3.1.6 

3.1.7 

3.1.8 

3.1.9 

The jaws shall be segmented, power curvable type, equipped with hydraulic 

curving cylinders and adjustable stops to limit curvature infinitely between 

straight and a.curvature of 120-inch radius to the primary jaws and a 

curvature of 30-inch radius for the auxiliary jaws. (Capable of curvature in 

both directions "S" curve.) Design limitations of primary jaws may limit 

"S" curvature capability - seller to note. 

Jaw carriages are to be provided with wear strips on moving surfaces. The 

machine main rails shall be equipped to minimize friction under heavy 

loads. The machine main rail ways are to be hardened steel machined and 

polished on the bearing faces. 

The relative movements of the jaws and table shall be such that the tension 

load in the workpiece is maintained at the prescribed level throughout the 

entire forming cycle. These movements shall effect a smooth "wrapping" 

of the workpiece around the die to provide a duplication of the motion 

experienced with a stretch-wrap press. 

The jaws shall be individually programmable to provide independent and 

variable (to provide variable elongation) tension cylinder motion during the 

forming cyde to effect the proper wrap of the workpieces around 

asymmetrical dies. 

Repositioning of jaw carriages from one keyway to another, on the main 

frame, shall be power positioned to the desired keyway. 

Keys to be power assisted for disengagement and reengagement at the 

desired keyway. 

Automatic Elongation Control 

An available device for the automatic, progressive, and positive regulation 

of elongation during the entire forming process through tension control, 

jaw movement, or a combination of the two controls. 

Pre-Elongation Control 

Adjustable stroke limiting devices which allow the work pieces, regardless 

of variations in length, to be elongated a predetermined amount prior to 

the forming process. 

Final Elongation 

Adjustable, automatic stroke limiting devices to allow elongation at 

forming cycle completion to be stopped at a predetermined point anywhere 

within the full stroke range of the forming device involved. 

Yield Point Detector 

A device attached to the press which will sense yield of parts that can be 

pulled in the extrusion jaws with a minimum of a 150-ton capability, 

provide a visual indication of the yield condition and after the condition is 

attained, initiate the forming cycle. 

115 

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Specification No. 4437 

Page -7- 

3.1.10 Sheet Jaws 

3.2 

Devices with gripping surfaces in a fixed plane for holding work pieces 

during stretch forming process. 

Control 

3.2.1 The control shall be a "Computer Numerical Control" (CNC), 

microprocessor based system, with capacity for operating in the following 

modes and with the capability for separate tutorial input. 

a. 

b. 

d. 

e. 

f. 

g* 

h. 

C. 

Manual - Pressure form mode (see paragraph 3.2.12) 

Record 

Auto Form 

Memory 

Edit 

Interface Troubles hooting 

Self Testing (Diagnostic) 

Yield Point Detection 

Manual Data Input Calculator (Keyboard) with full alpha numeric Cathode 

Ray Tube Display (CRT) shall be mounted in the control, convenient to the 

operator. 

The control shall include manual, automatic (forms an entire part requiring 

only loading and unloading assistance from the operator) and a mode where 

a part is produced by entering values and all parameters are recorded by 

the microprocessor in order to reproduce the same part in automatic mode. 

3.2.2 

3.2.2.1 An automatic operation shall be initiated by a single pushbutton. 

3.2.3 The control shall include a means to record, on tape cassette, entire sets of 

commands and data to reproduce a part at a later date (playback). 

3.2.3.1 The cassette tape shall be industry standard, digital quality type. 

3.2.3.2 Programs on tape shall be searchable via recorded part numbers. 

3.2.3.2.1 Any limitations on the alpha-numeric part number shall be noted. 

3.2.3.3 A means shall be provided, such as a directory list, displayed on a CRT, of 

programs on a particular tape as an aid in selecting the proper tape and 

program. 

3.2.3.4 Parameters stored on tape shall include but not be limited to pre-stretch, 

jaws and die table paths, post-stretch and wrap speed, etc. 

3.2.3.4.1 Recorded wrap speed shall not be adjustable by the operator during 

production operation. 

3.2.4 The control shall include an edit mode to correct or adjust stored programs 

and tables. 

116 

D180-27884-3 
Specification No. 4437 

Page -8- 

3.2.5 The control shall include a CRT display, mounted in a console located 

convenient to the operator in his normal work position and protected from 

damage during loading, unloading and wrapping operations. 

The CRT shall display all stored data required for reference while wrapping 

a part or during setup. 

3.2.5.1 

3.2.5.2 The CRT shall display the position of the jaws, die table, and bulldozer. 

3.2.5.3 The CRT shall display the tables of axis limits, dwells and sequencing; 

available through keyboard recall. 

3.2.5.4 The CRT shall automatically display machine maintenance data such as 

hydraulic low level, over-temperature and dirty filter conditions, etc. 

3.2.6 The control shall detect and perform an orderly halt at any attempt to 

exceed fixed or programmable axis or jaw limits. 

3.2.7 All feedback units shall be direct driven (Le., direct coupling , gearing, 

rack and pinion, etc. ), utilizing anti-backlash devices. If direct driven 

units are impractical at certain locations, cable pulls in a straight line may 

be proposed. 

3.2.7.1 Feedback units shall be protected from damage during normal loading, 

unloading and production operation. 

3.2.7.2 Feedback units shall be protected from entry of dust and debris. 

3.2.7.3 Yield point detector shall incorporate force and distance measuring devices 

mounted on the machine. The detector shall monitor force and distance 

and effectively look at the stress-strain curve for each part. Yield shall be 

determined by detecting an offset from the straight line portion of this 

curve. 

3.2.8 The control shall include an alpha numeric keyboard by which instructions 

for forming a part can be entered into the control system and employed by 

the microprocessor to produce a part in automatic mode. 

3.2.8.1 Information entered through the keyboard must be able to be displayed on 

the CRT to provide the operator with reference data and instrucitons 

required to produce a part. 

All operator's controls, gauges, indicators and regulating devices shall be 

mounted in a console and in locations compatible with good functionability 

and visibility. 

3.2.9 

3.2.9.1 All controls, gauges, switches, etc. shall be identified as to function. 

Identification shall be accompiished by means of engraved, stamped or 

etched nameplates located for maximum visibility. 

The control panel shall include an "emergency stop)' button to turn off 

hydraulic and electric power. 

3.2.10 

3.2.10.1 The control panel shall include an "all stop" button to stop all linear and 

rotary motion without the loss of memory. 

117 

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Specification No. 4437 

Page -9- 

3.2.1 1 

3.2.12 

3.2.13 

3.2. 

3.2. 

3.2. 

3.3 

3.3.1 

3.3.2 

3.3 

3.3.4 

3.3.5 

3.3.6 

3.4 

3.4.1 

3.4.2 

3.4.3 

3.4.4 

4 

5 

5.1 

The face of the CRT shall be protected by a durable plexiglass cover to 

prevent damage during movement of dies. 

Manual mode is defined as the standard pressure forming technique of 

stretch forming. 

The control cabinet shall operate in a 500 to 1200F, ambient temperature 

range and up to 95% humidity and shall be equipped with an air 

conditioning device. 

Programmable die table and jaw carriage rates shall be capable of variable 

speeds to be used in the same program. 

A deflection sensing device shall be located on the die table, non-tilting 

axis, to sense excessive deflection due to eccentric loading. 

Upon receiving this signal, an audible alarm shall alert the operator and the 

die table force shall be reduced, to prevent damage, without changing the 

jaw tonnage. 

Lubrication 

All lubrication systems shall be automatic (failsafe) and shall include all 

piping, hoses, fittings, ejectors, etc. to lubricate all slide ways, gearings, 

etc. 

Instructions regarding procedure, frequency and type of lubricant for all 

filler and lubrication points shall be provided. 

Systems which collect and reuse lubricating oils shall have oil filtering 

equipment which is easily changed without having to drain the reservoir. 

Clogged filters shall be so indicated by a signal. 

All lubrication reservoirs shall have a low level indicator. 

Suitable low lubrication pressure switches with visual and audible devices 

shall be provided to alert the operator to a low pressure condition. One 

minute a f t e r a l e r t of low pressure signal, the machine shall stop. 

Adequate oil reservoir capacity for at least 80 hours of continuous 

lubrication shall be provided. 

Elect rics 

All interconnecting wiring, cables, etc., between machine tool and control 

shall be furnishd and be of plug-in type. 

All electrical components shall be protected from contamination and 

foreign matter, and from damage due to power surges, transients, power 

failures, etc. 

All relays rated at 120 VAC or less shall be of the sealed plug-in type. 

Arc suppressions shall be furnished for all motors, solenoids and relays to 

minimize noise. 

118 

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Specification No. 4437 

Page -10- 

3.4.5 

3.4.6 

3.4.7 

3.4.8 

3.4.9 

3.4.10 

3.4.11 

3.5 

3.5.1 

3.5.2 

3.5.3 

3.5.4 

3.5.5 

3.6 

3.6.1 

3.6.2 

3.6.3 

All motors one-half horsepower and larger shall be dual-wound, 3-phaseY 

have magnetic starter and 3-phase overload protection. 

Control circuites shall be 120 volts or less; transformer supplied with 

fused, grounded secondary. 

The complete system shall include protection for and not be limited to 

self-destruction due to overload, loss of feedback, loss of field or input 

phase, power supply fault, accidental motor reversal, over-temperature, 

shorted SCR’s, etc. 

The control systems shall be insensitive to any RFI or EM1 either selfinduced or generated by other equipment in its industrial environment. The 

system shall not generate RFI or EM1 which may impair the operation of 

other equipment in its industrial environment. 

Equipment shall be capable of operation from a 480 volt, 3 8, 4 wire 

distribution system, and shall be wired for 480 volts. Three phase motors 

shall be 240/480 volt wired for 480 volts. 

There shall be a single point of power disconnect. 

All motors, associated controls and enclosure located in the pit area shall 

be suitable to NEMA Standards i.e. NEMA 12 for enclosures and Totally 

Enclosed Fan Cooled (TEFC) for motors. 

Environm ent/Utilities 

Temperature Range 500 - 1200F. 

Humidity Range 5% - 95%. 

Power fluctuations - 210%. 

Shop Air 90 psi Max. 

Water Temperature 600F at 50 psi. 

Construction 

This machine shall be constructed to comply with the requirements of this 

specification and the codes and standards applicable to this type of 

euqipment, NAS930 in particular. 

Provide appropriate safety covers to protect all sliding and rotating 

surfaces, except power unit, from foreign material. Covers used shall be 

readily accessible and removable to allow inspection. 

Rotating and sliding surfaces shall be protected by felt and/or wire 

reinforced rubber wipers. 

Removable deck and over plates shall be provided to cover all operatiorial 

and maintenance work areas. Interior platforms shall be designed to 

provide various configurations as required by the machine setup. They 

119 

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Specification No. 4437 

Page -11- 

3.6.4 

3.6.5 

3.6.6 

4.0 PAINT 

4.1 

5.0 

4.1.1 

4.1.2 

4.1.3 

4.2 

shall hav dequate locking mechanisms 3 maintain platform stability. 

Removable handrails shall 6e provided for setup, maintenance and forming 

purposes. A minimum of three (3) sets of fill in foot walks shall be 

provided between the transverse platforms. 

All welded steel components subject to forming load application or which 

directly or indirectly affect machine accuracy are stress relieved. 

The machine shall be designed and constructed to allow rated tonnage and 

independence of control of all motions at all positions speeds, and tonnage, 

or any combination thereof, during the forming cycles. 

Shock waves, caused by breakage of a part, shall be absorbed without 

damage to machine components, foundation, or operting personnel. 

Complete machine tool and its peripheral equipment shall be painted as 

follows: 

Pittsburgh Paint: 

Item (1) - To be Determined 

Item (2) - To be Determined 

All machines shall be painted in the following manner: 

TensionCylinders - Item 2 

Die Table - Item 2 

Electrical Panels - Item 2 

Miscellaneous - Item 2 

Jaw Cartridges - Item 1 

OSHA color to remain as required. 

Reference OSHA, Section 1910.144. (OSHA Safety Colors) 

RELIABILITY 

5.1 Machine shall be operated continuously for eight hours. There shall be no 

failure during this run. 

6.0 QUALIFICATION 

6.1 Seller shall perform suitable measurements and tests to confirm 

compliance to Paragraph 3.1 and other requirements of this specification. 

Seller shall provide test tools, tapes and materials as applicable. In 

addition, Seller shall perform the following tests to prove out required 

capabilities of the equipment. 

6.1.1 Form a sheet metal skin which requires curvature of the sheet metal jaws. 

6.1.2 Form an extruded part requiring the use of the extrusion jaws. 

120 

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Specification No. 4437 

Page -12- 

6.1.3 

6.1.4 

6.2 

6.3 

6.3.1 

6.3.1.1 

6.4 

7.0 TESTS 

7.1 

7.2 

7.3 

7.4 

7.5 

7.5.1 

7.5.2 

Form a sheet metal part, demonstrating the stretch-draw capability 

requiring the use of the bulldozer. 

Form a sheet metal and extruded part to demonstrate the stretch-wrap 

capability. 

Buyer shall supply dies, extrusion jaw inserts and material for forming 

parts as required by paragrahs 6.1.1, 6.1.2, 6.1.3 and 6.1.4. The selection 

of these parts shall be by mutual agreement of Seller and Buyer. 

Above tests (paragraph 6.1) shall be made by Seller with certified/verified 

results submitted to buyer. 

Test shall include a demonstration of the press at full tonnage at Buyer's 

facilities. 

Due to the size of the equipment, complete assembly and testing will be at 

the Buyer's facility. However, all components, subassemblies etc. will be 

subject to inspection and approval by customer prior to shipment to final 

installation site. 

After delivery and completion of installation at the Buyer's plant, Seller's 

representatives will complete all acceptance tests. Final acceptance shall 

take place after all tests are successfully completed and full compliance to 

this specification has been met. 

All strokes, movements, other requirements and physical dimensions as 

specified in Paragraph 3.1 shall be checked to assure that the specified 

requirements are fulfilled. 

Wrap rates shall be checked to assure that maximum and minimum rates 

are attained. 

The die table, tension cylinders, jaw carriages and any other machine 

elements for which a maximum force is specified shall be loaded at a limit 

of travel through the use of appropriate dies and work pieces to assure that 

the rates forces are attained or exceeded. 

The same components specified above shall be loaded to the minimum 

specified tonange at the lmit of travel to ascertain if machine control is 

available at the specified minimum tonnage. 

Either separately or simultaneously, with above tests, the press shall be run 

with each component loaded to full force capacity between the limits of 

travel of each component. Each component shall be inspected and 

evaluated to determine that: 

There is no permanent visual deformation or indication of failure, 

impending failure, or underdesign. 

There is no deflection under full load that would affect satisfactory 

forming. 

121 

D180-27884-3 
Specification No. 4437 

Page -13- 

7.5.3 

7.5.4 

7.5.5 

7.5.6 

7.6 

7.6.1 

7.6.2 

7.6.3 

7.7 

Operation is performed without binding, chattering, or stickiness. 

Unusual sounds do not emanate from the pumping system or from 

structural movement of components. 

No undesirable scuffing, scoring, or abrasion of bearing surfaces result 

from operation of the machine. 

Adequate control of movement is provided. 

A typical part shall be formed to demonstrate the capability of all phases 

of the control system. 

For this test, the Buyer shall provide the applicable stretch form die and 

part material. 

Parts shall be formed by different techniques to test and demonstrate the 

various means by which parts can be produced and means by which 

processing information can be introduced into the machine. This should 

include forming parts manually, by CNC, through keyboard inputs, by tape 

control, and by yield point detection of sectional parts. 

The microprocess control shall be certified by a production part run of ten 

parts consecutively stretch wrapped with deviation of not more than .030 

inch in the free state. 

The Seller shall furnish tapes, material, and fixtures for all machine 

capability tests with the exception of those described in Paragrpah 7.6. 

8.0 ENVIRONMENT/SAFElY 

8.1 Electrical systems or any portion thereof shall conform to NEC, NEMA and 

original manufacturing standards. 

8.2 All exposed non-current carrying metal parts that may be energized under 

abnormal conditions shall be grounded. 

8.3 All power transmission apparatus shall be guarded for personnel protection 

in accordance with "ANSI B15.1-1972". 

8.4 Proper grounding 120 volt control circuits, protection against elements, 

etc., shall be provided. 

All pinchhip points, sharp edges/corners, hazardous moving elements, etc., 

shall be guarded. 

8.5 

8.6 Safety stops shall be used to limit excess travel of all axes. 

8.7 A system shall be provided, mercury, limit excess travel of all axes. 

8.8 

8.9 

Safety devices shall operate an indicator light where applicable. 

Fail-safe design shall be employed (e.g., power failure device). 

122 

D180-27884-3 
Specification No. 4437 

Page -14- 

9.0 

8.10 All components shall be Seller's latest design, affording full safety 

features, ease and convenience of operation and maintenance. 

8.11 The maximum sound pressure levels measured at a distance of 6 feet from 

the equipment shall not exceed 85 db on the sound level meter "A" scale. 

8.11.1 A minimum of three sets of noise level readings shall be submitted where 

each set is taken at a 6 foot distance from each of the four principal 

orthogonal surfaces of the equipment. Each reading shall not exceed 85 db 

on the "A" scale. 

8.11.2 The test area shall be typical shop-like environment. Specifically, not an 

acoustically treated room. 

8.11.3 The tests shall be made under normal operating conditions, Le., no load and 

under load. 

8.11.4 The individuals conducting the tests shall have proven capabilty in noise 

measurement and use approved measurement equipment and acceptable 

m easur em en t procedures. 

The ambient noise level in the test area shall be less than 75 db on the "A" 

scale. 

8.11.5 

HYDRAULICS 

9.1 This machine may be used on hot stretch forming operations. Its hydraulic 

system, Le., hoses, filters, seals, joints, etc., shall theref ore be designed 

for use with fire resistant hydraulic fluids approved by factory Mutual 

Engineering Division and Underwriters Laboratories Group ' 2. Specific 

fluids shall be as per these listed below or equivalent. - Trade Name Manufacturer 

Phosphate Esters, Cellulube Celanese Corporation 

Chlorinated Hydro- 150, 200, 

carbons or other 

synthetic fluids. 

300 & 600 

Pydraulic F9 Monsanto Chemical Company 

Arodor 1248 Monsanto Chemical Company 

and 1254 

Houghton E. F. Houghton Company 

safe 1120 

Shell SFR Shell Oil Company 

Fluid B or C 

Pyrogard Scony Mobile Oil Company 

4353 or 4355 

9.2 Suitable over-temperature signalling devices shall be provided to alert 

operator to an over-normal temperature condition and to ailow shutdown of 

machine at end of cycle. 

123 

D180-27884-3 
Specification No. 4437 

Page -15- 

9.3 Heat exchangers shall be of stainless steel type capable of maintaining 

fluid temperature below the maximum operating temperature. 

9.4 Reservoir shall be non-pressurized type. 

9.5 Maximum hydraulic system operating pressure 5,000 psi for continuous 

machine operation as separate and removable units. 

9.6 All hydraulic cylinders, except jaw actuating cylinders, shall be 

constructed as separate and removable units. 

Plugged "Tees" for pressure gauges shall be provided and suitably located 

to allow for troubleshooting. 

Over-temperature thermal switches, alarms for each hydraulic pump shall 

be provided to alert the operator to an over-temperature condition and 

shut the system down automatically. 

Hydraulic fluid reservoirs shall be equipped with low level alarm system, 

and automatic shutoff of affected pump motor. 

9.7 

9.8 

9.9 

9.10 The hydraulic system shall receive 100% filtration. All servo valves are to 

have individual filters at the input port. A bypass shall be provided for all 

filters. 

9.11 Reference Paragrphs 9.7, 9.8, and 9.9 faulty indications shall be displayed 

on the CRT. 

9.12 A gauge shall be conveniently located, for the operator, that indicates the 

level of fluid in the reservoir. 

9.13 A fluid fill tube will be provided at floor level for ease of maintaining 

proper fluid level. 

All hydraulic gauges shall indicate pressure (P.S.1.) and corresponding force 

(tonnage) on the face. 

Pumps are to be sized or system shall be isolated, when satisfied and 

maintained, to allow the maximum pressure settings to remain constant 

when the maximum form rates, as specified, are required. 

9.14 

9.15 

10.0 REQUIRED ATTACHMENTS 

The following items are to be quoted as additional options, to be delivered and 

installed with the machine. 

10.1 Extrusion Jaws 

Two (2) 5,000-ton extrusion jaws with 24" openings complete with adapters 

shall be furnished for mounting on the standard sheet jaws. The extrusion 

jaws and mounting adapters shall be capable of mounting on the sheet jaws 

without the use of special tools. Provisions shall be included for quick 

disconnect of extrusion jaw hydraulic lines from the main power unit of the 

press. Controls for opening, closing, rotation, swing, extension and 

retraction shall be located on the extrusion jaws. 

124 

D180-27884-3 
Specification No. 4437 

Page -16- 

10.1.1 Distance between jaws: 

Minimum when fully extended 

Rotation about tension cylinder E minimum 

320 inches 

2150 

10.1.2 Torque Requirement (Minimum) 850,000 in. lbs. 

10.2 Die Table Extensions 

The two following types of table extensions are desirable for various 

purposes. They should all be capable of supporting rated forming loads, 

including typically unbalanced loads which can be expected. Options should 

be priced by item to facilitate selection. 

10.2.1 Full Width Cover 

The full width cover type of extension is placed on top of the die table and 

consists of one continuous plate extending across width suitable gusseted 

and supported from underneath in overhang areas. Desired sizes are as 

follows: (Approximate Size) 

10.2.1.1 Item 1: (1) each. 60" full width x 108" long 

(1) each. 60" full width x 60" long 

(1) each. 90" full width x 108" long 

(1) each. 90" full width x 60" long 

10.2.1.2 Item 2: 

10.2.1.3 Item 3: 

10.2.2 Angular Extensions 

(1) each. 144" full width x 144" long 

This type of extension attaches flush with the top of the die table and may 

support only a portion of the length of the die. Individual segments should 

be capable of being attached at various positions along the entire length of 

the die table. Segment width shall be designed to produce overall die table 

widths as indicated in the following items when one angular extnesion is 

mounted on each side of the die table. 

10.2.2.1 Item I: (4) each. Angular extension segments 12" long to produce 72" 

overall table width. 

10.2.2.2 Item 2: (4) each. Angular extension segments 20" long to produce 84" 

overall table width. 

10.2.2.3 Item 3: (4) each. Angular extension segments 30" long to produce 108" 

overall table width. 

10.3 Provide a leading edge forming capability with bullnose segments. 

10.3.1 If a strongback is required during leading edge forming at full tonnage bull 

nosing (650 tons per jaw), a limit switch shall be added to indicate the 

strongback is in place and to prevent jaw swing. When the stongback is not 

in place, the limit switch shall prevent locking of the jaw swing cylinder. 

125 

D180-27884-3 
Specification No. 4437 

Page -17- 

11.0 

12.0 

10.4 

10.4.1 

10.4.1.1 

10.4.1.2 

10.4.1.3 

10.4.1.4 

10.4.1.5 

10.4.1.6 

10.4.1.6.1 

10.4.1.6.2 

10.4.1.6.3 

Vertical Bulldozer (Minimum Requirements) 

The bulldozer shall be four post, bridged, traveling gantry type and shall 

have the following characteristics: 

Capacity: Maximum 1,000 Tons 

Platen Size: Length 210 Inches 

Width 85 Inches 

Die Mounting Hole Pattern and/or Keyway Locations shall be provided by 

Buyer . 

Stroke: 96 Inches 

Daylight: 144 Inches 

(Bullaozer fully extended and die table fully retracted.) 

Distance between centerline 48 inches of Jaw Trunion and Bulldozer 

bottom surface (Jaw horizontal and bulldozer fully extended.) 

Speeds 

Gantry travel from park position 150 I.P.M. to centerline of the die table 

(and back to park position). 

Rapid advance Down (closing) - 100 I.P.M. 

At selected forming Tonnage - 30 I.P.M. (at closing). 

SHIPPING INSTRUCTIONS 

11.1 Equipment shall be adequately protected from inclement weather, rust and 

damage during shipping. Electronic equipment shall be shipped by padded 

van, or equivalent. 

Shipping weight and size of all cartons, crates, skids, etc. shall be furnished 

to Buyerls Purchasing Department prior to receipt of equipment. 

The quantity of shipping units and/or crates shall appear on each unit 

and/or crate. 

11.2 

11.3 

11.4 Seller shall notify Buyer's Purchasing Department of shipment 48 hours 

prior to arrival of equipment at site. 

MANUALS/DOCUMENTATION 

All data shall be furnished to the Facilities Department via the Purchasing 

Department. Five (5) complete sets of data shall be furnished. One set requried 30 

days prior to machine delivery and additional pre-installation and installation 

instructions and procedures. The remaining sets shall be delivered at time of 

shipment. Each set shall include but not be limited to the following: 

. 126 

D180-27884-3 
Specification No. 4437 

Page -18- 

12.1 

12.1.1 

12.1.2 

12.1.3 

12.1.4 

12.1.5 

12.1.6 

12.2 

Maintenance 

Procedures, drawings, diagrams, schematics, etc., to maintain the 

mechanical, electrical, electronic, hydraulic and pneumatic mechanisms of 

the complete machine tool and all peripheral equipment. 

Preventive maintenance procedures in Buyer's format indicating frequency 

schedule sample. 

Complete listing of all parts by name and number, including a 

recommended spare parts list. 

Plan and elevation views of complete system showing all necessary 

dimensions. 

Installation and instruction data including levelling and alignment 

requirements, location and size of all utilities required. 

'Theory of Operation" for maintenance trouble-shooting covering detailed 

operation of the complete system. 

Operating Procedures 

Procedures, drawings, illustrations to simplify operation of the machine 

tool and all peripheral euqipment. 

1 3.0 INSTALLAlION/INSTRUCTIONS 

13.1 Seller shall be completely responsible for the equipment installation, to 

include all required personnel, transportation, rigging and equipment 

(holddowns, pads, levelling screws, etc.) and performing all testing 

procedures. Buyer shall furnish all utilities and a suitable foundation. 

Buyer's personnel shall make all final utilities connections. 

Buyer's cognizant personnel shall be notified to witness only the final test 

procedure. 

Training of personnel that is not concurrent with the installation at Buyer's 

facility shall be defined as to where it will take place, the duration and 

type of training and the quantity and type of personnel required. 

13.2 

14.0 SELLER'S REQUIREMENTS 

14.1 For the successful installation and checkout of the new machine. 

14.2 

14.3 

Seller's personnel shall adhere to Buyer's security and fire regulations. 

Where this specification causes a deviation from the Seller's standard 

product, quote the standard product in addition to the requirements 

specified herein. 

14.3.1 Seller shall indicate where the standard product deviates from this 

specification. 

127 

D180-27884-3 
Specification No. 4437 

Page -19- 

14.3.2 Seller shall reply by item number when there is compliancehon-compliance 

with this specification. 

Seller shall agree that availability of field service on a one-shift and twoshift basis in response to a service request by Buyer during the warranty 

period and also after its expiration shall not exceed 48-hour period. 

14.4 

14.5 Seller shall respond to each paragraph of this specification and inquiry, 

indicating his concurrence or not, and including a brief explanation of his 

intent. 

14.6 Seller shall provide an upgraded schedule, monthly, from the start to the 

completion of the job. 

128 

D180-27884-3 
APPENDIX E 

NASA STATEMENT OF WORK 

(NAS8-35969/EXHIBIT A "SCOPE OF WORK" AND EXHIBIT I) 

129 

D180-27884-3 
_,. . .. 

. 

EXNI BIT IcA" 

SCOPE OF WORJt 

Contract NAS8-35969 

LARGE STRETCE PRESS ?AGILITY 

The purpose of this 8tudy is to (1) assess and document the 

rdvantages/disadvant8ges.ef a governrent 8gency fnvertmcnt in a 

hrge 8tretcb form press on the order of 9000 tons capacity (2) 6.velop procurement rpecificatfon tor tbe press, t3) provide 

trade study d8ta that rill permit an optimum site location. 

INTRODUCTION 

A NASA/CIJSFC survey indicates that an investment in a large 

stretch form press on the order of 5000 ton capacity (largest 

existing facility is 750 ton capacity) would be cost effective 

for several applications if implementation is made in a timely 

manner. The potential benefits to the Shuttle External Tank 

would be to stretch form-dome caps, larger dome gores, and larger 

aft ogive gores. 

benefits i.e. low tooling costs, quick change over, low 

distortion and minim1 springback. Reduced manufacturing costs 

with improvements in component quality are projected for the dome 

caps now being rpun formed. Fewer welds would result by forming 

larger gore and ogive sections. 

Stretcn fo-ming offers several potential 

PRASE I 

TASK A 

COST STUDY FOR THE SHUTTLE EXTERVAL TANK 

Develop ET dome cap, gore, and ogive cost data for a projected 

necessary to produce the end items, i.c. cost projections for 

manufacturing, inspection, handling etc. Ghipping costs, 

material costs and stretch press capitalitation/depreci8t~on cost 

should be omitted as parts of the ET component manufacturing cost 

data! 

he cap (SPUN), dae gore stgaents and aft ogive gores which are 

rtretch formed. Parts drawintas and current cost data uill-be 

Bade available to the successful bidaer Anticipated 

manufacturing cost'savings rrom awe gore and aft ogive gores would 

come from the ability to form larger parts (150% in width) than 

Are currently wed, (See Appendix 1 for projected External Tank 

components manufacturing rates.) 

\ stretch form process. Cost data shall include all costs 

Corrcnt Danufactoring cart d8ta are available for the ET 

TASK B 

USER SURVEY 

Contact specific design[manufacturing orgahizations of the 

various government agencies and identify those agencies which 

have requirements (or ptential) for a large stretch press 

130 

D180-27884-3 
6RiciL , 

OF POW G.- __ , 

facility. 

governraent agencies. The survey questions should be 

constructed to establish both current needs: i.e. project 

hardware which is being produced by other means because large 

capacity rtretch presses are not available, and future needs, 

i.c. 

forming assuming a larger rtrctch press was available. 

PHASE If 

TASK A 

?allow up with a survey form and rail to the selected 

project hardware which could be designed for stretch 

Site Selection Trade Study 

txplore the feasibility of a government owned, contractor 

operated Stretch forming facility conveniently located nearby 

applicable ancillary equipment. 

Two options on site location rhould be provided. 

should be the optimum site recommendation to support the external 

tank project and the second option should be the optimum site 

- recommendation for supporting all NASA/Government programs. 

(Both options may be the same site.) Site location 

recommendations arc to be supported with sufficient costltrade 

study data to substantiate the rccommendationf. *his is to 

include ancillary equipment and facilities needed to support the 

stretch forming press such as building size, heat treating 

facilities, storage and handling, inspection equipment and other 

metal processing equipnent and facilitiesj 

One option 

TASK B 

PRESS DESSGN REQUXREWENTS/PROCUREMENT SPECIFICATIONS 

Prepare a specification for the design, procurement, 

installation, performance and inspection of a stretch press with 

a 5000 ton minimum capacity, The specification shall list 

minimum requirements and shall not limit design'advances, safety 

features and convenience of operation and maintenance. The 

stretch press is to be utilized for stretch forming ferrous and 

non-ferrous alloy sheet and plate into complex contoured shapes 

to quality standards typical of aerospace industry. Therefore it 

must comply with applicable sections of. BAS930 - .Stretch ?orring 

-'W.cbiner - Airframes' in addition to applicable electrical, 

mechanical, structural and safety codes. The press may be 

modular design with initially lovtr capacity and capability but 

Bust be capable of achieving the target 5000 ton ram force with 

subsequent modular additions. 

A Skeleton outline of the specification (to be fully expanded) is 

1 is ted below: 

1. Codes and Standards 

2. Responsibilities (design, fabrication, installation, test and chec 

131 

DI 80-27884-3 
3. 

3.1 

3.2 

4. 

5. 

6. 

1. 

8. 

9. 

10 . 11 . 12. 

13 

14. 

15 . 16 . 

out, training). 

-ml 

Die table capacity and features 

Jaw capacity and features 

Elongation controls and yield point detection 

Lubrication f eatur es 

Electrical features 

Controls, Console (microprocessor, memory capability, etc.) 

Cnvi t onment 

Utility hook up 

Construction 

Re1 i abili ty, Qual i f icat ion, Acceptance Test 

Safety 

Hydraulics 

Options 

Manuals, Documentation (maintenance, operating procedures) 

Installation, training instructions 

132 

D180-27884-3 

~ - 
1 I 

.. 

APPENDIX I 

BXTUUIAL TANK STRETCE mRHED CORPONE131 UWIRUWITS 

Ai8TfCfPATED PRODUCTION RATE O? mm EX' COMPONENTS 

Current/Yr 

Hid 1907 4 

?eb 1989 

?eb 1990 

?ud Aft Gores Cam Gores Caps Cotes Caw 

104 156 1S6 13 156 13 156 13 

192 288 288 24 288 24 288 24 

240 360 360 30 360 30 360 30 

320 480 480 40 480 40 400 40 

-----. -- 

Grand 

of each 

Bardmare 

Item to be 

Manufactured 1800 2700 2700 22s 2700 255 2700 225 

Tot81 NO. 

Tot81 Po. ?vd Ogive Gores---------------- 1800 -Iar&l gore 

Total Bo. Aft Ogive Gores (Current size---2700 sections --la00 

total Uo. Dome Coret-------U per unit)----8100 8 per unit)--5100 

133 

0180-27884-3