TRIANGULAR GROOVE CHAMBER MFG

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TRIANGULAR GROOVE CHAMBER MFG

• June 14, 2007

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Requirements

• Triangular Grooves
• Groove Width 2mm
• Groove Depth 3 mm
• Groove Length 13 in
• Taper Angle 20 degrees
• Radius at Top Bottom 0
• ID of Chamber 1.730 in (was 3.510)

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Basic Problem

• Sharp radius at base top of grooves
  unattainable by normal mfg methods
• Checked with MFD several outside vendors

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Mfg Options

• Extrusion (min radius 0.008in)
• EDM normal min dia about 0.006 in, using 4mm
  wire
• Experimental min dia 0.003, using 1mm wire
• Foil Use individual strips, 2 mm thick
• Taper strips braze together
• Insert assembly into inside of tube
• May be vacuum problem
• Etch Etch out individual strips, braze together
  insert into tube. Etching process can not
  control tapers
• Laser Cut Normally used for thru cutting

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Mfg Options

• Broach Serrations into inside of tube
• Press No place for metal to move to.
• Die Casting Doubtful if metal will flow into
  sharp corners
• Isostatic Pressing Uses powder metal binders
  which would probably not be suitable for vacuum
  usage
• Except extrusion, split tube required for all
  above options

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OPTIONS

• Use 0.008 radii extrusion (cost 62K)
• Fab extrusion try to rework grooves radii close
  to being sharp may have to split chamber (est
  min additional cost 2 weeks, 80 hrs _at_ 100/hr
  8K - Could be much higher if broach required )
• Experiment with different machine cut grooves. If
  successful, proceed to make 2 halves of chamber
  weld together (estimated min cost 2 months, 320
  hrs _at_100/hr 32K)