How long to erase & format a drive?

Hi, how long should it take to erase and format a 640 GB internal hard drive on my Mac Pro?
My Mac Pro is an 8-core, 2.8 ghz MacPro, which I've had for about a year. It came with a 320 GB primary drive. Recently I bought a Western Digital Caviar WD6401AALS 640 GB drive so that I can run Time Machine on it. The WD drive came formatted with NTFS.
After opening Disk Utility, I selected my 640 GB drive and then selected Mac OS extended (journaling) before clicking on Erase. After less than a minute this ended with "Disk Erase failed with the error." I tried this a few more times and got the same result each time. Then I clicked on the "Repair" button but got messages that stated "Disk Utility stopped repairing 'diskOs1' because the following error was encountered."
I then selected the volume (listed under the WD 640 GB drive), with format Mac OS extended (journaling) again and clicked on Erase. This set a barber pole at the bottom right of the box into motion. It's been running, however, for over 13 hours at this point. If I try to quit Disk Utility, a dialog box comes up that states the operation is still in progress. Should I exercise more patience or is something wrong with the procedure?
Here is the last part of the log so far:
2009-05-08 20:37:00 -0700: Preparing to erase : “disk0s1”
2009-05-08 20:37:00 -0700: Partition Scheme: Master Boot Record
2009-05-08 20:37:00 -0700: 1 volume will be erased
2009-05-08 20:37:00 -0700: Name : “disk0s1”
2009-05-08 20:37:00 -0700: Size : 596.2 GB
2009-05-08 20:37:00 -0700: Filesystem : Mac OS Extended (Journaled)
2009-05-08 20:37:00 -0700: newfs_hfs: /dev/rdisk0s1: partition size not a multiple of 4K.
Can anyone tell me what the last line means? Thanks for your help.
Larry

Wow, Hatter, that's the fastest response I've ever received to a question in any forum I used!
I purchased this WD 640 GB drive from Tech for Less. It was advertised as an "Open Box" item and was supposed to be unused.
In my first few attempts I selected the WD6401AALS itself and tried to erase it. Every time I tried this, the procedure failed. This is the first part of the log:
2009-05-08 18:41:37 -0700: Disk Utility started.
2009-05-08 18:43:45 -0700: Preparing to erase : “WD640”
2009-05-08 18:43:45 -0700: Partition Scheme: Master Boot Record
2009-05-08 18:43:45 -0700: 1 volume will be created
2009-05-08 18:43:45 -0700: Name : “WD640”
2009-05-08 18:43:45 -0700: Size : 596.2 GB
2009-05-08 18:43:45 -0700: Filesystem : Mac OS Extended (Journaled)
2009-05-08 18:43:45 -0700: Creating partition map.
2009-05-08 18:43:47 -0700: Formatting disk0s1 as Mac OS Extended (Journaled) with name WD640.
2009-05-08 18:43:48 -0700: Disk Erase failed with the error:
File system formatter failed.
2009-05-08 18:43:48 -0700: Erase complete.
2009-05-08 18:43:48 -0700:
2009-05-08 18:43:49 -0700: Disk Utility failed during an unspecified action with the error:
I noted that one of the entries at 18:43:48 -0700: states "Erase complete." This is followed 2 lines later, however, with "disk Utility failed during an unspecified action with the error:"
When I selected the "volume" itself and clicked on Erase, the erasing and formatting operation seemed to begin. I guess that in selecting "volume" I selected only the NTFS partition itself.
The only way I can stop the current erasing and formatting operation seems to be to pull down on Disk Utility in the menu bar and select "quit Disk Utility." This brings up a dialog box, however, cautioning that stopping in the middle of an operation can render some disks nonoperational.
My WD 640 GB drive is supposed to have the same warranty as a new WD drive - according to Tech for Less. I hope that pulling the plug this way won't void the warranty.
Thanks for your rapid response.
Larry

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