8-20-SOW-Finalv.2.pdf

Statement of Work for Advanced Metals Forming Machine

1.0 Introduction

This Statement of Work (SOW) describes all work required to design, fabricate, and install an advanced metals forming machine at NASA Langley Research Center (LaRC).

This SOW also calls for Options to design, fabricate, and incorporate ancillary equipment for enhanced capabilities.

1.1 Scope

The Contractor shall provide all personnel, equipment, and supplies necessary to successfully complete all requirements as described in this SOW. This SOW covers the minimum requirements for the advanced metals forming machine, including any necessary design considerations to accommodate the incorporation of Options listed in Section 4.0. This will facilitate the addition of Options at a future date, but will not obligate the Government to exercise any of the Options listed in Section 4.0. If any Options are exercised, the Contractor shall also provide all personnel, equipment, and supplies necessary to design, fabricate, and incorporate ancillary equipment into the advanced metals forming machine, as described in Section 4.0 of this SOW.

1.2 General Description

The focus of this SOW is to provide an advanced metals forming machine which will be used to conduct state-of-the-art materials and manufacturing research and development. Examples of specific research and development tasks which will be enabled by this machine are described below.

1.2.1 Manufacturing Research and Development

The advanced metals forming machine will support manufacturing research and development at NASA LaRC for programs in NASA’s Aeronautics and Space mission directorates.

Under Aeronautics, the advanced metals forming machine will enable LaRC researchers to address the Advanced Air Transport Technology (AATT) project goal of high-rate manufacturing for future commercial transport structures. Fundamental research on the Integrally Stiffened Cylinder (ISC) forming process will be conducted using this machine to specifically address high-rate fuselage production and to contribute to the AATT Advanced Metallic Fuselage Manufacturing Demonstrator.

Under Space, Lunar Gateway and Mars Mission needs will benefit from research conducted using the advanced metals forming machine to fabricate near-net-shape launch vehicle structures to realize low cost, lightweight structural requirements.

Applications include, but are not limited to, descent and ascent vehicle stages and storage tanks. These applications will benefit from reduced weight, cost, and manufacturing time to produce single-piece formed metallic structures such as domes, nozzles, cylinders, conical sections and toroidal shapes as well as irregular shapes such as oval cross-sections, formed flat shapes, fluted, lobed or conformal structures.

Future needs in both Aeronautics and Space will be addressed through fabrication of unique geometries and prototype articles for NASA and US industry using the advanced metals forming machine.

1.2.2 Materials Forming Research

The advanced metals forming machine will be used to conduct research to characterize limits of manufacturability of metals such as aluminum, titanium, nickel, copper, and iron-based alloys. Microstructural evolution and alloy development will be studied under various forming conditions and geometries using the advanced metals forming machine.

1.2.3 Forming Process Definitions

The following definitions of the forming processes are provided for the purposes of this

SOW:

- Spin Forming - a flat rotating, clamped work piece is formed by compressive and tensile forces imparted by forming rollers with minimal reduction in the thickness of the part

- Flow Forming - compressive forces imparted by forming rollers form a cylindrical shaped preform by reducing the thickness of the part

- Shear Forming - compressive forces imparted by forming rollers form a flat preform by reducing the thickness of the part

- Necking-in Forming - diameter of a tube or cylinder is reduced by multiple forming passes as would occur in the neck of a gas cylinder

- Counter Roller Forming - a flat rotating, clamped work piece is formed by a reduction of thickness between diametrically opposed rollers without a mandrel

- Duplex Incremental Sheet Forming - a flat fixed, clamped work piece (typically sheet metal) is formed by applying pressure between opposing rollers that incrementally pushes out to form the sheet into the form of the 3D tool path with minimal reduction in the thickness of the part

The coordinate axes for the advanced metals forming machine as referenced in this SOW are defined in the sketch in Figure 1.2.3.

2.0 Advanced Metals Forming Machine Specifications

The advanced metals forming machine shall include all structure, plumbing, wiring, cabling, valving, cooling, controls, and safety devices for safe, research-oriented operation.

2.1 Forming Capabilities

The machine shall be capable of routinely conducting forming experiments on metallic materials such as aluminum, titanium, nickel-based alloys, and steels.

-The machine shall be capable, as a minimum, of the following forming processes: spin forming, shear forming, flow forming and necking-in forming.

- The machine shall be capable of forming parts with a range of inside diameters from a minimum of 2 inches to a maximum of 24 inches, and at least 24 inches in length.

- The machine shall be capable of forming with and without a mandrel.

- The machine shall be capable of symmetric and non-symmetric forming.

- The machine shall be capable of forming at temperatures from ambient to 875 degrees Fahrenheit.

- The machine shall be modular in design with interchangeable roller configurations.

Different roller configurations shall include the ability to use multiple roller sets simultaneously, the flexibility to alter the number and size of the rollers, the ability to change the angular and positional orientation of the rollers, and enable different forming processes as detailed above.

- The machine shall be capable of programmable, Computer Numerical Control (CNC) controlled forming.

2.2 Machine Design and Construction

The machine shall be designed to accommodate interchangeability to allow for future research growth, including capabilities such as the Options listed in Section 4.0.

- The machine dimensions shall be no larger than 30 feet (length) x 17 feet (width) x 17 feet (height). The ability to tailor the orientation of components during the design phase to optimize accessibility and use of the available floor space in the facility at NASA LaRC will be considered added value.

- The machine shall arrive at NASA LaRC in components with dimensions that will permit unencumbered passage through a rollup door entryway of 11 ft. 11 in. (width) x 11 ft. (height) allowing for additional clearance needed for forklifts, floor jacks and overhead cranes handling equipment.

- The machine shall have a minimum of two diametrically opposed, independently controlled, forming rollers that can be slewed to angles between 0 and 45 degrees to facilitate different forming processes as detailed in Section 2.1.

- The machine shall have programmable CNC control of the vertical and horizontal displacement of the rollers.

-The machine shall have a programmable spindle drive speed that can be continuously varied from 300 rpm to at least 1000 rpm for spinning the mandrel under forming forces.

- The machine shall have programmable roller displacement and force capabilities that can be continuously varied over the operating range from 0 to the maxima below:

- The machine shall have a maximum vertical working speed of at least 55 ipm with a maximum vertical (axial) force capability of at least 65 kips. These requirements shall be met concurrently.

- The machine shall have radial working speed of at least 36 ipm with a radial force capability of at least 55 kips. These requirements shall be met concurrently.

- The machine shall have selectable flow control to enable forming with or without coolant on the work piece.

- The machine shall have an integrated air conditioning and dehumidifying system for environmental control of the supporting electronics cabinet(s).

2.3 Machine Programming and Controls:

The control system for the advanced metals forming machine shall consist of the following:

- A user interface that shall permit the development, compiling and downloading of forming programs to the CNC controller.

- Manual controls that shall allow selection, adjustment and override of programmed settings for all pertinent process parameters such as spindle and forming roller speed, force and displacement. These manual controls shall be located on an operator’s console such that manual adjustment of pertinent process parameters is permitted real-time while the forming process is ongoing.

- The machine shall be designed to include capacity to add extra control channels as may be required to support any or all of the Options listed in Section 4.0.

2.3.1 Control Computer Hardware: The advanced metals forming machine shall include a PC-based computer that provides the primary interface between the user/operator and the programmable CNC controller. The PC-based computer shall have, as a minimum: processor speed of 3.0 GHz, 8 GB of system RAM, 2 TB hard drive, DVD-RW optical drive, Gigabit Ethernet and a 21-inch monitor. Computer capabilities in excess of these requirements are acceptable. The computer operating system shall be Windows 10 Pro 64 bit, Version 1903. The control computer shall be configured such that it can routinely be operated without requiring any internet connectivity so that it may be isolated from the NASA network except while transferring programs and data files.

2.3.2 Software Program Control and File Format: The advanced metals forming machine shall include software for automated system control of the forming process, process programmability, and data collection and storage.

- If CAD-to-CAM capabilities are included as part of the process programmability, the input CAD-data file format shall be a universal file format such as IGES, STL or STP.

- Pertinent process data, such as input set points and actual feedback measurements for key process parameters (including but not limited to spindle speed for the mandrel, roller translation position and speed, axial and radial forces, coolant flow) shall be collected and saved after each run and accessible for subsequent documentation archival and evaluation.

- All system input and output data files shall be stored in a format that may be uploaded into Microsoft Office programs (such as Word, Notepad, Excel) and shall be transportable to and from another PC for further data analysis and archiving via USB-connection or network connection.

- If required, licenses for installing system software on an additional three PC’s for data analysis and programming shall be provided.

- Compatibility with commercial-off-the-shelf software is preferred whenever possible.

2.4 Utilities

Power supplies shall permit full operation of the advanced metals forming machine as required in this SOW. The advanced metals forming machine shall be capable of full, safe, and controlled operation using the following utilities planned for the designated laboratory location at NASA LaRC: 460 volt / 60 Hz / 3 phase AC, 100 psi (nominal) compressed air, and city water. Floor space, floor loading, power, and other utility requirements for full operation shall be specified at the time of contract award to allow time to prepare the site for the equipment.

2.5 Water Cooling

All closed-loop water chillers/heat exchangers shall be stand-alone and all necessary plumbing, valving, and monitoring devices required for operation of the advanced metals forming machine shall be included.

2.6 Safety

All applicable OSHA health and safety specifications shall be met, including noise and fall protection. Safety features shall include interlocks that will activate automatic shutdown in the event of: power failure, loss of coolant or lubricant flow, loss of hydraulic pressure, or any other potentially hazardous situation associated with operating of the advanced metals forming machine. An emergency stop button to shut down the entire system shall be accessibly located at the operator’s console.

3.0 Acceptance Tests

The Contractor shall perform Preliminary Acceptance Tests at the Contractor’s facility, and Final Acceptance Tests at NASA LaRC. The Government maintains the final authority on decisions of pass or fail for all Acceptance Tests, based on the Acceptance Criteria specified for each test. If the equipment is unable to meet the Acceptance Criteria specified, the advanced metal forming machine will be rejected unless it can be made to conform to the specifications as described in the SOW and subsequently pass the Acceptance Test in question within the period of performance. The Contractor shall notify the Government a minimum of two (2) months prior to performing the Preliminary Acceptance Tests to allow travel time for a Government representative to observe the Preliminary Acceptance Tests. Preform materials required for Preliminary and Final Acceptance Tests shall be provided by the Contractor.

3.1 Preliminary Acceptance Tests

The Contractor shall demonstrate, at their own facility prior to shipping the advanced metals forming machine to NASA LaRC that the system, including all components, subsystems, and instrumentation is fully operational and satisfies the specifications, as described in the SOW. These Preliminary Acceptance Tests shall be performed in the presence of a Government representative.

As a minimum, the Preliminary Acceptance Tests of the advanced metals forming machine shall include the following:

3.1.1 Basic Position and Speed Tests

The intent of these tests is to verify the programmability, translation ranges, speeds, and positioning accuracy of each translation axis.

- Demonstrate the full travel distances and speeds of each radial and vertical roller axis by running a program that traverses the full range of travel for each axis at the maximum rated speed under maximum forming forces.

- Commanded and feedback data for the position, speed, and force of each axis shall be collected and recorded at a data rate of at least 5 Hz during the test to demonstrate programmability and data recording capabilities of the advanced metals forming machine.

- As a minimum, each radial roller translation shall be demonstrated from 1 to 12 inches radially, at a translation speed of 36 ipm under 55 kips force.

- As a minimum, each vertical roller translation shall be demonstrated from 0 to 24 inches vertically, at a translation speed of 55 ipm under 65 kips force.

- For the slewable rollers, demonstrate the ability to tilt each slewable roller in increments of 5.0 degrees through the full range of motion.

- Demonstrate the spindle speed for the mandrel by running the full range of spinning speeds under forming forces.

Acceptance Criteria: Positioning system achieves full range of motion at maximum speeds and maximum forming forces for each radial, vertical, and rotational axis, as specified by the Contractor in the proposal.

- Feedback data for the position, speed, and force of each axis (each roller radial and translation axis and spindle speed) shall be compared to the commanded values and shall be within 1% of full scale for each variable and each axis.

- Position, translation, and force feedback data shall be verified that the full operating range has been achieved:

- Each radial roller axis: 1.0 to 12.0 +/- 0.1 inches translation, 0 to 36 +/- 0.5 ipm translation speed, 0 to 55 +/- 0.05 kips force.

- Each vertical roller axis: 0.0 to 24.0 +/- 0.1 inches translation, 0 to 55 +/- 0.5 ipm translation speed, 0 to 65 +/- 0.05 kips force.

- Each slewable roller: 0.0 to 45.0 +/- 0.5 degrees angular positioning.

- Spindle speed feedback data shall demonstrate the spindle achieves the full range of controlled rotational speeds from 300 to 1000 rpm under forming forces.

3.1.2 Multiple Forming Process Test

The intent of this test is to verify the advanced metals forming machine is capable of performing a minimum of three different forming processes on a single part using a single set-up. Using a mandrel of the Contractor’s choice, demonstrate the ability to perform spin forming, flow forming, and necking-in forming on a single part. Two (2) weeks prior to performing this acceptance test, the Contractor shall provide drawings of the proposed mandrel and expected formed part for concurrence of the Government.

The part shall have a geometry with the following features:

- A spin-formed section of at least 4 inches in length.

- A flow-formed section of at least 4 inches in length, demonstrating at least 50% reduction in wall thickness. This section shall include a uniform thickness, thin-walled section of 0.125 inches thick or thinner along at least 4 inches in length.

- A necking-in section that reduces the outside diameter of the component by at least

0.50 inches.

Acceptance Criteria:

- Successfully form a part that includes three different forming processes (spin forming, flow forming, and necking-in forming) in the same component and one set-up (i.e. all steps are programmed so the only manual operations are installing the preform at the beginning of the test and removing the part at the conclusion of the test) while maintaining accurate dimensional tolerances, with no visible cracking in the part.

- The dimensions of each forming section shall be within +/-0.01 inches for the thickness, length, and diameter measurements based upon the specific dimensions of the mandrel selected for demonstration.

- Thickness measurements taken at 0.5-inch increments along a 4-inch length of the flow-formed section where the wall thickness has been reduced at least 50% to 0.125 inches or thinner shall be within a thickness tolerance of +/-0.01 inches.

3.2 Final Acceptance Tests

The Contractor shall demonstrate, after shipping, installation and verification at NASA LaRC that the advanced metals forming machine, including all components, subsystems, and instrumentation, is fully operational and that it satisfies the specifications as described in the SOW. As a minimum, the Final Acceptance Tests shall consist of repeating the Preliminary Acceptance Tests as described in Section 3.1.

4.0 Options

4.1 Options – To Be Exercised within Sixty (60) Days after Time of Award The Contractor shall price Options to enhance the capabilities in the advanced metals forming machine shown below (Sections 4.1.1 to 4.1.2) which may be exercised within sixty (60) days after time of award or up to one (1) week after the preliminary design drawings and hardware specifications have been delivered to the Government, whichever comes first.

If exercised, the Option(s) shall be required to be fully integrated into the advanced metals forming machine. If an Option is exercised by the Government, the Contactor shall propose to the Government within fifteen (15) days of exercising the Option, the schedule of work to be performed and Acceptance Tests for the exercised Option. If any of these Options are exercised by the Government, the modifications shall be reflected in the final design of the system and these items shall replace the corresponding lower capacity item(s) in the base unit. Since these modifications will be made to the base unit design, the period of performance shall remain the same as the base unit.

4.1.1 Increased Hydraulic Capacity Option

The intent of this Option is to increase the hydraulic capacity of the advanced metals forming machine base unit to provide for possible future capabilities. The hydraulic system, including pumping capacity and any necessary upgrades to hydraulic lines, sensors, pumps, or other associated hydraulic infrastructure required for safe operations, shall be increased to allow for an additional four (4) concurrent moving components (such as additional roller configurations, hydraulic slewable rollers) beyond the base unit.

If this Option is exercised, the increased hydraulic capacity shall replace the hydraulic system in the base unit design. This change shall be reflected in the final system design drawings and shall be integrated into the advanced metals forming machine.

The timing of this Option is intended to minimize the cost and time to implement such that it does not affect the delivery date for the base unit. There are no required acceptance tests for this Option.

4.1.2 Increased Work Piece Length Option

The intent of this Option is to increase the maximum length of the parts that can be formed in the advanced metals forming machine base unit. (Reference the requirement in Section 2:1: “The machine shall be capable of forming parts with a range of inside diameters from a minimum of 2 inches to a maximum of 24 inches, and at least 24 inches in length.”) If this Option is exercised, this requirement will be changed as follows: “The machine shall be capable of forming parts with a range of inside diameters from a minimum of 2 inches to a maximum of 24 inches, and at least 36 inches in length.” All other requirements for the advanced metals forming machine will remain as defined in this SOW. In addressing this Option in the Proposal, the Contractor shall note if the increase in work piece length changes the overall height of the machine above the 17 feet height as specified in Section 2.2.

Acceptance Criteria:

Reference the Acceptance Test in Section 3.1.3: “As a minimum, each vertical roller translation shall be demonstrated from 0 to 24 inches vertically, at a translation speed of 55 ipm under 65 kips force.” Similarly, reference the Acceptance Criteria in Section 3.1.1: “Each vertical roller axis: 0.0 to 24.0 +/- 0.1 inches translation, 0 to 55 +/- 0.5 ipm translation speed, 0 to 65 +/- 0.05 kips force.”

If this Option is exercised, the Acceptance Test in Section 3.1.1 will be changed as follows: “As a minimum, each vertical roller translation shall be demonstrated from 0 to 36 inches vertically, at a translation speed of 55 ipm under 65 kips force.” Similarly, the Acceptance Criteria in Section 3.1.1 will be changed as follows: “Each vertical roller axis: 0.0 to 36.0 +/- 0.1 inches translation, 0 to 55 +/- 0.5 ipm translation speed, 0 to 65 +/- 0.05 kips force.” Note that this same Acceptance Criteria shall be required for the Final Acceptance Tests as described in Section 3.2.

4.2 Options – To Be Exercised within Six (6) Months after Time of Award The Contractor shall price optional items shown below (Sections 4.2.1 to 4.2.4), which may be exercised within six (6) months after time of award. Each Option described below, if exercised, shall be required to be fully integrated into the advanced metals forming machine. Acceptance Tests for each Option are described below. These Acceptance Tests shall be performed at NASA LaRC after completion of integration of each individual Option into the advanced metals forming machine. The Government maintains the final authority on decisions of pass or fail for all Acceptance Tests based on the Acceptance Criteria specified for each test. If the equipment is unable to meet the Acceptance Criteria specified, the equipment for that Option will be rejected unless it can be made to conform to the specifications as described in the Options below and subsequently pass the Acceptance Test in question. The Contractor shall provide all preform material required for the Acceptance Tests.

4.2.1 Counter Roller Forming Capability Option

This Option shall consist of designing, fabricating and integrating hardware and associated controls to provide the advanced metals forming machine with a counter roller forming capability. The counter roller forming capability shall employ two diametrically opposed independent rollers that apply force to a work piece that is clamped in a fixture and spun in the plane of the work piece. Instead of using a mandrel to react against, the counter roller forming process uses diametrically opposed rollers to react forming forces against each other. The counter rollers are translated and slewed in coordinated tool paths to incrementally form parts like conical sections and domes. A schematic of the counter roller forming process is shown on the left in Figure 4.2.1. Note that the orientation of the work piece may be either vertical or horizontal in the advanced metals forming machine, as long as the counter rollers are configured accordingly to form the part. A photo of a hemispherical dome in the as-built condition that was produced using counter roller forming is shown on the right in Figure 4.2.1 as an example of the type of geometry of interest to be built using this Option.

If this Option is exercised, the Contractor shall design, fabricate, and integrate the hardware and associated controls to provide the necessary clamping fixtures to securely hold and spin the work piece and programmable translation and slewable counter rollers with sufficient range of motion to enable counter roller forming. All modifications to the advanced metals forming machine shall be modular such that the base unit rollers, slides, spindle and mandrel can be interchanged with the counter roller forming hardware for this Option. Specific requirements to enable the counter roller forming process include:

-The machine shall have a programmable spinning drive speed that can be continuously varied from 100 rpm to at least 500 rpm for spinning the work piece under forming forces.

- Maximum work piece diameter shall be 24 inches.

- Counter roller linear and angular displacements shall be capable of forming a hemispherical dome 24 inches in diameter and 12 inches in height, with a minimum wall thickness of 0.01 inches.

- The machine shall have programmable roller displacement and force capabilities that can be continuously varied over the operating range from 0 to the maxima below:

- The machine shall have a maximum vertical working speed of at least 55 ipm with a maximum vertical (axial) force capability of at least 65 kips. These requirements shall be met concurrently.

- The machine shall have radial working speed of at least 36 ipm with a radial force capability of at least 55 kips. These requirements shall be met concurrently.

Acceptance Test for Option 4.2.1

The counter roller forming capability Option shall be demonstrated in the advanced metals forming machine to form a hemispherical dome similar to the photo on the right in Figure 4.2.1. The machine shall be programmed to form a hemispherical dome, starting with a 0.25 inch thick, 24-inch diameter preform and incrementally forming it into the dome 24 inches in diameter and 12 inches high. The forming may take several passes to attain the final 12-inch height. Due to the inherent nature of the counter roller forming process, thickness of the formed part will vary with position on the dome. The minimum allowable thickness shall be 0.05 inches.

Acceptance Criteria:

- Successfully form a hemispherical dome using programmed counter rollers and a spinning work piece, without a mandrel.

- The height and contour of the hemispherical dome shall be within +/-0.01 inches of the programmed tool path for the final pass, as measured from the outside surface of the dome.

- The advanced metals forming machine shall be demonstrated to be reconfigurable between the base unit with a spindle and mandrel to a counter roller configuration and back again.

4.2.2 Duplex Incremental Sheet Forming Option

This Option shall consist of designing, fabricating and integrating hardware and associated controls to provide the advanced metals forming machine with a duplex incremental sheet forming capability. The duplex incremental sheet forming process shall employ two diametrically opposed independent rollers that apply force to a work piece that is installed in a fixed, clamped chuck. As is the case with the counter roller process, instead of using a mandrel to react against, the duplex incremental sheet forming process uses diametrically opposed rollers to react forming forces against each other. The counter rollers are translated and slewed in coordinated tool paths to incrementally form parts like a corrugated or fluted panel. Since the work piece is fixed, the duplex incremental sheet forming process requires the counter rollers to be able to translate in three orthogonal (X-Y-Z) directions, while applying forming forces to the sheet metal work piece. A schematic of the duplex incremental sheet forming process is shown on the left in Figure 4.2.2. A photo of a hat-stiffened formed panel that may be produced using duplex incremental sheet forming is shown on the right in Figure 4.2.2 as an example of the type of geometry of interest to be built using this Option.

If this Option is exercised, the Contractor shall design, fabricate, and integrate the hardware and associated controls to provide the necessary clamping fixtures to securely hold the fixed work piece and programmable translation and slewable counter rollers with sufficient range of motion to enable duplex incremental sheet forming. All modifications to the advanced metals forming machine shall be modular such that the base unit rollers, slides, spindle and mandrel can be interchanged with the duplex incremental sheet forming hardware for this Option. Specific requirements to enable the duplex incremental sheet forming process include:

- Maximum fixed work piece shall be 18 inches wide by 24 inches high.

- The machine shall have programmable roller displacement and force capabilities that can be continuously varied over the operating range from 0 to the maxima below:

- The machine shall have a maximum working speed of at least 36 ipm with a maximum force capability of at least 55 kips in each X-Y-Z orthogonal axis.

Acceptance Test for Option 4.2.2 The duplex incremental sheet forming capability Option shall be demonstrated in the advanced metals forming machine to form a hat stiffened panel similar to the photo on the right in Figure 4.2.2. The machine shall be programmed to form a three-hat stiffened panel, starting with a 0.125 inch thick, 18-inch wide by 24-inch high flat panel and incrementally forming the stiffeners. Each hat stiffeners shall be 1.25 inches tall, 1.0 inches wide, with a wall angle of 75 degrees relative to the base and spaced 2.5 inches apart, shall be formed into the panel across the 18-inch dimension. Stiffeners shall taper down to the base at the top and bottom of the panel, forming a stiffened region 20 inches long along the 24-inch long dimension of the panel. The forming may take several passes to attain the final 1.25-inch stiffener height. Due to the inherent nature of the duplex incremental sheet forming process, thickness of the formed part will vary with position on the panel. The minimum allowable thickness shall be 0.05 inches.

Acceptance Criteria:

- Successfully form a three hat-stiffened panel using programmed counter rollers and a fixed work piece, without a mandrel.

- The height and contour of the hat stiffeners shall be within +/-0.01 inches of the programmed tool path for the final pass, as measured from the outside surface of the panel.

- The advanced metals forming machine shall be demonstrated to be reconfigurable between the base unit with a spindle and mandrel to a duplex incremental sheet forming configuration and back again.

4.2.3 Programmable CNC Roller Option

The intent of this Option is to automate any manual rollers in the advanced metals forming machine. This Option shall consist of integrating hydraulic actuation and programmable CNC control for any manually adjustable rollers on the advanced metals forming machine. This Option shall enable programmable roller displacement (angular and/or translational) and force capabilities that can be continuously varied over the operating range from zero to the maximum angular or translation position available for the manually adjustable rollers. This Option shall enable programmable slewable rollers to operate at a maximum working speed of at least 90 degrees per minute with a maximum force capability of at least 55 kips. These requirements shall be met concurrently.

Acceptance Test for Option 4.2.3 The intent of this test is to verify the programmability, angular motion ranges, speeds, positioning accuracy and control of rollers not demonstrated in Section 3.1.1. Using a mandrel of the Contractor’s choice, demonstrate the operation of the programmable slewable rollers concurrent with the vertical and radial roller axes by programming and forming a part with multiple radii of curvature, such as a nosecone or a nozzle. Two (2) weeks prior to performing this acceptance test, the Contractor shall provide drawings of the proposed mandrel and expected formed part for concurrence of the Government.

Acceptance Criteria:

- Ability to program and form a part with multiple radii of curvature using programmable slewable rollers.

- Positioning system achieves full range of motion at maximum speeds and maximum forming forces for each slewable roller.

- As a minimum, the angular translation shall be demonstrated to 45 degrees, at an angular speed of 90 degrees per minute under 55 kips force.

4.2.4 Forming Mandrel Option

This Option shall provide the mandrel used for conducting the Preliminary and Final Acceptance Tests for the base unit, as described in Section 3.1.2, as a deliverable.

There are no acceptance tests required for this Option.

5.0 Installation and Verification

The Contractor shall provide the necessary field engineers/technicians and be responsible for shipping, unloading, installing, inspecting, and verifying that all components of the advanced metals forming machine are in good condition and operating properly, at the designated site at Langley Research Center.

6.0 Deliverable Items

The Contractor shall supply the following items at the times indicated. The Contractor shall supply all required drawings, hardware specifications and manuals in English.

6.1 Specifications and Site Requirements

6.1.1 Preliminary Design Drawings

One (1) electronic set of preliminary hardware design drawing shall be delivered within sixty (60) calendar days after time of award, and may be delivered early. These drawing shall include the floor plan, including basic dimensions and weights of the components that make up the advanced metals forming machine and ancillary support hardware and cabinets. These drawing shall also include notation on the locations for associated water, electrical, compressed air, and ventilation requirements. The intent of these drawing is to provide preliminary information to the Government for making decisions on the location and site preparations and allow for minor adjustments to the machine layout and decisions on Options 4.1.1 and 4.1.2 before the hardware designs have been finalized. These documents shall be delivered to the Contracting Officer and to the Contracting Officer Representative (COR) at NASA LaRC.

6.1.2 Final Design Drawings

A minimum of two (2) complete hard copy sets and one (1) complete electronic set of final detailed mechanical, electrical and plumbing drawings and hardware specifications, in English, for the advanced metals forming machine shall be delivered within ninety

(90) calendar days after award. These documents shall include site requirements showing the floor plan and elevations for the location of all system components. These documents shall detail the associated water, electrical, vent utility and floor loading requirements and installation clearances (overhead and side-to-side to enable maneuvering hardware to complete on-site assembly). These documents shall be delivered to the Contracting Officer Representative (COR) at NASA LaRC.

6.2 Documentation

A minimum of two (2) complete hard copy sets and one (1) complete electronic set of manuals, in English, shall be delivered to NASA LaRC within two (2) weeks after the successful completion of the Preliminary Acceptance Tests (see Section 3.1). These manuals shall consist of the following:

6.2.1 Operation/Maintenance Manuals: A minimum of two (2) complete hard copy sets and one (1) complete electronic set of manuals, in English, shall be provided for the entire system. These manuals shall contain detailed operation, maintenance, and trouble-shooting instructions for all system configurations and components. These manuals shall also include electrical wiring diagrams of the advanced metals forming machine and components, as well as schematic diagrams of the components showing the pertinent physical characteristics.

6.2.2 Software Manuals: A minimum of two (2) complete hard copy sets and one (1) complete electronic set of software manuals, in English, shall be included for the entire system. These manuals shall contain detailed operation, maintenance, and trouble-shooting instructions for the software operation of the advanced metals forming machine and attachments.

6.3 Equipment

The complete advanced metals forming machine as described in this SOW shall be delivered within one (1) year after contract award, but not before successful completion of Preliminary Acceptance Tests at the Contractor’s facility, as described in Section 3.1.

The ability to satisfy all of the requirements in the SOW and deliver the equipment in less than this length of time will be considered added value. The Contractor shall provide an estimated shipping arrival date a minimum of one (1) month prior to the arrival of the equipment to allow for site preparations to be finalized prior to the arrival of the advanced metals forming machine.

7.0 Place of Delivery

The Contractor shall deliver the advanced metals forming machine to the following address:

NASA Langley Research Center Attention: Karen Taminger Building 1148, Room 104 Hampton, VA 23681-2199 Phone (757) 864-3131

Documentation, as described in Sections 6.1 and 6.2, shall be forwarded to the NASA LaRC COR.