Atch 1 - T9_Second_TAD_Sting_SOW.pdf

September 6, 2023

STATEMENT OF WORK

FOR

AEDC/WHITE OAK (TUNNEL 9)

Second TAD Sting, Modifications, and Storage

Rev 1

Distribution A Approved for Public Release. Distribution is unlimited.

Per IRA #5351 & AEDC PA#2020-228

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

10905 NEW HAMPSHIRE AVE.

WHITE OAK, MARYLAND 20903-1050

Tunnel 9 Second TAD Sting SOW September 6, 2023

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

Revision Log

Revision Date Description

0 29 June 2023 Initial Release

1 6 September 2023 Removed reference to CAD as an Attachment – CAD STEP files will be delivered after contract is signed.

Removed quantity 0 items from Table 1.

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

1. SCOPE

1.1. This Statement of Work (SOW) is for a second Tetra Adjustable Dogleg (TAD) Sting required at Arnold Engineering Development Complex’s (AEDC) Hypervelocity Wind

Tunnel No. 9 Facility, hereafter referred to as AEDC White Oak, located in White Oak, MD. AEDC White Oak has one TAD Sting manufactured in 2014 and uses it enough that we require an identical, interchangeable second TAD Sting. This second sting must be machined per the supplied STEP file so that it is identical as well as machining from so

2D drawings of additional accessories or modifications. Note that not every item in the

STEP file is to be manufactured, please see details below for which items to include.

1.2. However, before fabricating the sting, a set of custom washers must be designed to work with the existing & second TAD Sting. Also, before fabrication, all redlines of drawings need to be implemented in the CAD (if required) or on the drawing. Note:

AEDC White Oak does not have the electronic drawing files, therefore the contractor must recreate all drawing from the step files to include the unmarked & redlined dimensions, tolerances, and notes.

1.3. Third, a mobile storage solution for both the current TAD Sting (including all pieces not made as part of the second sting) as well as storage for the second TAD sting pieces.

1.4. The contractor shall design and fabricate the custom washers, shoulder bolts, all required items for the second sting, and the storage solutions per the requirements in this SOW and in the supplied drawings. There are also requirements for additional hardware (spare screws).

1.5. There will be a multi-day on-site (at contractor) acceptance of the parts to verify the fabrication and performance of the sting and storage solution. After acceptance, the contractor shall then ship all items safely in wooden crates to AEDC White Oak.

2. APPLICABLE DOCUMENTS

2.1. The following documents are attached to this SOW and referenced throughout this

SOW in defining the design requirements:

Appendix A Redlined drawing of original 1250005-1000 top assembly

Appendix B Redlined drawing of original 1250005-1001 balance adapters

Appendix C Redlined drawing of original 1250005-1002 yaw block items

Appendix D Redlined drawing of original 1250005-1003 arc sector items

Appendix E Redlined drawing of original 1250005-1004 arc sector support

Appendix F Drawing of original 1250005-1005 sting base modifications

Appendix G Redlined drawing of original 90-1051 sting base

Appendix H Drawing of Fairing 89-1034

Appendix I Drawing of NLTC Sector Head Bow Fairing 20-1090

Appendix J Drawing of Roll Adjust Ring 04-1018

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

Appendix K Drawing of Coral Shim 10-1033

Appendix L Plug drawings, 14-1032

Appendix M Pin Pullers, 20-1054

Appendix N Model Stress Report Requirements

3. CLIN 1: Custom Washers

3.1. Overview and general description

3.1.1. In the Yaw Block, there are 6x ½-20 screws that prevent the Yaw Block from rotating once the yaw angle has been set. The screw heads only contact the counterbored slots on the two sides of the slot. There is not enough bearing surface between the screwhead and counterbore surfaces and the Yaw Block would be yielding under the necessary screw preload torque. Because of this, the

Yaw Block cannot support the originally intended loads for the TAD Sting. For now, we have backed off on the preload torque and down rated the sting’s capability.

However, by designing a custom washer that fits in the slot & still allows enough room for ±5° yawing, there can be more bearing area and the Yaw Block will not yield under the screw when the screws are preloaded to the torque required. This will then allow the TAD Sting to support the original loads required.

3.2. Detail Requirements

3.2.1. The washer (estimated 2 different designs required) must fit in the existing 6

Yaw Block slots (detail AF & AG of Appendix C) and allow the full range of ±5° yawing. If the slots must be modified to achieve this, then there will be the additional requirement to modify the existing Yaw Block of the current TAD Sting and must be done as part of this contract/SOW.

3.2.2. The ID of the washer must be Ø 0.516” or smaller.

3.2.3. The washer must be 0.250” thick.

3.2.4. The washer must be made from SS 15-5PH H 1025.

3.2.5. The final design must be approved by AEDC White Oak before fabrication.

3.2.6. 5 sets of 6 washers (30 washers total) must be fabricated, inspected, and delivered as part of this contract to be used on the current and second TAD Sting.

3.2.7. New screws will be required. Currently the screw is a ½-20x2.75” Holo-Krome

SHCS. Since the washer will be ¼” thick, these screws will need to be replaced on the current sting as well as the second sting. Therefore, this contract will require that (for both current and second stings) a total of 75 (seventy-five) ½-20x3”

Unbrako SHCS as part of this contract.

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

4. CLIN 2: Update Drawings and Other Design Changes

4.1. Revise all drawings per redlines (Appendix A through Appendix G).

4.2. Revise all drawings to have the following statement on each sheet:

Distribution A

Approved for Public Release. Distribution is unlimited.

Per IRA #1377 & AEDC PA#2014-180

4.3. Since AEDC White Oak does not have the original CAD files (except for Creo files for

Appendix G), the contractor will need to recreate the drawings in their CAD program from the STEP files (shipped after vendor is on contract). Note: drawings must contain all parts, including those not made as part of the second sting fabrication.

4.4. Create drawings for Taper Gauges, 12550005-9003-1-03 & -05 (STEP files shipped after vendor is on contract).

4.5. Implement all redline changes in the drawing (and STEP files as required) before starting fabrication of any parts.

4.6. Part number 1004-11 & 1004-13 must also me redesigned slightly to allow for the easy removal (pull forward) of the fairing on the arc sector support. Three sets of these redesigned fairings must be fabricated as part of the contract.

5. CLIN 3: Second TAD Sting Fabrication

5.1. Overview and general description

5.1.1. AEDC White Oak requires a second TAD Sting that is comprised of less parts than the original TAD sting. We do not require the 45° arc sector, less arc sector covers, the 1.5 MK balance adapter, nor the sliding supports. There are also some items that may have quantities listed below that are more than what is needed for a single TAD Sting – these are intentional spares needed for both the current and second sting. There is also the requirement to fabricate a new Sting Base (with some fairings and other pieces). There are also a few additional items such as plugs, pin puller tips, and custom Unbrako shoulder bolts.

5.2. Details Requirements

5.2.1. For the second sting fabrication, make the following items only (after completing design modifications specified in CLIN 1 and CLIN 2. Note the project number

(12550005) has been dropped from the drawing list below for clarity.

Drawing Dash Number Description Quantity Needed

1001 -05 MC 30H Balance Adapter 1

1001 -09 Level Plate for MC 30H B.A. 1

1001 -11 Balance Roll Pin 18

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1002 -03 Sting Draw Nut 1

1002 -05 Yaw Block 1

1002 -07 Yaw Gear 1

1002 -09 Year Gear Block 1

1002 -11 Wire Cover 1 1

1002 -13 Wire Cover 2 1

1002 -15 Wire Cover 3 3

1002 -17 Yaw Base Plate 1

1002 -19 Wire Cover 4 1

1002 -21 Hex Nut Spanner Wrench 1

1002 -23 Swivel Hoist Ring 1

1002 -25 #10-32 SHCS Captive Screw 50

1003 -03 Arc Sector Baseline (25°) 1

1003 -07 Arc Sector Cover Mid 1 5

1003 -09 Arc Sector Cover Mid 2 2

1003 -19 Arc Sector Wire Cover 1 1

1003 -21 Arc Sector Wire Cover 2 1

1003 -23 Arc Sector Bottom Cover 2

1004 -03 Arc Sector Support 1

1004 -09 Level Plate for Arc Sector Support 1

1004 -11 Upper Fairing 3

1004 -13 Lower Fairing 3

1004 -19 1/4-28 Captive Screw x .75L 50

1004 -21 Washer 25

1004 -23 Hex Nut 5/8-11 25

1005 -03 Sting Base Modification 1

1005 -05 Sting Base Cover 1

1005 -07 Leveling Plate for Sting Base 1

1005 -09 Rotating Support Shim 3

Table 1 Detail quantities of parts required of original TAD Sting.

5.2.2. All new items fabricated must be etched/stamped/engraved with the part number, revision, and a “#2” so that this matched set of TAD Sting parts can be identified separate of the current TAD Sting.

5.2.3. Note: for 1001-05 Balance Adapter and 1002-05 Yaw Block, there are taper gauges to use to verify fit. These will be sent from AEDC White Oak when requested.

5.2.4. Note: some of the items are level plates and need to be installed, then inspected to the correct features for misalignment, then skim cut until the angular tolerance of the leveling plate when compared to the Pitch and Roll axis shall be a maximum of ±0.050 deg, and then reinspected to find the as-built misalignment. These numbers must be reported in the inspection documentation.

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

5.2.5. Note: Unless specified as Unbrako screws, all other screws are to be Holo-Krome.

5.2.6. There are also some additional parts that need to be fabricated that were not part of the original TAD Sting.

5.2.6.1. The first is the Sting Base – this was originally sent out for modification

(1005-03). However, this time we need a second Sting Base fabricated based on the 90-1051 drawing (Appendix G) with the modifications shown in 1005-

03.

5.2.6.2. Associated with the Sting Base are two fairings, a roll ring, and a coral shim (Appendix H through Appendix K). CAD files for these items are available if desired.

5.2.6.3. Another addition to the TAD sting is plugs for some of the Arc Sector’s holes (Appendix L). CAD files for these items are available if desired.

5.2.6.4. As mentioned in 3.2.7, 75 (seventy-five) 1/2-20x3” Unbrako SHCS are required for the new washers.

5.2.6.5. There are 3 Pin Puller Adapters that are needed (Appendix M). CAD files for these items are available if desired.

5.2.6.6. Lastly, there are the custom Unbrako shoulder bolts (added to drawing

1003 sheet 3, Appendix D).

Part Number Description Quantity Needed

90-1051 Sting Base (38”) 1

89-1034-1 Fairing (6.510 ID) 1

20-1090-1 Sector Head Bow Fairing, Standard 2

04-1018-3 Roll Adjust Ring (120° arc, 6.5 ID) 1

10-1033-01 Shim, Sting Base, Coral 2

14-1032-1 Plug, Counterbored 10

14-1032-2 Plug, Round 8

14-1032-3 Plug, D (flat cut) 2 n/a ½-20x3” Unbrako SHCS 75

20-1054-01 Pin Puller, 8-32UNC 2

20-1054-02 Pin Puller, 10-32UNF 2

20-1054-03 Pin Puller, 1/4-20UNC 4

1003-25? Custom Unbrako Shoulder Bolt 50

Table 2 Detail quantities of additional parts needed for second TAD Sting.

5.2.6.7. These new pieces must also be marked “#2” like the TAD Sting pieces.

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

6. CLIN 4: Inspection Requirements

6.1. Overview and general description

6.1.1. At the contractor’s site, the TAD sting needs to be assembled and inspected and then reassembled into other dogleg positions and inspected again. It is suggested that the Sting Base be clamped to a very heavy table and then the TAD Sting be assembled cantilevered from this position. With the use of a chain fall or similar lifting mechanism, the sting can be assembled and the offset dog angle set (7.5° to

25°). Part of the acceptance (buyoff) will be to adjust the angles and measure repeatability to accuracies of ±0.005° or better. The Sliding Support Brackets

(1004-05 & -08) can be sent to the contractor for use during this inspection.

6.2. Inspection Requirements

6.2.1. Before parts are made, copies of material certifications are required. These material certifications will be part of the inspection report package.

6.2.2. Once each part is made, it needs to be inspected to verify it meets dimensions and tolerances. These part inspection reports will also be part of the inspection report package.

6.2.3. Tapers will be inspected with dye to ensure over 90% mating to the gauge.

Photographs of the dye will be taken as part of the inspection report package.

6.2.4. The TAD Sting will be assembled in the 15° setup and the yaw will be zeroed out using the yaw fine adjustment screws.

6.2.5. The yaw accuracy of the Balance Adapter will be measured in each yaw position

(-5°, -4°, -3°, -2°, -1°, 0°, +1°, +2°, +3°, +4°, and +5°). Additional repeatability measurements will be taken 2 (two) more times at each of -5°, 0°, and +5°. The yaw angle between the starting (zeroed) position and each of these positions must be measured to ±0.005° or better. This is preferred to be performed during acceptance. This data will be part of the inspection report package.

6.2.6. The yaw will be set back to 0° and the pitch offset dogleg angle of the Balance

Adapter will be measured. The offset angle accuracy will be measured in each blade assembly position (7.5°, 10°, 12.5°, 15°, 17.5°, 20°, 22.5°, and 25°).

Additional repeatability measurements will be taken 2 (two) more times at each of

15° and 25°. The offset angle between the Sting Base centerline and each of these positions must be measured to ±0.005° or better. This is preferred to be performed during acceptance. This data will be part of the inspection report package.

6.2.7. The offset will be set back to 15°. Then the roll at the Sting base will be measured by using the side of the Arc Sector. The accuracy between 0°, 90°, 180°, and 270° will be measured. Additional repeatability measurements will be taken 2

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

(two) more times at each of 0° and 180°. This is preferred to be performed during acceptance. This data will be part of the inspection report package.

7. CLIN 5: Storage Solutions

7.1. Overview and general description

7.1.1. The TAD Stings (both current hardware and second sting) require a storage solution when not in use. AEDC White Oak would like two or three wheeled carts that the hardware can be hung on and wheeled over to a crane to lift the hardware off (those items over 50lbs.). We would like to store the TAD Sting (from Arc

Sector Support to Balance Adapter, when in the 15° configuration, i.e., no Sting

Base) in the upright position (as shown in zone E8 of sheet 3 of the 1000 drawing).

We would like the Sting Base stored over the TAD Sting. Other Balance Adapters (6 of them), the 45° Arc Sector, covers, level plates, and miscellaneous hardware must also have storage locations.

7.1.2. We encourage a novel design from the contractor, however, as a starting point to convey design intent, we suggest the following. Start with a steal tube structure that has a cross section shape of an upside-down T. The vertical of the T would have forklift-like forks coming off it that would support the sting, Balance Adapter, Sting Base, etc. on both sides. Near the bottom could be a couple drawers for the small parts. The base would be big enough to prevent tipping. Non-inflatable tires under the base (need to roll on concrete with no obstacles on floor).

7.1.3. Several design reviews will need to be held until the final design is approved for fabrication.

7.1.4. A stress report will be required showing that there are Factors of Safety above 3 on Ultimate Stress & 2 on Yield Stress (refer to as the “3/2 requirement”) as detailed in Appendix N. See also the bolt analysis required in the stress report requirements.

7.1.5. The storage solutions must be rust-proof & otherwise non-degrading for 30 years, either using stainless steel, aluminum, or for structural steel utilizing painting/powder coating alloy or other metal surfaces to inhibit corrosion.

Distribution A: Approved for Public Release. Distribution is unlimited. Per IRA #5351 & AEDC PA#2020-228

8. Shipment

8.1. All parts must be safely crated for shipment to AEDC White Oak. Note that EMI shielding is not required for these items.

8.2. The contract includes all shipping costs to deliver the items to AEDC White Oak.

8.3. Ship to:

Will Vodra

AEDC White Oak, Bldg. 405

10905 New Hampshire Avenue

Silver Spring, MD 20903

9. Schedule

9.1. The contractor shall develop and present a complete project schedule including major milestones. Design periods, fabrication periods, progress milestones, and delivery dates are to be included. Meetings to review the design at various stages to identify/correct deficiencies, address manufacturing issues, review cost and schedule will be held.

9.2. Delivery on-stie must be No Later Than Tuesday April 30, 2024.

10. Acceptance and Submittals

10.1. The Government will accept the second TAD sting, modifications, and storage solutions during an acceptance/buyoff at the contractor’s site prior to shipment to

AEDC White Oak. At that time, review of required submittals below will also be reviewed to determine if they are also acceptable.

10.2. The contractor shall submit all documentation in accordance with Table 3.

No. Submittal Description Due

1 Detail Schedule 1 week before Kick-off meeting

2 Preliminary CAD Files 2 weeks before PDR

3 Draft stress report 2 weeks before PDR

4 Final CAD & 2D drawings 2 weeks before CDR

5 Final stress report 2 weeks before CDR

6 CD with as-built CAD, drawings, stress report, inspection reports, material certifications.

Delivery

Table 3 Required Submittal List

108 will be 3"L

Need to modify.

See 1003 drawing

Verify that all quantities are correct, all items on drawings 1001-1005 are shown on this drawing and are in the BOM and verify all quantities are correct.

Torque to 95 FT-LBS

2x 102 & 2x 104 Torque to 20 FT-LBS

2x 102?

Torque to 20 FT-LBS

This page needs correct callouts of which covers are used & how many needed for each configuration.

Will be 3"L

Torque to 45 FT-LBS

Torque to 90 FT-LBS Torque to 30 IN-LBS

Torque to 20 IN-LBS

Also show 10x 105.

Torque to 40 FT-LBS

Torque to 95 FT-LBS

4x plugs (need to add to BOM) 1x partial plug (need to add to BOM) 1/4-20 screw x ?length? (need to add to BOM) Torque to 30 IN-LBS May want to show in another view from far side.

This page needs correct callouts of which covers are used & how many needed for each configuration.

12550005-9001-05

2A

SS PH 13-8 Mo

H1050, AMS 5629

12550005-9001-05

2A

DIA 0.390 +0/-.0002

UNBRAKO ALLOY

STEEL

12550005-9001-03

MAKE FROM UNBRAKO ALLOY STEEL

ASTM A574 MIN ULT=190KSI

Do NOT make this machining error on the second sting. Revise drawing to remove this in Rev E.

Need drawing of custom shoulder bolt Need Chamfer 45deg x .13

Move Note 6 from 1000 drawing to here.

Note these need to be inspected - there is a tighter tolerance on the shoulder bolt size than Unbrako manufactures these to. Therefore you need to buy more than required in order to get enough that pass inspection.

11.977

3.937

7.687

R41.505

FARSIDE

INSTALL

KEENSERT

(KNHL0832J)

EXTENDING 0.250"

DEPARTMENT OF THE AIR FORCE

WHITE OAK DETACHMENT, SILVER SPRING, MD 20903

A

B

C

D

TITLE

DWG NO.

SCALE: RELEASE DATE: SHEET OF

REVSIZE

INTERPRET DRAWING IN ACCORDANCE

WITH ASME Y14.100-2000

DO NOT SCALE THIS DRAWING

DESIGN:

CHECKED:

DRAWN:

MAJOR SYSTEM:

DATE

REVISIONS

ZONE LTR DESCRIPTION DATE APPROVED

APPLICATION

NEXT ASSY SYSTEM

SYSTEM ENGINEER: DATE

UNLESS OTHERWISE SPECIFIED:

DIMENSIONSARE IN INCHES

TOLERANCES

DECIMAL ANGULAR

.XX �#�

.XXX �#�

Heater System Only

Test Cell Only Diaphragm & Nozzle System Only Nitrogen & Driver Vessel System Only

Vacuum System Only

.951

.740

1.000

.375

.438

THRU.266

.312

45�$� X

3 PLCS.

.020

.951

.500 .375

45�$� X

3 PLCS.

.020

(AS REQUIRED

AT ASSEMBLY LEVEL)

.200

3 3

1102/12/152.000

A14-1032

PLUG, BLADE HOLE

THREADED-HOLE KEYED

MODEL SUPPORT14-1001

PARULSKI06/15/23ORIGINAL PRO/E DRAWING/RELEASE PER DRR-23-10027XO-

VODRA 02/12/15

VODRA 02/12/15

HACKETT 02/12/15

KEFAUVER 02/12/15

MODEL SUPPORT

REMOVE BURRS AND SHARP EDGES

.010 R OR CHAMFER MAX

INSIDE CORNERS .005 R MAX

SURFACE ROUGHNESS: 125

0.010

0.50.06

"PRELIMINARY"

REFERENCE ONLY

NOT FOR MANUFACTURING

Different sized statement boxes (stamps) are availble in Intralink / Library / Formats / DISTRIBUTION_STATEMENTS.DRW That file also contains directions for entering dates & other information.

DISTRIBUTION STATEMENT A

Approved for public release; distribution is unlimited.

(IRA #3782 & AEDC PA #2018-103)

NOT SENSITIVE

Approved for public release;

distribution is unlimited.

DISTRIBUTION STATEMENT E

Distribution authorized to DOD components only; Administrative or Operational use.

14 Mar 2018. Other requests for this document shall be referred to AEDC/TSTT

AEDC White Oak, 10905 New Hampshire Ave, Silver Spring, MD 20903-1050.

(AEDC IRA #3782)

(IRA #3357 & AEDC PA #2017-212)

Distribution authorized to DOD components only; Critical Technology;

Export Controlled; 15 Aug 2017. Refer other requests for this document to AEDC/TSTT, 10905 New Hampshire Ave, Silver Spring, MD 20903-1050. (Phone #301-394-1750)

(AEDC IRA #3366)

(IRA #3367 & AEDC PA #2017-221)

EXPORT CONTROL WARNING

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq), as amended.

Violations of these export laws are subject to severe criminal penalties.

Disseminate in accordance with provisions of DoD Directive 5230.25

DESTRUCTION NOTICE

Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

(IRA #3768 & AEDC PA #2018-138)

(IRA #3738 & AEDC PA #2018-073)

01 Dec 2017. Other requests for this document shall be referred to AEDC/TSTT

(AEDC IRA #3738)

SECTION A-A

PN: 14-1032-1

PN: 14-1032-2

1/4-20 UNC - 2B TAP THRU

#7 DRILL ( 0.201 ) THRU -( 1 ) HOLE

PN: 14-1032-3

SAME AS 14-1032-2 EXCEPT DIMENESION SHOWN

NOTES:

1. MATERIAL: ALUMINUM 6061-T6

2. WEIGHT: 0.05 LBS.

3. STAMP OR ENGRAVE WITH: PART NUMBER AND REV LETTER

Sheet 1

Views

VIEW_TEMPLATE_1

top_2 new_view_3 top_4 new_view_5 top_6

SCALE: RELEASE DATE: SHEET OF

REVSIZE

MAJOR SYSTEM:

APPLICATION

NEXT ASSY SYSTEM

Test Cell Only Diaphragm & Nozzle System Only Nitrogen & Driver Vessel System Only

1.000

.500

SD

SL

L

.270

45.00�$�

3/8-24 UNF-2B X �x� 0.875

No.8(.164)-32 UNC-2B X �x� .430

10-32 UNF-2B x �x�.375 �n� .200 THRU

1/4-20 UNC-2B X �x� 0.375 �n�.260 THRU

1106/03/202.000

A20-1054

PIN PULLER ADAPTER

THREADED

TAD STING

MODEL SUPPORT20-1039

PARULSKI06/15/23ORIGINAL PRO/E DRAWING/RELEASE PER DRR-23-10027A-

VODRA 06/03/20

HACKETT 06/03/20

.010 R OR CHAMFER MAX

INSIDE CORNERS .005 R MAX

0.010

0.50.06

PART NO.DESC2DWG_NOLSDSLTHRD_NO_1-4THRD_NO_6THRD_NO_10

20-1054-018-32UNC20-1054-012.250.250.860NYN

20-1054-0210-32 UNF20-1054-021.480.370.350NNY

20-1054-031/4-20UNC20-1054-031.480.430.475YNN

SECTION X-X

STAMP PER "DESC2"

& PART NO. SEE TABLE

-01

SCALE 1.000

-02

-03

1. MATERIAL: STEEL, STAINLESS

2. WEIGHT: 0.09 LBS.

Sheet 1

Views

VIEW_TEMPLATE_1

top_2 new_view_3 new_view_4 new_view_5

12345678

12345678

D D

AMAJOR SYSTEM:

SIZE

SCALE: RELEASE DATE: SHEET OFAPPLICATION

SYSTEMNEXT ASSY

REV

Test Cell Only Diaphragm & Nozzle System Only

Nitrogen & Driver Vessel System Only

2X 15.0�$�

3.250

3.50

1.53

1.375

1.60

2X 45�$� X .10

FL

R FD

9.440 .002

R SB

.550

1.440

2.000

20.0�$�

R MAX

ROUND NOT

REQUIRED

SHARP ALLOWED

.125

( )6.04

( )6.1

1/2-13 UNC-2B THRU

2 X NEAR SIDE

2 X FAR SIDE

MODEL SUPPORT87-F-1057

0.005

0.50.03

VODRA12/15/20ORIGINAL PRO/E DRAWING/RELEASE PER DRR-20-10031A-

1112/15/201.000

A20-1090

NLTC SECTOR HEAD

BOW FAIRING

VODRA 12/15/20

HACKETT 12/15/20

.010 R OR CHAMFER MAXIMUM

INSIDE CORNERS .010 R MAXIMUM

PART NUMBERFDFLSBTEXT

20-1090-15.0402.9503.340STANDARD

20-1090-25.0402.9503.440FOR 05-1043 STING BASES

20-1090-35.6624.0503.320FOR 74-2373 FAIRING

R .030

ENTIRE EDGE

SECTION H-H

(CONICAL)

(CYLINDRICAL)

1. MATERIAL: ALUMINUM 6061-T6

2. WEIGHT: 3.46 LBS.

STAMP OR ETCH:

PART NUMBER, REV LETTER, AND "TEXT"

1/8 CHARACTER HIGH

Sheet 1

Views

VIEW_TEMPLATE_1

right_2 left_3 top_4 bottom_5 bottom_6 new_view_7

1289969760E

Rectangle

Oval

Oval

Text Box

Revise - remove these flats.

MODEL STRESS REPORT REQUIREMENTS – ADDENDUM

(file: common\metzger\model work\model reporting addendum – rev-4.doc)

Date:4/28/2008

This is an addendum to the "Wind Tunnel Model Criteria and Model Report

Requirements Document" (NSWC MP 90-254). The information below is intended to supplement that document and make clear the optimum format to follow to permit the most efficient review and approval of Wind Tunnel test model systems to be operated in AEDC

Tunnel 9.

MANDATORY REPORT SECTIONS

The Model Stress Report must now have the following Mandatory Sections/Elements and

Formatting:

a) Report shall be bound, 8.5 x 11, except drawings can be larger (11 x 17 is typical)

b) Title Page, to include: Title, Date, Author, Phone/Fax number, Company.

c) Table of Contents -- keyed to page numbers.

d) Report pages for following sections to be logically and uniquely numbered.

e) Introduction Section.

f) Summary Section.

g) Design Loads Section.

h) Analysis Section.

i) Material Properties Section.

j) Assembly/Part Drawing Section.

k) Additional Sections/Appendices as needed

Section Descriptions

The section descriptions are as follows. The Introduction Section should include background information about the test and any highlights relative to the analysis. The

Summary Section should summarize the results of the analysis. Any special test considerations and any sub-standard Factors of Safety requiring special consideration should be mentioned here.

Also, if all Factors and Margins of Safety meet the rules given below, state so here. The Design

Loads Section should include the worst case running loads to be imposed on the model. These loads will be referred to in the Analysis Section. The Analysis Section will usually represent the bulk of the report. Here the various model components are analyzed using the loads from the

Design Loads Section. A more detailed description of this section is given below. The

Material Properties Section includes all material properties that require corrections and adjustments for temperature or other environmental effects. The adjustments are shown in this section. The Drawing Section includes a full set of drawings for the test configuration being analyzed. Additional Sections or Appendices can be included as required. The Appendices can be page numbered separately from the body of the report, if the appendix prefix is used (e.g.

page "A-3").

ANALYSIS SECTION DESCRIPTION

1. Every component analyzed in the assembly must be treated in the analysis section as follows:

- Reference the drawing/part number of the component being analyzed. This number must be the drawing/part number used on the assembly drawing.

- Provide sufficient narrative to indicate what the part is, why it is being analyzed, and how it is to be analyzed. Include any appropriate assumptions and idealizations required.

- Make sure all significant loads, reactions, pressure, and thermal effects acting on the part are accounted for.

- Loads that are deemed not significant should be so stated, and in cases where it is not obvious, state the rationale for why the load or reaction can be ignored.

- Account for all effects of operating temperature or other environmental factors. In particular, the material properties should be degraded for temperature appropriately.

- Material properties that do not require modification for temperature or other environmental effects do not have to appear in the Material Properties Section.

However, the source that the properties were obtained from must be referenced in this Analysis Section at the point where the properties are first introduced.

- All calculations for a given component in the analysis section will normally terminate in one or more "Factor-of-Safety" or "Margin-of-Safety" values. These

Factors are defined below. Except in unusual cases, all structural calculations for a component shall terminate in one of these Factors.

Factor-of-Safety Defined

The Factor of Safety is a calculated quantity based on an estimated "worst case" condition and is defined as:

Factor of Safety, FS = defined failure condition estimate of actual "worst case" condition

The "defined failure condition" in the above equation is a value such as a yield stress or buckling force or critical deflection or temperature, etc., that constitutes failure of the structure. The "worst case condition" in the above equation is an estimate of the actual stress level (or force or temperature or deflection, etc.) that occurs in the component when the estimated harshest loading, which the structure will ever be subjected to in service, is applied. An FS value substantially greater than "1.0" provides for adequate separation between the failure condition and worst case condition and is necessary because the estimates of these conditions have some degree of uncertainty. The minimum allowable Factor-of-Safety values for model hardware for

AEDC's Tunnel 9, are given below.

Margin-of-Safety Defined

A Margin of Safety (MS) is defined as:

Margin of Safety, MS = ( defined allowable condition - 1.0 ) estimate of actual worst case condition

The "allowable" condition does NOT constitute a failure condition, but rather is a maximum safe condition. The "allowable" includes an implicit factor of safety which provides the necessary separation from the failure condition. A positive (or zero) MS value indicates that a stress, or force or temperature or deflection, etc., does not exceed the allowable condition. A negative MS indicates the stress, or force or temperature, etc., exceeds the allowable condition. By its definition an Margin of Safety is acceptable if it is positive (or zero) and unacceptable if it is negative. Margins of Safety will typically be applied to commercial parts that have a manufacturer's maximum safe load rating.

Summary of Factor of Safety and Margin of Safety Use

A Factor of Safety should be computed whenever the limiting condition is a failure condition (such as a yield or ultimate strength, buckling or collapse load, etc.). Minimum acceptable values for Factor of Safety are given below.

A Margin of Safety should be computed whenever the limiting condition is an allowable condition (such as a design allowable stress specified in a welding or pressure vessel code, or a working load rating of a commercial component).

Minimum Permissible Factors of Safety for Wind Tunnel Model and Model Support Hardware

For Ductile Materials (Defined as Charpy Strength > 12.0 ft-lbs at Use Temperature)

FS min > 2.0 based on yield strength (based on stress or strain whichever is more appropriate) at operating temperature.

Loading based on Tunnel 9 running loads.

FS min > 3.0 based on ultimate (based on stress or strain whichever is more appropriate) strength at operating temperature.

Loading based on Tunnel 9 running loads.

The criteria above is known as the "3/2 Rule". Both criteria given above must be satisfied.

Either the Von-Mises or the Tresca stress must be used to compute the FS values, or if more appropriate a strain based measure may be used. Margins of Safety can be calculated instead of

Factors of Safety, if the following allowable is used (strain measures may be used instead of stress if more appropriate):

Max. Allowable Design Stress = σyield/2 or σult./3 whichever is lower

(Von Mises or Tresca)

4. The above Factors of Safety are to be based on estimated maximum running loads, and not on "blockage" or other anomalous loading conditions. The 3/2 Rule accounts for the fact that loads greater than running loads could occur in case of a flow breakdown.

5. For cases where shear loadings are used, in lieu of other material data, the shear yield strength for ductile materials shall be taken as 1/2 the uniaxial tensile yield strength, and the ultimate shear strength shall be taken as 1/2 the uniaxial ultimate tensile strength, at the operating temperature.

6. The overall applied loads must be compared to the load limits of the Tunnel 9 Sector

Blade for all pertinent combinations of loading (e.g. Lift, Drag, Yaw Loads and Moment

Component combinations)

7. A sting “Divergence” calculation must be performed for the worst cases and must at a minimum include both a pitch plane loading condition and a side (Yaw) loading condition. NOTE: The side loading condition must include the contribution of the effect of the torsional compliance (i.e. twisting along the vertical axis of the blade) of the sector blade. This must be done regardless of whether or not there are side loads expected to be present in the actual test, unless side load induced displacements are computed instead and found to be within safe limits.

8. Some major components in the assembly may be deemed to not require analysis, due to negligible applied loading, or for other reasons. For completeness, all such components or groups of components should be identified as not requiring analysis, and the reasons why so stated. This will assure the reviewers that the components that are not specifically analyzed were at least considered and not simply overlooked.

9. Materials having a Charpy Impact Strength less than 12.0 Ft-lbs, after heat treatment and at the intended use temperature, are PROHIBITED from use in critical model support, model and sting structural, and pressure containment hardware.

10. Brittle materials (other than Glass -- see below for glass): The above "3/2" rule does not apply in this case. For these materials no specific acceptance criteria is given. It is the responsibility of the Designer to use sound criteria based on manufacturer's requirements and sound engineering judgement, considering the specific type of material and its specific use.

11. Glass (schlieren or other annealed glass): Maximum Allowable Tensile Stress < 500 psi

12. Materials not covered in this section. The designer is responsible to identify and use manufacturing guidelines or industry-standard safe design philosophy for the particular material in question.

13. Particle Impact Analysis: In certain cases a model may be susceptible damage due to high-speed particle impacts from the Tunnel flow. In these cases an analysis of the worst case impact should be discussed with countermeasures applied were appropriate.

- The Following Material is optional -

Bolted Joints: Mechanical connections which use bolts or screws to secure the joint shall comply with the following rules:

The design and use of the joint shall comply with applicable industry standards. When a commercial part is used in the joint, the manufacturer's specifications for use of the commercial part shall be followed and shall take precedence over requirements given in this section.

Except where otherwise noted, the Factors-of-Safety and Margins-of-Safety associated with the joint shall not be less than the minimum allowable factors and margins of safety given above. The stress report shall include Factor-of-Safety or Margin-of-Safety values for the following "Joint Parameters":

1. Axial tensile force in the bolt.

2. Axial pull-out of threads, based on average shear in the threads. Use the following formula to compute average shear:

τave = F or, τave = F π*db*lt π*dmin*lt where:

τave = average shear stress

F = Tensile force in bolt lt = length of thread engagement into parent material db/dmin = bolt major diameter for shear of parent material / bolt minor diameter for shear of bolt material

3. Average bearing stress in the flange material, at the bolt-head (or washer)/flange interface.

4. Shear-out of the flange material under the bolt head due to loading parallel to the bolt axis. Use the formula in (3) above and replace "d" with the appropriate diameter (e.g. the bolt head diameter).

5. Shear load in the bolt shank due to loading transverse to the bolt axis, if applicable.

6. Average bearing stress in bolt shank or flange, whichever is critical, due to loading transverse to bolt axis.

7. Transverse shear-out of flange material by bolt shank due to loading transverse to the bolt axis.

Normally a torque is applied to each bolt to develop a preload in the bolt prior to applying service loads. The preload is calculated to preclude separation of the joint in service and also to increase fatigue life of the bolt. The joint analysis should calculate and specify the required preload for each bolt in joints considered critical to the Model safety and operation.

Shear pins, keys, or centering diameters shall normally be used to take all shear loads in the joint. Joint Friction and shanks of bolts used to connect the joint shall normally not be used to take shear loads in the joint. Use of these latter shear reaction mechanisms requires pre-approval by AEDC.

In analyzing Joint Parameters 1 and 3 above (i.e. the Axial Tensile Force in the bolt and the Average Bearing Stress in the flange material at the bolt-head/washer/flange interface) there are two key tensile bolt forces to regard. The first is the Basic Bolt Force, FB , which is the tensile force that would occur in the highest loaded bolt in the joint if the preloads in all the bolts were zero and the externally applied loads were acting. Although a joint is not normally operated with zero preload in the bolts, the Basic Bolt Force calculated in this way, when compared to the tensile strength of the bolts, gives a measure of the gross load carrying capability of the joint.

The second force is the Maximum Axial Bolt Tensile Force, Fm , which is the maximum force that occurs in a bolt in service, and is equal to the bolt preload plus a fraction of the external load applied to the joint. The fraction of the applied load that the bolt sees in service is based on a "Bolt Load Sharing Factor", C, which is that fraction of the applied load that the bolt sees. C is a function of the joint design and is calculated using standard techniques given in machine design books.

The minimum Factors of Safety for the Basic Bolt Force, FB, and Maximum Axial Bolt

Tensile Force, Fm, are as follows:

Basic Bolt Force, FB:

The Basic Bolt Force, FB, shall not exceed the lesser of one half of the proof strength, Fproof, and one third of the ultimate tensile strength, Fu, and one half of the per-bolt net bearing area, AB , (under the head) times the bearing yield stress, SBY , of the bolt or flange material, at operating temperature, whichever is less, i.e.:

A S and

F and

BBYuproof

B ≤

Maximum Axial Bolt Tensile Force, Fm:

Bolt preloads can be a significant percentage of the bolt tensile yield strength and still provide safe service, so long as the Basic Bolt Force, FB , meets the 3/2 rule. For this reason the maximum allowable axial tensile force in the bolt, Fm-allowed, shall not exceed 90 percent of the proof strength, Fproof . In lieu of a manufacturer's specification for the proof strength, the proof strength shall be taken as 85 percent of the specified yield strength, Sy , multiplied by the stress area, Astress , of the bolt:

spec.)manf. oflieu (inAS.85=F

F.90= F stressyproof proofallowed-m

The maximum allowable bearing stress under each bolt head shall not exceed 90 percent of the bearing yield stress for the bolt head, washers (if any), and flange:

S.90= S BYallowed-B

Factors of Safety Minimums for Other Joint Parameters:

Regarding Safety Factors for the other joint parameters given above, except as note above, they should be based on the Basic Bolt Force, FB , and the "3/2" rule used. The single shear load strength of a bolt shall be assumed to be 50 percent of the corresponding axial strength. For joints for which any combination of simultaneously applied axial, moment, shear, and twisting loadings will occur in service, the effect on the joint strength of the simultaneously applied loads shall be accounted for.

Critical Joints

Critical Joints are those joints, the failure of which could reasonably result in unacceptable damage to the tunnel facility or the failure will result in such severe damage to the model or support systems that the test entry will be prematurely terminated. For these critical joints the bolts used in the joints shall be "certified" as to their grade. Certification is defined as any of the following:

- The bolts are delivered to the project engineer or model assembly technicians in a un-broken factory-sealed container.

- The bolts delivered are traceable to a specific manufacturer and grade of bolt.

- The bolts are otherwise certified as to their grade through standing certification procedures that have been approved by AEDC.

Automated Bolted Joint Design Aids Available

AEDC White Oak has developed a set of design equations that can greatly aid in computing the appropriate loads for a given bolted joint under either pure axial or pure bending loading. Also provided are formulas to compute the required minimum preloads in bolts to preclude separation under axial or bending load cases. Finally, we have these joint design aids automated on an EXCEL spreadsheet for PC's. Both the design formulas and automated spreadsheet are available upon request from the AEDC Mechanical Engineering Team (Contact

Mike Metzger, 301-394-2063) for more information.