12PWS_T38_FEM_PH_XVI_Rev_A_8Nov18.pdf

PERFORMANCE WORK STATEMENT

T-38 Fuselage Finite Element Model (FEM)

Phase XVI: T-38 FEM Sustainment and Improvement

Revision A

8 November 2018

Prepared by:

Michael P. Blinn

AFLCMC/WLDE

(801) 777-0535 michael.blinn@hill.af.mil

AIR FORCE LIFE CYCLE MANAGEMENT CENTER

MATURE AND PROVEN AIRCRAFT DIVISION

ENGINEERING BRANCH

STRUCTURAL INTEGRITY AND ANALYSIS SECTION

HILL AIR FORCE BASE, UTAH 84056

i

T-38 FEM – Phase XVI

Last Rev. Date: 8 Nov 18

TABLE OF CONTENTS

Page

LIST OF TABLES ....................................................................................................................... iii

RECORD OF REVISIONS ......................................................................................................... iv

1 DESCRIPTION OF SERVICES

1.1 Scope

2 SERVICE SUMMARY

3 GOVERNMENT FURNISHED PROPERTY AND SERVICES

3.1 Modification Drawings, Finite Element Models, and Reports Provided

3.1.1 T-38C Modification Drawings

3.1.2 T-38 Finite Element Models

3.1.3 Reports

3.2 Security and Access to Government Facilities and Equipment

3.2.1 Security Clearance

3.2.2 Access to Government Facilities

3.2.3 Obtaining and Retrieving Base Identification

3.2.4 Entry Procedures to Controlled or Restricted Areas

3.2.5 Procedures and Controls

3.2.6 Cybersecurity

3.2.7 Network Security

3.2.8 Operational Security (OPSEC)

4 GENERAL INFORMATION

4.1 General Requirements

4.2 Technical Objectives and Goals

4.3 Specific Requirements

4.3.1 Contractor Services

4.3.2 Integrated Management Support

4.3.3 Management Systems Requirements

4.3.4 Validation Program

4.3.5 Maintainability Program

5 APPENDICES AND ATTACHMENTS

5.1 Applicable Documents

5.1.1 Document Availability and Delivery

5.2 Applicable CDRLs

ii

Last Rev. Date: 8 Nov 18

5.2.1 CDRL List

5.2.2 Contractor Reporting

ACRONYMS AND ABBREVIATIONS

ATTACHMENT ONE: LIST OF APPLICABLE DOCUMENTS

ATTACHMENT TWO: APPLICABLE CDRLS

iii

Last Rev. Date: 8 Nov 18

LIST OF TABLES

Page

Table 1: Service Summary for Phase XVI of the T-38 FEM

Table 2: T-38 FEM – Phase XVI, Sustainment and Improvement

Table 3: CDRL List for the T-38 FEM – Phase XVI iv

Last Rev. Date: 8 Nov 18

RECORD OF REVISIONS

REV DATE

PAGE(S)

AFFECTED

SECTION

AFFECTED

REASON FOR REVISION

- 24 Sept 18 n/a n/a Draft PWS date of release

(proposal version)

A 8 Nov 18 10 4.3.1.3.1

4.3.1.3.3 Paragraphs revised

1 DESCRIPTION OF SERVICES

The following Performance Work Statement (PWS) provides a description of the required contractor services in support of the T-38 Aircraft Structural Integrity Program (ASIP), T-38

System Program Office (SPO), Air Education and Training Command (AETC), and other commands.

This contractual effort is limited to Phase XVI of the Finite Element Model (FEM) program and the required engineering efforts are binding towards meeting the Phase XVI requirements.

Additional follow-on efforts are merely mentioned to depict the SPO’s overall program scheme and to ensure current efforts are considered by the contractor to facilitate integration towards required follow-on efforts and options.

Phase XVI, in and of itself, is of value to the T-38 ASIP’s FEM program for the purpose of continual improvement of the overall T-38 sustainment efforts, regardless of whatever future efforts are accomplished.

1.1 Scope

This PWS specifies the Phase XVI tasks towards sustaining and improving the T-38C (PMP-equipped) fuselage FEM (as developed in Phases I through XV of this program), and final presentation of the updated model to the government. This tasking includes the associated program management, engineering, and technical support required for this program. It should be noted that the complete FEM program will use a multi-phased approach as follows: Phase I - preliminary

FEM development (complete); Phase II - idealized FEM development (complete); Phase III - FEM validation and final reporting; and Phases IV through XV – FEM sustainment and improvement.

Additional phases (e.g., Phase XVII) will be considered by the government on a yearly basis and will be discussed with the contractor before the conclusion of Phase XVI.

2 SERVICE SUMMARY

Table 1 describes the Service Summary (SS) for the tasks as outlined in this PWS. Most of the efforts as described in this PWS will be engineering services and program management related.

3 GOVERNMENT FURNISHED PROPERTY AND SERVICES

3.1 Modification Drawings, Finite Element Models, and Reports Provided

3.1.1 T-38C Modification Drawings

The government will provide the contractor with all required T-38C and PMP modification drawings, not previously delivered in Phase I through XVI. The intention here is for the contractor to have all the required configuration baseline data readily available, assisting in the development of the T-38C portion of the T-38 FEM.

Table 1: Service Summary for Phase XVI of the T-38 FEM

Performance Objectives

PWS

Reference

Performance Threshold

(Minimum Acceptable)

Engineering Technical Activities:

Contractor to provide support engineering analyses, assessments, and research towards the T-38 FEM’s development and improvement.

Contractor to provide modeling and engineering activities to a validated, functional FEM ready for implementation.

4.3.1.1 through

4.3.1.4, 4.3.4.1, 4.3.5.1

For engineering analyses (or assessments or studies): All actions accomplished as required with no more than one disapproval by the government for technical discrepancies per technical document/report. Any necessary corrections must be made within 30 days of government notification; the flow of analysis must be logical, the analysis steps must be shown in sufficient detail such that an entry-level engineer can follow and a journeymen engineer can recreate; the input values/units to the model must be cited; the mathematics must be free from significant errors; the results/conclusions must be clearly identified; and the implications of the result/conclusion must be clearly stated.

Computer Modeling Activities:

Contractor to provide modeling and engineering activities to a validated, functional FEM ready for implementation. Contractor to assist in technical questions to support their modeling activities.

4.3.1.1 through

4.3.1.4, 4.3.4.1, 4.3.5.1

Contractor to provide final version of the T-38

FEM as required with no more than one disapproval by the government for technical discrepancies, and 100% compatible with the computer systems at Hill AFB. The target tolerance for the Phase XVI FEM validation efforts shall be 10 percent, with the results subject to final government approval. Any necessary corrections must be made within 30 days of government notification.

On-Site FEM Support at Hill AFB:

Contractor to provide limited on-site support for integration and updating of the FEM systems (government’s and contractor’s); to assist in the integration of the FEM software.

4.3.1.2 through

4.3.1.4, 4.3.2.1, 4.3.4.1, 4.3.5.1

Final version of the contractor updates to the T-38

FEM is to be delivered as required, with no more than one disapproval by the government for technical discrepancies. Any necessary corrections must be made within 30 days of government notification. Contractor to prove compatibility by on-site visits to Hill AFB. On-site support can coincide with formal technical reviews.

Technical Documentation: Contractor to generate timely, error free FEM technical, management, and all other reporting and documentation; includes activities such as monthly financial reporting, meeting minutes, updates to the software (e.g., user’s manual), and the final Phase XVI reports.

4.3.1.1 through

4.3.1.4

4.3.2.1, 4.3.2.2, 5.2.1, 5.2.2

The T-38 FEM user’s manual shall be 100% complete. All actions accomplished are to be delivered with no more than one disapproval by the government for technical and financial discrepancies per each technical, financial, and other documentation. Contractor shall submit all documentation as identified in the attached

CDRLs. Any necessary corrections must be made within 30 days of government notification.

Last Rev. Date: 8 Nov 18

3.1.2 T-38 Finite Element Models

The government retains configuration control of the T-38 FEM, and is ultimately responsible for the model. The government will coordinate with the contractor to ensure that they have all the available T-38 FEMs.

3.1.3 Reports

The government will provide the contractor with all the necessary government Technical

Orders (TOs), Time Compliant Technical Orders (TCTOs), work statements, and contractor reports required to accomplish the tasks as detailed in this PWS (see also Ref.

8-49, Attachment One, for additional information on previous reporting).

3.2 Security and Access to Government Facilities and Equipment

3.2.1 Security Clearance

The efforts required for this task are UNCLASSIFIED and will not require contractor personnel to obtain a security clearance. Contractor personnel shall abide by all Air Force rules, procedures, and standard of conduct. Contractors requiring access to Air Force

Automated Information Systems (AIS) shall have background investigations and security awareness training completed prior to the start of contract performance. When the period of performance is complete and/or the contractor personnel leave work on this project, they will return all access cards and base identification badges within five days.

3.2.2 Access to Government Facilities

Access to government facilities is limited. Therefore, the contractor shall coordinate the need, time, and personnel requiring access to government facilities with the PM, at least one week prior to need. The government PM or designated representative will coordinate between the contractor and base personnel as required.

3.2.3 Obtaining and Retrieving Base Identification

Contractors requiring access to government installations shall obtain the appropriate base identification for all contractor personnel who make frequent visits to or perform work at government sites. Contractor personnel are required to wear or prominently display installation identification badges or contractor-furnished identification badges while visiting or performing work on the installation(s). During performance of the contract, the contractor shall be responsible for obtaining required identification for newly assigned personnel and for prompt return of credentials for any employee who no longer requires access to the work site(s). Upon completion or termination of the contract or expiration of base identification, the contractor shall ensure that all base identification passes issued to contractor employees are returned to the appropriate issuing office.

3.2.4 Entry Procedures to Controlled or Restricted Areas

Contractor employees shall comply with local base procedures for entry into government controlled and restricted areas. If contractor employees require unescorted entry to controlled or restricted areas, the contractor shall comply with the Federal Installations

Command Physical Security Plan and DoD Personnel Security Program, DoD 5200.2-R.

Last Rev. Date: 8 Nov 18

3.2.5 Procedures and Controls

The contractor shall implement and maintain security procedures and controls to prevent unauthorized disclosure of controlled unclassified information and to control distribution of controlled unclassified information IAW DoD 5220.22-M, National Industrial Security

Program Operating Manual. All contractor facilities shall provide appropriate means of storage for controlled unclassified information and materials. All controlled unclassified information shall be appropriately identified and marked as For Official Use Only IAW

DoD 5200.01, DoD Information Security Program: Controlled Unclassified Information

Volume 4 (enclosure 3) and DoD 5400.7-R Freedom of Information Act Regulation

Chapter 3. The contractor shall not store or transmit controlled unclassified information on personal information technology systems or via personal e-mail.

3.2.6 Cybersecurity

Cybersecurity (CS) is the discipline that protects and defends information and information systems by ensuring their availability, integrity, authentication, confidentiality, and non-repudiation. These measures include providing for restoration of information systems by incorporating protection, detection, and reaction capabilities. DoD Instruction 8500.01 establishes a DoD cybersecurity program to protect and defend DoD information and information technology. The contractor shall implement DoDI 8500.01 guidance for development of a cybersecurity strategy as defined below.

3.2.7 Network Security

The contractor shall take means (defense-in-depth measures) necessary to protect the availability, integrity, and confidentiality of government Controlled Unclassified

Information (CUI) in the same manner as the contractor would protect its own unclassified company proprietary information IAW DoD Instruction 8582.01. The contractor shall safeguard CUI stored on non-DoD information systems to prevent the loss, misuse, and unauthorized access to or modification of this information. The contractor shall ensure that contractor-owned and operated unclassified information technology (IT) network assets

(including assets used for contractor teleworkers) used to process sensitive government

CUI are managed and maintained IAW commercial best practices, vendor-specific, or other nationally or internationally-recognized IT configuration and management standards.

3.2.8 Operational Security (OPSEC)

OPSEC requirements are required in an effort to reduce program vulnerability from successful adversary collection and exploitation of critical information. OPSEC will be applied throughout the contract. A critical information list will be provided by the government.

4 GENERAL INFORMATION

4.1 General Requirements

General requirements for the Aircraft Structural Integrity Program (ASIP) are given in Air Force

Instruction (AFI) 63-101, Air Force Policy Directive (AFPD) 63-1, and AFI 63-140 (see Ref. 1-3, Attachment One). In addition, ASIP is detailed in Mil-STD-1530D (see Ref. 6). Finally, other reference sources are included for this task order (see Ref. 4, 5, and 7).

4.2 Technical Objectives and Goals

The T-38 fuselage has undergone significant structural modifications over the last 20+ years to extend its life to 2024 and beyond. Some of these modifications include the steel dorsal longeron replacement, new bulkheads, and the inclusion of auxiliary air intakes. These modifications change the internal loads, mass distribution, and stresses in the T-38 fuselage, thereby raising concern as to the applicability of earlier stress analyses for use on the current configuration T-38.

Further, these modifications have not been integrated into a unified analysis model to determine their effects on the overall strength and internal loads of the fuselage. To address these issues, an updated, comprehensive FEM is needed for maintaining the long-term health and reparability of the aircraft.

The purpose of Phase XVI of this program is to sustain and improve upon the FEM of the T-38 fuselage, empennage, and wing developed during Phases I through XV, then to make a final report of the work performed to the government. The updated and integrated Phase XVI FEM will continue to improve the accuracy of the loads and stress analysis of the aircraft, also allowing for more accurate damage tolerance analyses (DTAs). Further, the FEM information can be used to evaluate the legacy T-38 stress reports, currently used for structural analyses.

4.3 Specific Requirements

4.3.1 Contractor Services

The contractor shall provide the appropriate engineering, program management, and technical services as required for this PWS. Limited travel will be required to meet the goals of this effort.

4.3.1.1 T-38 FEM Program - Phase XVI: As part of Phases I-XV, a number of contractor reports were written to define the government plans and contractor’s progress for the various FEM efforts (see Ref. 33-43, Attachment One). Reports for Phase XV shall be completed by March 2019. As a logical follow-on of the first 15 phases, Phase

XVI will build from the most updated T-38 FEM program plan.

Improvement and sustainment modeling activities will be accomplished, with the T-

38 FEM and validation models refined to reflect the T-38C, PMP-equipped configuration aircraft (non-PCIII and PCIII configurations) and both the -29 wing and

-33 wing configurations. Areas of model improvement shall be as specified in Table

Last Rev. Date: 8 Nov 18

2. It should be noted that, as a minimum, the government requires basic requirements for the T-38 FEM’s viability. In addition, the government is also interested in pursuing other option(s) to improve the T-38 FEM’s capabilities; support of these options will depend on available resources for this task.

In addition to validation against the full scale fuselage test, the model will be improved by validating against full scale wing test data. All final deliverables are due 12 months

ARO contract award (CDRLs A002, A006, A008 and A009, Attachment Two).

Table 2: T-38 FEM – Phase XVI, Sustainment and Improvement

Basic

Phase XVI FEM PWS Tasks

Priority Task Description*

1 Documentation

1.1

Deliver an updated, detailed FEM report that documents and describes the CFD loads models, mass inertia spreads, load conditions mapping and validation, modeling methodologies, methodology study results and recommendations, standard and deep dive correlations, contact definitions, checkout steps and validation process, results, and data management

1.2 Similarly, update the FEM user’s manual to the same standard

1.3 Deliver an updated Excel spreadsheet for connection-related data (to contain identifying information, description, location, FEM groups, stiffness approximation method, etc.)

2 T-38 FEM – Phase XVI Full Aircraft Integration and Checkout

2.1

Integration/check and troubleshooting of all FEM updates for this phase. Checkout processes should be completed prior to model delivery in an attempt to identify any potential model/solution problems (including monitor point checks).

2.2 Ensure a correct update of the OML loads wherever the mesh has changed

2.3 Model run/release

2.4

T-38 full aircraft FEM – formal in-depth FEM checkout beginning with the highest priority checks not yet completed or not up-to-date as indicated by the FEM Checkout

Summary spreadsheet

2.5 Update monitor points (MONPNT) for Phase XVI changes to applied loads for evaluating the effects on bending/shear/torsion

2.6

Create an additional monitor point check for SPC and MPC loads (MONPNT3).

MONPNT3 is potentially capable of checking loads not captured by MONPNT and should include previous loading results back to Phase XI similar to the MONPNT check.

2.7 Updated Design and Fatigue FEMs and solutions shall be delivered to the Government for all configurations

2.8 Update section properties spreadsheet - to include all components including fastener compendium

Last Rev. Date: 8 Nov 18

3 Resolution of Known FEM Issues

3.1 Continue correcting FEM issues as they arise

3.2

Maintain a list of known issues (resolved and unresolved) in NLign. Provide the government with regular updates during the period of performance (quarterly at a minimum)

4 Correlation Update for Fuselage and Wing (-29 and -33) FEMs

4.1 Update T-38 standard and deep dive correlations

4.2 Update statistical correlation metrics

4.3 Present all correlation results in NLign and deliver this data to the government

5 Investigate FEM Areas of Concern (maximum of 3 areas)

6 Update Contact Models

6.1

Update all fuselage contacts for the test configuration from changes in Phase XV.

Update T-38C forward fuselage contacts due to known issues near FS 284 splice joint, the results from the Phase XIV hook slot study, and the Phase XV upper longeron splice re-mesh task. Additionally, the aft fuselage contacts may need to be updated if known

FEM issues are significant.

7 Perform Nonlinear Analysis for up to Three (3) Areas of Interest

7.1

Create a detailed model for an area of interest and run with material and deflection nonlinearities. Candidate location examples include but are not limited to: panel buckling, pressure panels, locations of large point-like loads, locations of known yielding, etc.

8 T-38 Aft Fuselage/Empennage Strain Survey Test Plan

8.1

The objective of this strain survey test plan is to provide the government with a comprehensive document that can be used to effectively implement a strain survey test for locations in the aft end of the T-38 that is lacking sufficient strain data for FEM correlation; the test plan should provide the details of obtaining the load, strain, and displacement data needed to correlate the aft fuselage and empennage of the current T-

38 FEM. An initial FEM analysis was performed in Phase XV to determine where strain data correlation is poor or non-existent in the aft fuselage and empennage; the work of that analysis will provide the foundation for the test plan requirements.

8.2

The test plan will include, but is not limited to, test article(s) acquisition, inspection, and configuration; test setup including required equipment, personnel, fixtures (including models), facilities, load frames, hydraulics, etc.; instrumentation and data acquisition requirements including control and data monitoring, strain gages location and installation, deflections, load measurement, required test load descriptions, etc.

8.2.1 It should be noted that the list in 8.2 is not all inclusive but represents a baseline for the contractor to expand upon.

9 Forward Fuselage FEM Comparison

9.1

This task will compare the SwRI forward fuselage FEM to the NGC FEM to develop recommendations for improvement of NGC FEM correlation. The task will include comparing loads, load application, load paths, stresses, and deflections between models to pinpoint areas of significant difference. Recommendations will be made for modifying the NGC FEM upon review of the results.

Last Rev. Date: 8 Nov 18

10 Deeper Dive Correlation

10.1

Expand upon the deep dive correlation methodology for strain gauges of high-importance that currently show poor correlation to include evaluation of load paths through/around the gauges using gauge data where available (comparison to legacy stress analysis for ungauged parts). Develop recommendations for changes to the FEM that will produce improved load paths from the results.

11 FEM Studies

11.1

Evaluate and compare results from MSC Nastran and NX Nastran. A design stress model will be run in NX Nastran and compared to the MSC Nastran results. Contact model analyses in select locations will also be compared between the two software packages. Following the completion of the comparisons, a feasibility assessment will be completed to determine the practicality of migrating to NX Nastran.

11.2 Study of K6ROT value for correlation; compare different values of K6ROT using strain and deflection correlation results; compare those to CQUADR results.

* Unless otherwise stated, tasks apply to -29 and -33 wing FEMs, standard and PCIII fuselage FEMs, design and fatigue load cases (test FEM also when applicable)

Options A-C

Option A

12 FEM vs Stress Analysis (5 Locations)

12.1

5 locations with negative margins in the stress reports (approved by the government) will be evaluated. This will include comparison of results to the current FEM, validating the FEM at that location, and modifying the FEM as necessary. If there are significant changes to the margin then an addendum to the stress analysis reports will be provided.

Option B

13 Loads: Re-spread

13.1

This task will involve re-spreading the coarse inertial loads on the wing and fuselage for improvement of load paths and reduction of stress concentrations. The current inertial loads are based on the original coarse FEM.

14 Study: 0-1000 Hour Fuselage Fatigue Test Data Correlation

14.1

Evaluate the quality of correlation and availability of data for the SwRI fuselage fatigue test 0-1000 hour block. Run the 0-1000 hour block correlation and analyze the results in comparison to the 1000-2000 hour data.

Option C

15 Extension of Nonlinear Analysis (Item 7) for Two (2) Additional Areas of Interest

16 Extension of FEM Areas of Concern (Item 5) for Two (2) Additional Areas

Option D

17 Fastener Tool Development

17.1 Update and improve upon the fastener shear allowable database table for improved accuracy of margin calculations

17.2 Expand upon the work done in the proof of concept for the 64.8 Rib to include all -33 wing structural components

Last Rev. Date: 8 Nov 18

4.3.1.1.1 Data Compatibility: All contractor FEM/FEA work shall be fully compatible with the version of PATRAN and MSC NASTRAN used by government personnel at Hill AFB and using MSFT Windows based operating system (CDRL A002, Attachment

Two).

4.3.1.1.2 Data Documentation: Data for the modeling and analysis (FEM/FEA) documentation activities for Phase I through III are fully addressed in the NOR 04-

100, April 2005 revision, and the initial requirements also detailed in the Phase I

SOW (see Ref. 32, and 8, Attachment One, respectively). An updated FEM is required in Phase XVI, and the final version is a deliverable entitled, “T-38 Aircraft

FEM – Phase XVI” and “T-38 FEM Validation Model – Phase XVI” (CDRL A002, Attachment Two). Update to two reports (main report and user’s manual) is required for Phase XVI: “T-38 Aircraft FEM – Phase XVI Report” (CDRL A008, Attachment Two) and “T-38 Aircraft FEM – Phase XVI User’s Manual” CDRL

A009, Attachment Two). Guidelines for reporting are further identified in Table

1, the Service Summary. Updates to the reports shall be consistent in format and style and shall reflect the current state of the FEM.

4.3.1.1.3 Recommended Phase XVII Activities: The contractor shall conduct a review of

FEM update status and provide a white paper outlining work that could be performed in a potential T-38 FEM - Phase XVII task order. This white paper is to be provided five months ARO as part of the 2nd quarterly report (CDRL A006, Attachment Two).

4.3.1.2 Formal Evaluations: The following formal evaluations are to be supported by the

Contractor:

4.3.1.2.1 Preliminary Program Review: A preliminary program review for the contractor to present their refined “way ahead” for Phase XVI, and further discuss the anticipated challenges with the tasks as described in this PWS, shall be held no later than two months ARO. The contractor shall provide a PPT document as well as present minutes of the meeting in the most appropriate quarterly report (CDRL A006, Attachment Two).

4.3.1.2.2 Status Updates: As a minimum, monthly status updates and technical interchange meetings between the government and NGC will be conducted. The technical interchanges can be accomplished via teleconferencing with the minutes being maintained by the government. For the technical interchanges, CDRL reporting is not required.

4.3.1.2.3 Final Program Review: A final review to present the final results and discuss the outcomes of the T-38 FEM program shall be held at the conclusion of the program

(CDRL A006, Attachment Two).

4.3.1.3 Contractor Travel: The following are the contractor travel requirements:

Last Rev. Date: 8 Nov 18

4.3.1.3.1 Preliminary Program Review Trip: If deemed necessary by the Government and the contractor, the contractor is authorized one trip with a maximum of two people

(minimum one engineer) for up to two days to Hill AFB, Utah, to present the T-38

FEM – Phase XVI “way ahead,” and further discuss the program’s anticipated challenges.

4.3.1.3.2 Final Program Review Trip: The contractor is authorized one trip with a maximum of two people (minimum one engineer) for up to three days to Hill AFB, Utah, to present the T-38 FEM – Phase XVI final results, and discuss the possible additional phases. Activities shall include working with Hill AFB engineers on the T-38 FEM, and ensuring compatibility of the contractor and government modeling systems.

4.3.1.3.3 Miscellaneous Program Support Trips: The contractor is authorized up to four trips with a maximum of two people (minimum one engineer) for up to five days to attend FEM/FEA related seminars, conferences, working groups, and/or forums including (but not exclusive to) the following activities: T-38 ASIP Summit

(Ogden, UT), AFGROW seminar (Ogden, UT), and the USAF’s ASIP Conference

(San Antonio, TX). Other USAF supported conferences within the continental US are permissible, at the discretion of the government.

4.3.1.4 Government Site Visits: The contractor shall provide for up to three site visits by government representatives. These visits are intended to provide the government with training on the use and configuration of the T-38’s FEM.

4.3.2 Integrated Management Support

4.3.2.1 Contractor Program Manager: For all tasks required by this PWS, the contractor shall identify and maintain a program manager (PM). The program manager shall have a defined and direct line of authority and responsibility over all aspects of the work effort. The contractor’s work progress, status and any corrective action shall be documented (CDRL A006, Attachment Two). The contractor shall report all contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the T-38 FEM via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil. Reporting inputs will be for the labor executed during the period of performance for this Task Order. While inputs may be reported any time during the performance period, all data shall be reported no later than 31 March 2019.

Contractors may direct questions to the CMRA help desk.

4.3.2.2 Contractor Interim Reporting: The contractor shall submit monthly progress and management reports and quarterly technical status reports on the T-38 FEM program’s progress (CDRL A006, Attachment Two). Reports shall be relatively error free and technically correct, as per the guidelines of Table 1.

4.3.3 Management Systems Requirements

Management systems requirements are to be provided by the contractor.

http://www.ecmra.mil/

4.3.4 Validation Program

4.3.4.1 FEM Validation: The T-38 FEM shall be validated using deflection and strain gage measurements made during the full-scale fuselage and wing fatigue tests at Southwest

Research Institute (SwRI). Strain gage data are currently available for use in validating the T-38 FEM. The contractor shall perform and log a strain gage correlation effort, the goal of which is to correlate within a ±10 percent tolerance.

FEM validation shall be compliant with the Northrop Grumman FEM Checkout

Process. The purpose of this correlation effort is to report correlation between testing and the newly modeled FEM. See Table 1 for additional guidelines on FEM reliability.

4.3.5 Maintainability Program

4.3.5.1 FEM Maintainability: The contractor is responsible for operating, validating, verifying, and maintaining the FEMs and the associated documentation. This includes retaining current and government compatible versions of the software used for

FEM/FEA activities.

4.3.5.2 Continuation of Essential DoD Contractor Services During Crisis: In accordance with

DODI 1100.22 (Dated 12 April 2010), this requirement is not considered mission essential.

5 APPENDICES AND ATTACHMENTS

5.1 Applicable Documents

5.1.1 Document Availability and Delivery

If the government deems appropriate, the contractor may use other applicable documents.

Also, the contractor shall request necessary documents from the government, as required.

In turn, the government shall supply all required TOs and TCTOs for the contractor to perform the tasks of this PWS.

5.2 Applicable CDRLs

5.2.1 CDRL List

The deliverable products (CDRL list) for this PWS are presented in Table 3 (see

Attachment Two). The FEM/FEA related files (CDRL A002, Attachment Two) shall be compatible with the most recent version software as discussed in Para. 4.3.1.2 (Data

Compatibility), and fully compatible with the AFLCMC/WLDE computer system (see also

Table 1).

Note: See DD Form 1423 for further details.

Last Rev. Date: 8 Nov 18

5.2.2 Contractor Reporting

The contractor shall submit reports in accordance with the DIDs specified in DD form 1423

(CDRLs A006 and A008, Attachment Two) with the following stipulations. Tables, figures, drawings, etc. shall be placed immediately following their reference in the main body of the text (i.e. same page if possible or on the next page). Reports shall be submitted in electronic format in both Microsoft Word for Windows and Adobe Acrobat (.pdf) format to the T-38 ASIP Manager at AFLCMC/WLDE. Any necessary corrections shall be made within 30 days of government notification. One copy (of the number required in the DD

Form 1423) of the final report shall be submitted in electronic form in both Microsoft Word for Windows and Adobe Acrobat (.pdf) format to the T-38 ASIP Manager at

AFLCMC/WLDE.

ACRONYMS AND ABBREVIATIONS

ACSTRSEQ - Aircraft Stress Sequence Program

AETC - Air Education and Training Command

AF - Air Force

AFB - Air Force Base

AFLCMC - Air Force Life Cycle Management Center

AirStats - Flight loads post-processing software

ARO - After Receipt of Order

ASIMIS - Aircraft Structural Integrity Monitoring Information System

(Tinker AFB, OK)

ASIP - Aircraft Structural Integrity Program

DoD - Department of Defense

DTA - Damage Tolerance Analysis

FCL - Fatigue Critical Location

FEA - Finite Element Analysis

FEM - Finite Element Model

FEM - Flight Loads Data Recorder

FMM - Fine Mesh Model (finite element)

FS - Fuselage Station

IATP - Individual Aircraft Tracking Program

IAW - In Accordance With

IFF - Introduction to Fighter Fundamentals

IMIS - Integrated Maintenance Information System (Boeing, St. Louis)

ISIDR - Instrumentation System/Installation Description Report

MAPA - Mature and Proven Aircraft (Division)

Mgr. - Manager

MSC NASTRAN - Solver for finite element computer program maintained by the MacNeal-Schwendler Corporation

MSFT - Microsoft

NGC - Northrop Grumman Corporation

NGTS - Northrop Grumman Technical Services

NOR - Northrop

OEM - Original Equipment Manufacturer

Para. - Paragraph

PATRAN - Finite element computer program maintained by the MacNeal-

Schwendler Corporation

PBESC - Performance Based Engineering Services Contract

PM - Program Manager

PMP - Propulsion Modernization Program

PWS - Performance Work Statement

QA - Quality Assurance

Ref. - Reference

ACRONYMS AND ABBREVIATIONS (Cont)

Sect. - Section

S/N - Serial Number

SPM - System Program Manager

SPO - System Program Office

SS - Service Summary

SUPT - Specialized Undergraduate Pilot Training

SwRI - Southwest Research Institute

TBD - To Be Determined

TCTO - Time Compliant Technical Order

TO - Technical Order

USAF - United States Air Force

WLDEJ - Structural Integrity Section

WLDM - Program Management Branch

WS - Wing Station

Last Rev. Date: 8 Nov 18

ATTACHMENT ONE: LIST OF APPLICABLE DOCUMENTS

Department of Defense (DoD) Specifications

1. Air Force Policy Directive (AFPD) 63-1, Integrated Life Cycle Management, 3 June 2016.

2. Air Force Instruction (AFI) 63-101, Integrated Life Cycle Management, 6 September 2016.

3. AFI 63-140, Aircraft Structural Integrity Program, 7 April 2014.

Department of Defense (DoD) Standards

4. MIL-HDBK-5E, Metallic Materials and Elements for Aerospace Vehicle Structures, June

1987.

5. MIL-STD-1521B, Technical Reviews and Audits for Systems, Equipment, and Computer

Software, (Canceled 10 Apr 1995).

6. MIL-STD-1530D, Aircraft Structural Integrity Program, 31 August 2016.

7. MIL-STD-1840C, Automated Interchange of Technical Information, 26 June 1997.

Contractual Documents

8. Statement of Work, “T-38 Fuselage Finite Model (Aft of FS 284) – Phase I: Background

Information and Preliminary FEM Development,” 23 February 2004.

9. Performance Based Statement of Work, “Phase II: T-38 Idealized FEM Development and

Preliminary Integration,” 16 June 2005.

10. Performance Based Statement of Work, “Phase III: T-38 FEM Validation and Final

Reporting,” 28 October 2006.

11. Performance Based Statement of Work, “Phase IV: T-38 FEM Sustainment and

Improvement,” 23 April 2007.

12. Performance Work Statement, “Phase V: T-38 FEM Sustainment and Improvement,” 7 August

2008.

13. Performance Work Statement, “Phase VI: T-38 FEM Sustainment and Improvement,” 6 June

2009.

14. Performance Work Statement, “Phase VII: T-38 FEM Sustainment and Improvement,” 30 June

2010.

15. Performance Work Statement, “Phase VIII: T-38 FEM Sustainment and Improvement,” 28

September 2011.

16. Performance Work Statement, “Phase IX: T-38 FEM Sustainment and Improvement,” 18

September 2012.

17. Performance Work Statement, “Phase X: T-38 FEM Sustainment and Improvement,” 19

September 2013.

18. Performance Work Statement, “Phase XI: T-38 FEM Sustainment and Improvement,” 28 July

2014.

19. Performance Work Statement, “Phase XII: T-38 FEM Sustainment and Improvement,” 14

September 2015.

20. Performance Work Statement, “Phase XIII: T-38 FEM Sustainment and Improvement,” 2 June

2016.

21. Performance Work Statement, “Phase XIV: T-38 FEM Sustainment and Improvement,” 27

June 2017.

22. Performance Work Statement, “Phase XV: T-38 FEM Sustainment and Improvement,” 20 June

Last Rev. Date: 8 Nov 18

Other Publications

23. NAI 57-41, “T-38 Basic Loads,” September 1958.

24. NAI 57-55, “T-38 Wing Stress Analysis,” November 1966.

25. NAI 57-57, “T-38 Fuselage Stress Analysis, Vol. I through III,” 1959-60.

26. NAI 57-58, “T-38 Vertical Tail Section Properties and Stress Analysis,” August 1958.

27. NAI 57-59, “T-38 Horizontal Tail Section Properties and Stress Analysis,” January 1963.

28. NOR 99-105, “T-38 Wing Life Improvement Program Phase II, Stress Analysis Report.”

29. NOR 99-107, “T-38 Wing Life Improvement Program Phase II, -33 Finite Element Model

Description and Internal Loads Report,” May 2005.

30. NOR 00-101, “T-38 Wing Life Improvement Program Phase III, Durability and Damage

Tolerance Analysis,” June 2000.

31. NOR 02-101, “T-38 Wing Life Improvement Program Phase VI, Loads Application Report.”

32. NOR 04-100, “T-38 Finite Element Analysis – T-38 Fuselage Program Plan,” November 2004

(revised April 2005).

33. NOR 05-101, “T-38 Fuselage Finite Element Model Program Phase I,” June 2005.

34. NOR 09-100D, “T-38 Fuselage Finite Element Model Program Phase IX - Fuselage Finite

Element Model Description and Internal Loads,” September 2013.

35. NOR 07-101E, “T-38 Fuselage Finite Element Model Program Phase IX - Finite Element

Model User's Manual,” September 2013.

36. NOR 09-100E, “T-38 Aircraft FEM - Phase X Report,” September 2014.

37. NOR 07-101F, “T-38 Aircraft FEM User’s Manual - Phase X Report,” September 2014.

38. NOR 15-101, “T-38 Aircraft FEM - Phase XI Report,” September 2015.

39. NOR 15-102, “T-38 Aircraft FEM User’s Manual - Phase XI Report,” September 2015.

40. NOR 15-101A, “T-38 Aircraft FEM - Phase XII Report,” September 2016.

41. NOR 15-102A, “T-38 Aircraft FEM User’s Manual - Phase XII Report,” September 2016.

42. NOR 15-101B, “T-38 Aircraft FEM - Phase XIII Report,” September 2017.

43. NOR 15-102B, “T-38 Aircraft FEM User’s Manual - Phase XIII Report,” September 2017.

44. NOR 15-101C, “T-38 Aircraft FEM - Phase XIV Report,” September 2017.

45. NOR 15-102C, “T-38 Aircraft FEM User’s Manual - Phase XIV Report,” September 2017.

46. SwRI 06-5898, “AETC T-38 SUPT Maneuver and Stress Spectra,” May 1994.

47. SwRI 06-6611, “T-38 Forward Fuselage Stress Analysis, NASTRAN Idealization Report,”

June 1997.

48. SwRI 06-6611, “T-38 Forward Fuselage Stress Analysis, NASTRAN Validation Report,”

November 1997.

49. SwRI 06-6723, “AETC T-38 IFF Maneuver and Stress Spectra,” May 1997.

50. SwRI 06-7278, “Revised T-38 Durability and Damage Tolerance Update Ground Rules

Report,” December 1998.

51. SwRI 18-11896, T-38 DADTA Update – Ground Rules Report,” September 2006.

52. SwRI 18-8353, “T-38 Wing Stress Analysis Idealization Report,” June 2000.

53. SwRI 18-8353, “T-38 Wing Stress Analysis Validation Report,” June 2000.

54. SwRI 18-1334, “T-38 SUPT/IFF Coupon Analysis Results,” March 2001.

55. SwRI 18-8674, “T-38 Longeron Splice Fine Mesh Model Integration.”

Note: If the government deems appropriate, the contractor may use other applicable documents. The above listed documents are to be used in their entirety.

ATTACHMENT TWO: APPLICABLE CDRLS

Table 3: CDRL List for the T-38 FEM – Phase XVI

PWS Paragraph CDRL CDRL Description DID

4.3.1.1, 4.3.1.1.1, 4.3.1.1.2, 5.2.1

A002 Computer Software Product End

Items:

- T-38 Aircraft Idealization FEM –

Phase XVI (Updated Version)

- T-38 Aircraft Validation Model –

Phase XVI (Updated Version)

DI-AVCS-80700A

4.3.1.1, 4.3.1.1.3, 4.3.1.2.1, 4.3.1.2.3, 4.3.2.1, 4.3.2.2, 5.2.2

A006 Contractor’s Progress, Status and

Management Report

DI-MGMT-80227

4.3.1.1, 4.3.1.1.2, 5.2.2

A008 Technical Report – Study/Services:

- T-38 Aircraft FEM – Phase XVI

Report

DI-MISC-80508B

4.3.1.1, 4.3.1.1.2 A009 Software User Manual

- T-38 Aircraft FEM

DI-IPSC-81443A