PD439030.pdf

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PD439030

REVISION LEVEL C SHEET 1 of 11

APPLICATION REVISIONS

NEXT ASSY USED ON SYM DESCRIPTION EO DATE APVD

405532-1 405368-1 RELEASED PER A/R 4387. 04/23/13 M. MCFATE

405536-1 A EXTENSIVELY REVISED. 06/11/13 M. MCFATE

B REVISED SHEET 1 AS MARKED. 12037 09/20/13 M. MCFATE

C REVISED SHEET 7 AS MARKED. 13520 09/03/14 E. POLTON

Government Purpose Rights : Expiration Date: June 24, 2013. The government's rights to use, modify, reproduce, release, perform, display, or disclose these technical data are restricted by paragraph (b)(2) of the rights in technical data noncommercial items clause contained in the Contract No. listed below. No restrictions apply after the expiration of date shown above. Any reproduction of technical data or portions thereof marked with this legend must also reproduce the markings.

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

Distribution Statement D: Distribution authorized to the Department of Defense and US DOD contractors only (Critical Technology) (14 January 2008). Other requests shall be referred to the Aeronautical Systems Center (ASC), Information Surveillance and Reconnaissance (ISR) and Special Operations Force (SOF) directorate, SOF and personnel recovery division, fixed wing branch (WISM), Wright-Patterson Air Force Base, OH.

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 (Title 50, U.S.C., App. 2401-2420). Violation of these export laws are subject to severe criminal penalties.

WRITER M. MCFATE 02/27/13

SARGENT FLETCHER INC.

2734 HICKORY GROVE RD. – DAVENPORT, IA 52804

CHK M. MCFATE 04/23/13

ENGR N. PEARSON 04/12/13

APPROVED T. DEPOUW 04/23/13 VARIABLE SPEED DROGUE,

CONTRACT NO. FA8629-08-C-2404 ACCEPTANCE TEST PROCEDURE FOR

APPROVAL COMPOSITE SPRINGS

REVISION LEVEL C SHEET 2

1. SCOPE

Sargent Fletcher, Inc (SFI) has been contracted to design, test and produce a Variable Speed Drogue (VSD), which is capable of refueling over a limited airspeed range using the 48,000 SFI series Air to Air Refueling (AAR) pod. The VSD must be able to function effectively and within specified drag requirements over the airspeed range and provide an adequate hose response during refueling as defined within.

The VSD concept uses an outer canopy and inner parachute arrangement, providing a fixed drag coefficient while the outer canopy moves through a pre-determined, drag-dependent angle range in order to vary the total drag coefficient through the airspeed envelope. The moments generated by the outer canopy and drogue ribs are reacted by composite springs.

This document defines the Production Acceptance Test (PAT) required on all “batten spring” (405532), and “spring opening moment” (405536) units that are part of the VSD assembly (405368). A total of 36 batten springs and 36 opening moment springs are required per VSD assembly. Fixture (408362) & plunger (408363) are required to perform the test.

2. APPLICABLE DOCUMENTS

The following documents form a part of this procedure to the extent specified herein. Unless otherwise indicated, the issue in effect on date of invitation for bids or request for proposals shall apply. When a specific document issue is indicated below, references to the document in subsequent sections of this procedure shall consist of the basic document number without repetition of the pertinent issue designation.

2.1 Government documents. There are no Government documents.

2.2 Non-Government documents.

DRAWINGS

405532 Batten Spring

405536 Opening Moment Spring

408362 VSD Spring test Rig

408363 Plunger, VSD

REVISION LEVEL C SHEET 3

OTHER DOCUMENTS

08-0062 Sargent Fletcher – Specification for Variable Speed Drogue, VSD

ASTM D3171 Standard Test Methods for Content of Composite Materials

MIL-STD-810 Environmental Engineering Considerations and Laboratory Tests

ST1637815 Engineering Change Notice, Configuration Control Standard

3. DEFINITIONS AND ABBREVIATIONS

AAR Air-to-Air Refueling i.a.w In Accordance With

KEAS Knots Equivalent Air Speed

PAT Production Acceptance Test

P/N Part Number

SFI Sargent Fletcher Inc.

TIS Test Information Sheet

VSD Variable Speed Drogue

4.0 RESPONSIBILITY

The prime contractor shall be responsible for all the tests specified herein.

5.0 PROCEDURES

5.1 Test conditions.

All tests should be carried out under standard ambient conditions (as defined within MIL-STD-810, as per Table I).

Table I. Ambient Test Temperature Range

Room / Chamber Temperature Min Max

15 °C 35 °C 59 °F 95 °F

5.2 Classification of tests.

5.2.1 Individual tests. Each spring shall be subjected to the acceptance tests in the order presented in table

II.

REVISION LEVEL C SHEET 4

Table II. Individual Tests

Test Information Sheet (TIS)

Test

A Visual Inspection B Batten Spring Test C Opening Moment Spring Test

5.3 Test sequence. The Individual tests listed in paragraph 5.2.1 are to be completed in the order presented.

5.4 Test equipment.

5.4.1 Calibrated equipment. Test stands and measurement devices used for the tests described herein shall be properly calibrated and capable of fulfilling the test measuring requirements of this procedure. Calibrated test equipment part/model numbers and serial numbers shall be recorded on the calibrated test equipment data sheet (at the end of this document). Calibration and certification of reference standards follow the NIST (national Institute of Standards and Technology) guidelines.

5.4.2 Alternate test equipment. Functionally equivalent test equipment may be used in place of the test equipment shall be done as follows:

• Analog and digital measuring equipment are not equivalent except on a case by case basis.

• The determination of equivalency can only be made by authorized personnel.

• A substitution of equivalent test equipment can only be made by the active design or test equipment and quality engineer.

• The test equipment must be capable of performing at the necessary parameters for the intended measurement.

• It must have sufficient capacity at the test points for the intended use. The equivalent equipment must have at least 3X the capacity of the intended measurement.

• Must have current calibration, and the current calibration must encompass the points tested.

• If the designated test equipment is not available, the person performing the test must contact their supervisor. If they agree to use equivalent test equipment, they shall contact the designated design or test equipment and quality engineer.

• The part number, model number, and serial number need to be noted on the test equipment data sheet and both the design and test equipment or quality engineer must initial and date the notation.

5.5 Test methods/procedures. The contractor shall use the methods/procedures of the TIS' contained herein to assure compliance with the requirements set forth in the contract. Test results will be recorded on the data sheets provided or on equivalent electronically generated test data sheets.

REVISION LEVEL C SHEET 5

5.6. Test setup. A tensile machine is required to perform this test.

Place 408362 on the base of the tensile machine. Insert 408363 on the load cell end of the tensile machine.

Ensure 408363 makes contact to the middle (+/- 0.125 in.) of the composite spring tested. Setup is shown in figure 1.

Figure 1. Example of Spring Test Fixture

5.7 Pass/fail criteria. This is based on the performance of the rib assemblies installed on the first Serial Number (S/N) VSD (405368-1) that has undergone successful wind tunnel and flight trials and allowing for 3 percent variability. The pass/fail criteria were determined by testing the initial batch of springs for the first serial number drogue and determining an average. To maintain the strict performance requirements of the drogue, the conservative stiffness tolerance of +/-3 percent was chosen.

6. REPORTS

Reports will be generated and shipped as required by the purchase order/sales order requirements.

7. NOTES

Changes to this document shall be made using the applicable practices described in ST1637815.

REVISION LEVEL C SHEET 6

TEST INFORMATION SHEET A

VISUAL INSPECTION

1. Test Equipment (record calibrated test equipment part/model and serial numbers on data sheet provided):

None required

2. Schematic/Figure: See figure 1.

3. Procedure:

WARNING

SAFETY GLASSES MUST BE WORN WHEN OPERATING THIS FIXTURE.

3.1 Before and after testing, visually check overall condition of batten and opening moment springs for signs of delamination or cracking or splitting.

3.2 Measure and record any deflection along the length of each spring. This is to ensure the springs aren’t bent to start with. In particular, check the lateral edges of the plies for delamination or voids. Voids, delamination, and cracks shall be reason for rejection.

3.3 If further investigation of the spring is needed to measure the amount of voids in the composite, either the spring can be examined by optical image analysis or by ASTM D3171. The composite void content is measured by weight through destructive testing with ASTM D3171. The matrix is dissolved by acid and matrix content measured by weight. Those operations are beyond the scope of this procedure.

3.4 Indicate acceptance or rejection, along with date and time stamp, on Data Sheet 1.

REVISION LEVEL C SHEET 7

TEST INFORMATION SHEET B

BATTEN SPRING TEST PROCEDURE

provided):

a) 405532 - Batten Spring

b) 408363 - Plunger, VSD

c) 408362 - VSD Spring Test Rig

2. Schematic/Figure: See figure 1

3.1 Place batten spring on the lower slot of 408362, as shown in figure 1.

3.2 Apply 11.2 lb of load.

3.3 Record deflection in the table on Test Data Sheet 1.

NOTE

Batten spring displacement for an 11.2 lb load should be between 0.264 and 0.278 in.

This is based on the performance of the batten springs installed on VSD, S/N 1, (65081320), Issue D that has undergone successful wind tunnel and flight trials and allows for 3 percent variability, at 0.271 in. mean.

Lower limit

(in.)

Mean (in.)

Upper limit

0.264 0.271 0.278

3.4 Indicate acceptance or rejection, along with date and time stamp, on Data Sheet 1.

REVISION LEVEL C SHEET 8

TEST INFORMATION SHEET C

OPENING MOMENT SPRING TEST PROCEDURE

provided):

a) 405536 - Opening Moment Spring

b) 408363 - Plunger, VSD

c) 408362 - VSD Spring Test Rig

2. Schematic/Figure: See figure A-1.

3.1 Place opening moment spring on the top slot of 408362, as shown in figure 1.

3.2 Apply 45 lb of load.

3.3 Record deflection in the table on Test Data Sheet 2.

3.4 Award pass if recorded force output is between limits shown. Pass/fail criteria rational is explained as follows:

Opening moment spring displacement for a 45 lb load should be between 0.296 and 0.314 in. This is based on the performance of the opening moment springs installed on VSD S/N 1, (65081320), Issue D that has undergone successful wind tunnel and flight trials and allows for 3 percent variability, at 0.305 in. mean.

Lower limit

Mean (in.)

Upper limit

0.296 0.305 0.314

3.5 Indicate acceptance or rejection, along with date and time stamp, on Data Sheet 2.

VARIABLE SPEED DROGUE (405368) — COMPOSITE SPRINGS (405532) AND (405536)

Build-Up No. ______________ Serial No. ____________________ Sales Order No. ___________________________

REVISION LEVEL C SHEET 9

TIS A. VISUAL INSPECTION

3.4 AC/RE ______________ Stamp ________________________ Date ___________________

TIS B. BATTEN SPRING TEST

The following tables should be filled out as appropriate and included within the test report.

3.3

P/N and Issue

Ambient temperature (°F)

Test engineer

Signed

Date

3.4 AC/RE ______________ Stamp ________________________ Date ___________________

DATA SHEET 1

SpringID Spring deflection at 11.2 Lbs load (in) Ob servations Pass/Fail

Build-Up No. ______________ Serial No. ____________________ Sales Order No. ___________________________

REVISION LEVEL C SHEET 10

TIS C. OPEN MOMENT SPRING TEST

The following tables should be filled out as appropriate and included within the test report.

3.3

P/N and Issue

Ambient temperature (°F)

Test engineer

Signed

Date

3.4

Spring ID Spring deflection at 45 Lbs load (in) Obs ervations Pass/Fail

3.5 AC/RE ______________ Stamp ________________________ Date ___________________

DATA SHEET 2

Build-Up No. ______________ Serial No. ____________________ Sales Order No. ___________________________

REVISION LEVEL C SHEET 11

Calibrated Test Equipment

Part/Model Number Serial Number