Statement_of_Requirements_Final.docx

Statement of Requirements

Agent Defeat Composite Casing

GSEAS/MAE

Naval Postgraduate School

1.0 Background/Introduction:

Faculty within the Naval Postgraduate School Mechanical & Aerospace Engineering Department are leaders in the research and testing of composite materials used in structural components. Currently a project is underway in collaboration with Lawrence Livermore National Laboratory that involves government researchers and NPS students in the pursuit of improved test methods for composite and energetic materials used in military applications. Even though the technology to produce composite wound cylinders has become more commonplace in recent years, the ability to precisely produce articles of the thickness and diameter necessary along with the post production machining of the pieces is more difficult to come by. The items requested here are full size test articles based on previous prototype fabrication and testing at a scaled level in the previous portion of this multiyear effort.

2.0 Minimal Technical Requirements/Salient Characteristics:

1. Item 1: Manufacture two (2) filament wound cylinders composed of Torayca T700S carbon fiber filament and UF3325 TCR Resin.

0. Quantity: 2

0. Dimensions:

1. Inner Diameter: 12.25 [inch]

1. Length: 23 [inch]

1. Wall thickness: 1.5 [inch]

0. Winding schedule: [±852,±45, ±852,±15]N

2. Final desired thickness 1.5 [inch], ‘N’ is an integer number of repeated layers equal to or greater than final wall thickness of 1.5 [inch]. Estimated ‘N’ quantity is 15, based on 0.00875 [inch] thickness per angle.

2. Winding angles indicate braided (helical) winding of opposing angles. Schedule begins with “hoop” winding (±85) nearest the mandrel.

2. Angles are measured in degrees from the cylinder axis, [90] indicates hoop or circumferential winding, while [0] indicates axial or longitudinal winding. Subscripts indicate repeated layers.

2. If intermediate cure necessary, adequate surface preparation (cleanliness, surface profile, etc.) is required to ensure following layers are properly adhered to partially cured layers.

0. Additional Features

3. Six (6) pilot holes at each end of the tubes drilled at 60 [degrees] apart and at 0.75 [inch] from end of tube. Diameter of holes 0.281 [inch]. Each hole shall be counterbored concentric with the through-hole with a diameter of 0.75 [inch] and a depth of 0.06 [inch]. Hole pattern on opposite end of tube shall be in alignment with first hole pattern.

3. Tubes ends (parting cuts) shall be perpendicular to the axis of the tube.

3. Tube end (A) shall have a 30[degree] chamfer on the inside diameter with a depth of 0.090 [inch] measured from the finished end of the tube. Tube end (B) (opposite tube end (A)) shall have a 45 [degree] chamfer on the inside diameter with a depth of 0.060 [inch] measured from the finished end of the tube.

3. Tubes shall have a milled shoulder on the inside of each end of the tube, concentric with the tube with a diameter of 12.625 [inch] and a length of 1.515 [inch] measured from the finished end of the tube.

0. Quality Control

4. Ends shall show minimal tearout of fibers due to any cutting operations

4. Tubes shall be free of naked-eye visible delaminations between any layers.

4. Outer surfaces shall be free of excess epoxy

4. Outer surfaces shall be free from dents or deformations greater than 3% of the wall thickness in depth as measured from the surrounding surface.

4. Outer surfaces shall be as-cured with any compression windings, peel-ply, vacuum bags removed. Marks left by compression windings are acceptable inasmuch as they comply with the maximum deformations indicated in paragraph 1.e.iv.

1. Item 2: Manufacture two (2) filament wound cylinders composed of Torayca T700S carbon fiber filament and UF3325 TCR Resin.

1. Quantity: 2

1. Dimensions:

1. Inner Diameter: 8 [inch]

1. Length: 50 [inch]

1. Wall thickness: 1 [inch]

1. Winding schedule: [±852,±45, ±852,±15]10

2. Final desired thickness 1.0 [inch], ‘N’ is an integer number of repeated layers equal to or greater than final wall thickness of 1.0 [inch]. Estimated ‘N’ quantity is 10, based on 0.00875 [inch] thickness per angle.

2. Winding angles indicate braided (helical) winding of opposing angles. Schedule begins with “hoop” winding (±85) nearest the mandrel.

2. Angles are measured in degrees from the cylinder axis, [90] indicates hoop or circumferential winding, while [0] indicates axial or longitudinal winding. Subscripts indicate repeated layers.

2. If intermediate cure necessary, adequate surface preparation (cleanliness, surface profile, etc.) is required to ensure following layers are properly adhered to partially cured layers.

1. Additional Features

3. Six (6) pilot holes at each end of the tubes drilled at 60 [degrees] apart and at 0.75 [inch] from end of tube. Diameter of holes 0.281 [inch]. Each hole shall be have a counterbore concentric with the through-hole with a diameter of 0.75 [inch] and a depth of 0.06 [inch]. Hole pattern on opposite end of tube shall be in alignment with first hole pattern.

3. Tubes ends (parting cuts) shall be perpendicular to the axis of the tube.

3. Tube end (A) shall have a 30[degree] chamfer on the inside diameter with a depth of 0.090 [inch] measured from the finished end of the tube. Tube end (B) (opposite tube end (A)) shall have a 45 [degree] chamfer on the inside diameter with a depth of 0.060 [inch] measured from the finished end of the tube.

3. Tubes shall have a milled shoulder on the inside of each end of the tube, concentric with the tube with a diameter of 8.060 [inch] and a length of 1.563 [inch] measured from the finished end of the tube.

1. Quality Control

4. Ends shall show minimal tearout of fibers due to any cutting operations

4. Tubes shall be free of naked-eye visible delaminations between any layers.

4. Outer surfaces shall be free of excess epoxy

4. Outer surfaces shall be free from dents or deformations greater than 3% of the wall thickness in depth as measured from the surrounding surface.

4. Outer surfaces shall be as-cured with any compression windings, peel-ply, vacuum bags removed. Marks left by compression windings are acceptable inasmuch as they comply with the maximum deformations indicated in paragraph 2.e.iv.

Office of Contracting and Logistics Management Revised 05 Mar 2015