Statement_of_Work.pdf

National Aeronautics and

Space Administration

NASA Langley Research Center Hampton, VA 23681

Advanced Composites Project (ACP)

Complex Contour Tooling (CCT)

Statement of Work

Table of Contents

INTRODUCTION

Section 1.0. SCOPE AND OBJECTIVES

Section 2.0. DESCRIPTION OF TASKS TO BE PERFORMED:

Section 2.1 GOVERNMENT DESIGN SPECIFICATION

Section 2.1.1. TOOLING SPECIFICATION

Section 2.2. ACP - TOOLING DESIGN

Section 2.3. MANUFACTURING

Section 2.3.1 COMPLEX CONTOUR TOOL (CCT)

Section 2.4. QUALITY DATA PACKAGE

Section 2.5. SHIPPING

Section 2.6. PLANNED PRESENTATIONS, MEETINGS, AND

TELECONFERENCES

Section 2.6.1. KICK-OFF MEETING

Section 2.6.2. PROJECT STATUS TELECON Section 2.6.3. DESIGN REVIEW Section 2.6.4. HARDWARE ACCEPTANCE REVIEW

Section 2.7. REPORTS

Section 3.0. DELIVERABLES

Section 4.0. GOVERNMENT FURNISHED INFORMATION (GFI)

Section 5.0. GOVERNMENT FURNISHED PROPERTY (GFP)

Section 6.0. ADDITIONAL DATA RIGHTS

Section 7.0. PERFORMANCE STANDARDS, PERFORMANCE METRICS, AND

ACCEPTANCE CRITERA

Section 8.0. SECURITY CLEARANCE REQUIREMENTS

Section 9.0. PERIOD OF PERFORMANCE

Section 10.0. POINTS OF CONTACT ...................................... Error! Bookmark not defined.0

INTRODUCTION

The objective of this portion of the ACP project is to evaluate the ability of the CG Tech

VCP/VCS fiber placement software to accurately predict layup laps, gaps, and wrinkles.

Section 1.0. SCOPE AND OBJECTIVES

The scope of this procurement is to design and manufacture a suitable complex contour tool

(CCT) that is capable of interfacing with the NASA Automated Fiber Placement rotator stand.

Figure 1: ACP Complex Contour Tool (CCT)

*Details from draft drawing 1281895.

Complex Contour Tool (CCT)

Laser Target Locations

Rotator

Automated Fiber

Placement (AFP)

Robotic Head

Clearance 33.5”

Section 2.0. DESCRIPTION OF TASKS TO BE PERFORMED:

The Contractor shall perform the following tasks:

Section 2.1 GOVERNMENT DESIGN SPECIFICATION

Section 2.1.1. TOOLING SPECIFICATION

The Contractor shall design and manufacture a complex contour tool that meets the following

Government requirements. The tool shall at a minimum meet the following requirements.

1. The complex contour tool shall be designed to facilitate the creation of the composite surface and allow for the part to be cured at a 350˚F cure temperature. NASA will provide a CAD Model of the required CCT surface.

2. Tool is required to interface with existing rotator stand. Details shown in Figure 2.

Figure 2: Rotator Mounting Plate

3. As defined by NASA the layup/cure tool is approximately 55” long x 19” wide x 26” deep.

4. Contractor will compensate tool for coefficient of thermal expansion (CTE) to that final part dimensions are accurate.

5. The tool surface shall be smooth and fair with a surface finish of RMS* 32 or better on all surfaces within the edge of part (EOP). (*Root-Mean-Square roughness in micro-inches)

6. The tool shall be identified. Identification shall include the assembly part number and measured weight.

7. The tool shall be capable of tolerating 350˚F during cure without any mold degradation.

This allows for temperature variations during the specified 350˚F cure cycle.

8. The ACP tool shall be capable of withstanding at a minimum five 350˚F cure cycles, each cure cycle will consist of a dwell at 350 ˚F for 4 hours.

9. The tool shall have a lifting provision. This can be a hole in the backup structure to accommodate a properly rated lifting shackle to be provided by the contractor.

10. Fixture shall rest flat on bottom surface to allow for easy storage.

11. ACP tool surface shall be constructed of a carbon laminate. A polyimide topcoat to increase surface hardness and chemical resistance is required.

12. The ACP tool shall have vacuum integrity with a maximum leak rate of 1/4” Hg in 60 minutes at 27” Hg.

13. Tool to have a minimum of 8 laser tracking locations. Locations to accommodate a ¼” post with a 2” minimum face area.

Section 2.2. ACP - TOOLING DESIGN

The Contractor shall develop a complex contour tool that complies with the Government Design

Specifications defined in section 2.1.1. The design shall include at a minimum.

1. 3D CAD models of all proposed hardware in their native file format and in ProE or STEP format. The Tooling assembly files shall be provided such that the individual components can be selected, opened, and modified at a later date by the Government. (i.e., the assembly files shall not be provided in a way that they can only be selected / opened as a single component)

2. Minimal fabrication drawings necessary to describe the design, assembly, and operations completed per contractors internal standards and including a bill of material (BOM) for all purchased material and hardware.

The Government will review the Tool Design at the Tooling Design Review and provide written approval to the Contractor Program Manager (PM) via email.

Section 2.3. MANUFACTURING

The Contractor shall fabricate, inspect, and deliver the following hardware in support of the ACP effort.

Section 2.3.1 COMPLEX CONTOUR TOOL (CCT)

The Contractor shall manufacture one CCT that complies with the specification in section 2.1.1 and the Government approved CCT Tool design. The contractor shall provide all of the materials and equipment required for the fabrication effort. The mold surface and backup structure fabrication shall begin as soon as the Contractor has successfully completed all of the tooling design review requirements and received written authorization from the Government. Early fabrication of specific critical path items / activities may be permitted by the Government on a case-by-case basis. For these items, the Contractor shall receive written authorization from the

Government prior to starting fabrication. The Government reserves the right to witness the tooling fabrication and assembly efforts.

Section 2.4. QUALITY DATA PACKAGE

The Contractor shall assemble and deliver a Quality Data Package that contains the following information.

1. Material specifications and overall certificates of conformance.

2. Surface integrity / verification inspection report to be provided to the Government in the

Contractor format.

3. Room temperature vacuum integrity report.

4. Dimensional inspection of the tool surface shall be recorded. These shall include a graphic tool representation to show location of the inspection data as well as the magnitude of surface deviation.

5. Contractor to provide an as built laser scan of the layup surface relative to the specified coordinate system. Scan format to be compatible with ProEngineer. This scan to be sent immediately upon completion. Coordinate system detailed in Figure 3.

Figure 3: Complex Contour Tool (CCT) Coordinate System

6. Contractor to provide table detailing laser tracker ball positions (1.5” diameter ball with

¼” ball holder) relative to coordinate system shown in Figure 3.

7. Documentation of any anomalies that occurred during the manufacturing process and their impacts on part quality.

8. Surface finish verification (32 RMS).

The content and format of the quality data package shall be coordinated and approved by the government before fabrication begins.

The Government reserves the right to witness all inspection processes.

Section 2.5. SHIPPING

Following a successful Hardware Acceptance Review, the contractor shall ship the Complex

Contour Tool to Langley Research Center (LaRC). The Contractor shall be responsible for all shipping costs, arrangements, and applicable permits required to safely deliver the CCT. The

CCT shall be fully protected from the elements and shock during shipping. The contactor shall have a protection plan for the shipping and handling.

Shipping address:

NASA LANGELY RESEARCH

4 South Marvin Street Bldg 1206

Hampton, VA 23681-2199

Attn: Joe McKenney

Section 2.6. PLANNED PRESENTATIONS, MEETINGS, AND TELECONFERENCES

The Contractor shall be required to participate in and/or travel to the presentations/ meetings/teleconferences as specified below.

MEETINGS:

Task MEETING FREQUENCY/DATE

ESTIMATED

DURATION

PLANNED

LOCATION

2.6.1 Kick-Off

Meeting

Within 1 week from Task Order

Award date.1 ~1 hour Telecon

2.6.2 Project Status

Telecon Bi-Weekly (i.e., every 2 weeks) 1 ~1 hour

Telecon

2.6.3 Design

Review

Prior to starting the manufacturing of the ACP Tool 1 ~1 hour

Telecon

2.6.4

Hardware

Acceptance

Review

Prior to shipping the ACP Tool 1 ~1 hour

Telecon

1Date and time to be mutually agreed upon by the Contractor and the Government.

Table 1. Presentations, Meetings, and Teleconferences.

Section 2.6.1. KICK-OFF MEETING

For the Kick-Off Meeting, the Contractor shall prepare a Kick-off Presentation that facilitates review and discussion of the proposed tooling and fabrication plans. An electronic version of the

Presentation shall be delivered to the Technical Monitor (TM) at the time of the presentation.

Section 2.6.2. PROJECT STATUS TELECON

For the Project Status Telecon, the Contractor shall participate in bi-weekly teleconferences to discuss the ongoing work status. Any issues affecting cost, schedule, or part quality shall be discussed, documented in writing and emailed to the TM.

Section 2.6.3. DESIGN REVIEW

The Contractor shall:

1) Prepare, present, and deliver a Design Review Presentation containing at a minimum a review of:

a. The ACP Fixture design (i.e., CAD models & drawings)

b. The ACP Tool functionality and how the hardware designs meet the specification listed in section 2.1.1.

c. The shipping plans and methods for protecting the hardware.

d. The ACP Tool inspection plans.

2) Deliver the ACP – Tooling Design.

An electronic copy of the Design Presentation shall be delivered to the TM at the time of the briefing.

Section 2.6.4. HARDWARE ACCEPTANCE REVIEW

The Hardware Acceptance Review will take place at the Contractor’s manufacturing facility or via telecon. During this review, the Contractor shall:

1. Present, and deliver the Quality Data Package in an editable Microsoft Word compatible format.

2. Review the shipping arrangements and discuss how the ACP Tool will be protected during transportation to LaRC.

The Quality Data Package shall be delivered to the NASA TM at the time of the briefing.

Section 2.7. REPORTS

No reports are required for this task.

Section 3.0. DELIVERABLES

The Contractor shall deliver the following items FOB Destination. All deliverables shall be delivered with unlimited rights and unrestricted rights.

Item

No.

Task

Ref.

Deliverable Description Qty. Due Date

Delivery

Instructions

3.1 2.6.1 Kick-off Presentation 1 EA Within 2 weeks of

Task Order Award See Task Ref.

3.2 2.6.3 ACP Tool Design 1 EA At the Design

Review See Task Ref.

3.3 2.4 Surface Scan 1 EA At Task Order

Completion See Task Ref.

3.4 2.4 Tracker ball locations 1 EA At Task Order

Completion See Task Ref.

3.5 3.1.1 ACP Tool 1 EA At Task Order

Completion See Task Ref.

3.6 2.6.4 Quality Data Package 1 EA

At the Hardware

Acceptance

Review

See Task Ref.

Section 4.0. GOVERNMENT FURNISHED INFORMATION (GFI)

The Government will provide the following to the Contractor as follows:

Item

No.

Task

Ref.

ITEM

QTY

Date to be Furnished to the

Contractor (on or before)

4.1 2.1.1

ACP Tool Surface Model

(CCT_Surface_1.prt, CCT_Surface_1.igs, CCT_Surface_1.stp)

1 EA Upon Task Award

Section 5.0. GOVERNMENT FURNISHED PROPERTY (GFP)

None

Section 6.0. ADDITIONAL DATA RIGHTS

Reserved

Section 7.0. PERFORMANCE STANDARDS, PERFORMANCE METRICS, AND

ACCEPTANCE CRITERA

Quote must be best value for NASA.

Section 8.0. SECURITY CLEARANCE REQUIREMENTS

None

Section 9.0. PERIOD OF PERFORMANCE

All hardware shall be on dock at Langley 8 weeks from date of Purchase Order award.