Tab_02_-_Statement_of_Work.pdf

Statement of Work for Cylindrical Tool

INTRODUCTION

Langley needs tooling that will be used to lay up a carbon-epoxy towed steered composite cylinder.

Section 1.0. SCOPE AND OBJECTIVES

The scope of this procurement is to design, analyze, and manufacture a suitable layup/cure cylindrical tool (see Figure 1) that is capable of interfacing with the NASA Automated Fiber Placement (AFP) rotator interface (see Figure 2).

Figure 1: GO-1 Cylindrical Tool

*Details from draft drawing 1281902 Tooling Concept 1281903

Surface Model VCP/VCS 1281904

Cylindrical Tool to be supplied

~25” ±0.1” OD

Composite Part: ~73” Long

Laser Target Locations (8) 4” extensions top and bottom

Rotator

Automated Fiber Placement (AFP) Robotic Head

Clearance 33.5”

Lead In/Out 10” Top and Bottom

Lead In/Lead Out 10”

Crane lift point

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, analyze, and manufacture a layup/cure cylindrical tool that meets the following Government requirements. The tool shall at a minimum meet the following requirements.

1. The GO-1 cylindrical tool shall be designed to facilitate the creation of the composite surface and allow for the part to be cured at a 356˚F cure temperature. NASA will provide a CAD Model of the required surface upon contract award.

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

Figure 2: Rotator Interface

X

Z

3. As defined by NASA the layup/cure tool is approximately 135.5” tall with a 25” diameter.

4. Contractor will compensate tool for coefficient of thermal expansion (CTE) so that final part dimensions are accurate. This will require the contractor to perform thermal analysis to determine tool deformation at the specified cure temperature. This information and related files to be provided to NASA for review as part of the design and analysis review (2.6.3).

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 356˚F during cure without any mold degradation.

This allows for temperature variations during the specified 356˚F cure cycle (356±10˚F).

8. The tool shall be capable of withstanding at a minimum five 356˚F cure cycles, each cure cycle will consist of a dwell at 356 ˚F for 4 hours.

9. The tool shall have a lifting provision for use with a 5 ton crane, single hook. This can be a hole in the backup structure to accommodate a properly rated lifting shackle to be provided by the contractor. If the tool and standoff are separate, both need to have lifting provisions. Structural analysis for worst case lifting loads should be performed and provided at the time of design review (see 3.2).

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

11. Tool surface shall be constructed of a proper material to allow for part removal after cool down (such as aluminum). Actual material to be determined by contractor through experience/analysis.

12. Surface shall be within +/- 0.005” of the surface model provided.

13. Tool to have 0.010” deflection or less with the bottom of the stand-off fixed and 120 lb applied at the very top in the direction perpendicular to the longitudinal axis of the tool.

Perform structural analysis to determine deflection should be provided at the time of design review (see 3.2).

14. The tool shall have vacuum integrity with a maximum leak rate of 1/4” Hg in 60 minutes at 27” Hg performed at room temperature.

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

16. Tool to have provision to be placed horizontal for autoclave process. Can rest on base if upper portion can be placed into cradle (contractor to provide) or a cure cart to be designed/provided. Structural/Thermal analysis to determine the tool will not deflect under heat/load conditions.

17. Added 0.030” Positional accuracy of surface to RT1 coordinate system.

18. Request for sealer/release recommendations

Section 2.2. TOOLING DESIGN

The Contractor shall develop a cylindrical 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. Thermal and structural analyses showing the predicted tool deformation: (a) at the nominal specified cure temperature and pressure (85 psi +15 psi / ‐0 psi) (b) under crane lift conditions prescribed in Figure 1. Lifting from top center.

3. 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 GO-1 effort.

Section 2.3.1 GO-1 CYLINDRICAL TOOL

The Contractor shall manufacture one GO-1 cylindrical tool that complies with the specification in section 2.1.1 and the Government approved 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 with measurement points spaced no farther than 0.25 in. in both axial and circumferential directions relative to the specified coordinate system. Scan format to be compatible with ProEngineer. This shall include a graphic tool representation to show location of the inspection data as well as the magnitude of surface deviation (see 3.3). Scan format to be compatible with ProEngineer and also provided in plain ASCII format (ie: x, y, z) using coordinate system detailed in Figure 3.

Figure 3: GO-1 Coordinate System

5. 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. Data to be sent in plain ASCII format (ie: x, y, z). (See 3.4)

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

7. Surface finish verification (32 RMS) (see 3.7)

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 cylindrical tool to Langley Research Center (LaRC). The Contractor shall be responsible for all shipping costs, arrangements, and applicable permits required to safely deliver the GO-1 cylindrical tool.

The tool shall be fully protected from the elements and shock during shipping. The contactor shall have a protection plan for the shipping and handling. Information to be provided to NASA prior to shipment (see 3.8)

Shipping address:

NASA LANGELY RESEARCH

4 South Marvin Street Bldg 1206 Hampton, VA 23681-2199

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 day

Contractor’s manufacturing facility and/or via Telecon

2.6.2 Project Status Telecon

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

2.6.3 Design & Analysis Review

Prior to starting the manufacturing of the GO-1 Tool 1

~2-3 hours Telecon

2.6.4 Hardware Acceptance Review

Prior to shipping the GO-1 Tool 1 ~1 day

Contractor’s manufacturing facility and/or via 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 & ANALYSIS REVIEW

The Contractor shall:

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

a. The fixture design (i.e., CAD models & drawings) and analysis (i.e., structural and thermal, including input and output analysis files and hand calculations) performed during this task.

b. The 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 tool inspection plans.

2) Deliver the 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 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 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 Tool Design & Analysis 1 EA At the Design & Analysis Review

See Task Ref.

3.3 2.4 Surface Scan

(within +/- 0.005”)

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 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.

3.7 2.4 Surface finish verification (32 RMS)

1 EA

At the Hardware Acceptance

Review See Task Ref.

3.8 2.5 Shipping Plan 1 EA At Task Order

Completion 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

GO-1 Tool Surface Model (GO1_Surface_1.prt, GO1_Surface_1.igs, GO1_Surface_1.stp)

1 EA Upon Task Award

Section 5.0. GOVERNMENT FURNISHED PROPERTY (GFP)

None

Section 6.0. PERIOD OF PERFORMANCE

All hardware shall be on dock at Langley 8-10 weeks from date of Purchase Order award.