Attachment_0001_-_Scope_of_Work.pdf

Muzzle Brake, PN 11582647 Simulation SOW 9/19/2018

Scope of work:

Rock Island Arsenal Joint Manufacturing Technology Center (RIA-JMTC) is requesting services to simulate and provide analysis on an existing casting design (gating and riser design) validating it with existing casting inspection results provided by RIA-JMTC.

Upon funding the vendor is welcome to visit RIA-JMTC to review existing tooling foundry practices and review results of past attempts. Alternatively information can be provided via telephone and E-mail. The simulation shall use the software called Magma soft 5.3.1.3 which will include the Magma Stress & Magma Steel modules and performed by an operator that is certified in Magma Stress module through Magmasoft Company. The vendor shall demonstrate and explain their simulation results in multiple ways, building a case as to why the defect is occurring, as well as specifically how and why they choose their scales. They are also expected to fully explain how the simulations were set-up and ran. To expedite the simulations the vendor will have no less than an 8 cores licenses. Once simulation is compete the vendor shall provide immediate feedback as to the results while continuing to alter/improve the design without removing material from the original casting. While performing and validating simulations, and while altering the mold design, to improve simulation results, the vendor shall plan and lead weekly meetings with RIA-JMTC to communicate status and allow for technical collaboration. After the vendor believes they have a mold design that will yield an acceptable casting, and RIA-JMTC has reviewed the design, to ensure it can be facilitated at RIA-JMTC, they shall provide RIA-JMTC with a solid model identifying any modifications that were made to facilitate an acceptable simulation, as well a power point presentation, explaining the results. An acceptable casting is one that would pass the radiographic, magnetic particle and visual inspection, in accordance with muzzle brake drawing 11582647 rev -. It is expected this presentation will document and confirm what has already been discussed and agreed upon during previous weekly meetings.

Using the information provided by the vendor RIA-JMTC will produce a mold and facilitate a pour from which RIA-JMTC will validate the findings in the simulation. The vendor shall be on-site at RIA-JMTC to review the results of the simulation and the physical casting. If casting is not acceptable a second simulation effort shall be performed by the vendor to duplicate the defect and provide recommendations, as was done in the first effort. Delivering the same deliverables as the first time.

Communication & Site Visits:

Conference calls are expected to occur no less than weekly via phone. After each simulation that is poured the vendor is expected to review the results at RIA-JMTC and compare them to the simulation. After which the vendor will supply an after action report explaining what if any difference from the simulation.

Timeline:

After receiving the solid models from RIA-JMTC the first accepted evaluation of the simulation shall include, providing the solid model, and power point brief all to be finished in 42* days or less. During the 42* days meetings are to be held weekly if not more frequently if either vendor or RIA-JMTC request it. (VIA Teleconference)

After the casting is poured and has been inspected vendor is expected to return to review results and compare them to the simulation. If the casting does not pass the drawing’s surface and internal quality requirements they, the vendor is to begin the second simulation effort which should be completed within 30* days.

RIA-JMTC will provide the following:

• muzzle brake drawing 11582647, Rev -

• Which identifies the dimensional and quality requirements (radiographic, magnetic particle and visual criteria).

• History of work done so far

• Photos of defects

• X-ray results

• Gating history

• Chills used

• Sleeves used filters used

• Cores and core materials used

• shrink factors used

• Computer Aided Design (CAD) model of the mold design (any format requested if readily available)

• cast alloy typical chemistry

• pouring temperature range pouring method (lip vs bottom pour)

• mold sand and binder system

• Any special sands for chills or cores

• Mold wash used

• Filter type

• Chill material

• Core design

• Pouring time or rates throughout the full ladle

• Ladle dimensions

• Nozzle diameter

• Dimensional and quality inspection data from prove-out pour

Contractor will provide:

•- user results as listed

• Recommended pour temperature

• Hot tear prediction

• Cold crack prediction

• Shrink rate prediction for multiple dimensions in the X, Y, & Z direction

• Porosity prediction

• Niyama prediction

• Micro-porosity prediction

• Soundness prediction

• Hot spot Fraction Solid Time (FST) time prediction

• Air entrapment prediction

• Flow tracer with particle conglomeration (showing where dirt and oxides may stick)

• Contractor may substitute their own user results to show defects with approval from the contracting officer

• Contractor must be able to create user defined results to show predicted defects upon request from RIA-JMTC

• Contractor shall choose appropriate scales and radiographic settings; however RIA-JMTC reserves the right to require scales be changed to improve interpretation

• Provide full simulation package and explain results, including validation of model against actual results, within 42* days of receiving RIA-JMTC mold design CAD model and casting inspection results

• Provide full simulation package of the second attempt and explain results within 30* days after reviewing the results from the first attempt.

• Simulation results shall be in PowerPoint. Other formats the contractor believes will perform as well must be approved through the contracting officer.

• Explanation of inputs and outputs from the software including range

• Recommendations for mold design changes to positively affect simulation results and actual pour results.

* Working days (approximate and dependent on circumstances)

** If file sizes are too large to provide via electronic means (E-mail, AMERDEC safe site, etc.) then RIA-JMTC will visit contractor site. RIA-JMTC personnel must be able to travel to contractor's site, review the simulation package and return in 72 hours. This will avoid a lengthy response time and high travel.

Security Training (not needing a CAC):

1. AT Level I Training.

All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete AT Level I awareness training. The COR will be provided a copy of the RIA-JMTC AT Level I awareness training and assuring the training is completed.

The contractor shall sign a Memorandum of Record for each contractor employee and subcontractor employee to the RIA-JMTC Operations Center prior to a RIA-JMTC electronic keys and access pass being issued.

2. Access and General Protection/Security Policy and Procedures.

The contractor and all associated subcontractors employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services.

The contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DoD, HQDA, and/or local policy. In addition to the changes otherwise authorized by the change clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

3. For contractors that do not require CAC, but require access to a DoD facility or installation.

Contractor and all associated subcontractor employees shall comply with adjudication standards and procedures using the National Crime Information Center interstate identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05/AR 190-13), applicable installation, facility access and local security policies and procedures (provided by government representative). The COR will provide guidance to complete the Access Control Records Check request Form thru the RIA Directorate of Emergency Services.

4. Access Badges and Electronic Keys.

Contractor will acquire and need to return all issued U.S. Government Common Access Cards, installation badges, and/or access passes. Use FAR 52.204-9 or PADDS Clause IF00015 IF00015 at the end of the contract or the last day of an individual contractor’s employment.

4.1. RIA-JMTC electronic keys and access passes are accountable items and will be returned within 24 hours of no longer being needed. Items will returned to the COR or placed in a drop box at a RIA-JMTC access point.

4.2 Contractors who routinely fail to return these items will not be issued them in support of any future contract.

5. IWATCH (See Something, Say Something) Training.

The Contractor and all associated subcontractors shall brief all employees on the local iWATCH program. The iWATCH training will be provided in the RIA-JMTC AT training.

6. Impact on contractor performance during increased FPCON during periods of increased threat.

During FPCONs Charlie and Delta, services may be discontinued/postponed due to higher threat. Services will resume when FPCON level is reduced to level Bravo or lower. The FPCON descriptions will be provided in the RIA-JMTC AT training.

The COR will keep the contractors informed on the current FPCON or any possible FPCON change.

7. Random Antiterrorism Measures Program (RAMP) participation.

Contractor personnel working on Rock Island Arsenal are subject to participation in installation RAMP security program (e.g. vehicles searches, wearing of ID badges, etc.).

Contractors will comply with any instructions given by the Rock Island Arsenal Police Department.

The RAMP program is discussed in the RIA-JMTC AT training.cost.