AFFDL-TR.76-87Volume II - Appendix

II- L ,.. ,... .L ."rL G '_t

KADVANCED COMPOSLTE COST ESTIMATING MANUAL

NORTHROP CORPORATIONAIRCRAFT DIVISION

HAWTHORNE, CALIFORNIA 90250

AUGUST 1976

TECHNICAL REPORT AFFDL-TR-76-87FINAL REPORT FOR PERIOD APRIL 19'o5 - MARCH 1976

C ) JApproved for public release; distribution unlimitedLWIdC C= AIR FORCE FLIGHT DYNAMICS LABORATORY

AIR FORCE WRIGHT AERONAUTICAL LABORATORIESAIR FORCE SYSTEMS COMMANDWRIGHT-PATTERSON AIR FORCE BASE, OHIO 454.33

. 94rbp

NOTICE

Whe':n Coverunent drawings, specifications, or ofther data are used for any purposeother than in connection with a definitely rolatt'd ;ovcrnment procurolmont operation,the United States Government thereby incurs no responsibility nor any obligationm;;atsoever; and the fact that the government rmnij have formulated, furnished, or inany way supplied the said drawings, spacificat ;ons, or other data, is not to beregarded by implication or otherwise as in any irnnner licensing the holder or anyother person or corporation, or conveying any rights or permission to mkinufacture,use, or sell any patented invention that may In any wag be related thereto.

This technical report has been reviewed and is approved.

RHADJ. HfYRTProject EngineerVehicle Synthesis BranchAeromechanics DivisionAF Flight Dynamics Laboratory

FOR THE COWANDER

R D. I 1Chief, Aerourechanics D , sionAF Flight Dynamics La r tory

This report has been reviewed and cleared for open publication and/or public releaseby the appropriate Office of Information (01) in accordance wi.h AFR 190-17 and DODW)5230.9. There is no ob.ection to unlimited distribution of this report to the publicAt large or by DDC to the National Technical Information Service (NTIS).

Copies of this report sho-uld not be returned unlosG return Is required by securitYconsiderations, contractal obligations, or notico on a speicific document.

A I P R n .4I -AA~vl 1,,,)

- '

- - - -

UNCLASSIFIEDSIECURITY CLASSIFICATION OF THIS PAGE (Wh,., Dlata Ento,.d)

REPORT DOCUMENTATION PAGE BEFPORE C'OMPLEINGi FORMI. %EPOSI' NUMBUPS v 2 OcVT ACCt . 3 Sl'ENSCAA

AFFDL(-TR-76-87 'vol 1; (AppendixL_ __ _______________

4. TITLE (snd $ubttfiD)A E10C V R1.)

VOLUME ~ .I AprWW75 4a'3l M rVOUM 1K:Apedx j j j MANUALIN OR R/!" [:Z2R9FNUM--1 JLeblnct T:/Betn~rF33615-75-C-3103

9I. COF '0LMING 0111PMc.P NAME AND ADRESS 0PORMEMNTPOJCAS

Air Force Flight Dynamics Laboratory A~ Au 76Air Force Systems Conmand NRO AEWright-Patterson Air Force Base, OH 45433 153

14 M01ORmNG A.ENCN NAME & kDORSlSiIf difo.pt ?bm C,.ntrtIIrnd Office 15 SECURITIF CLASS (of thlo report)l

UNCLASSI FlED

SCiEDUI

4~ O);T N ItUTICON ,TATEMENT tot the. Repot,

Aprvdfor public release; distribution unlimited.

L?7ZI MN of th *1411tnfoloc In II IIIOIt 2,O ilit 1 ,4 i't'l1b PiLc~EMINAR'l NOFFS

14 K F NWORDS f ,nn,, -n reverse. edm in.ti, onsatv ard tCentift- bi- block niamh., - .

Advanced Composite Materials, Detailed Parametric, Cost Estimating,Met hodo logy

20 ABSTRACT r,,,,tlnu,..,n riivlrab Mne. It ,poct,804f and Ieoenelf Iss block n-ter, p)

This program concentrated on the development of a computerized system that esti-mates the recurring costs associated with the fabrication of advanced compositedetail parts and components. The system employs industrial Engineering Stnndardequations developed in the program to calculate standard hours for the detailcomposite fabrication operations of layup, core preparation, part consolidationand finishing. With these standards as base, recurring Losts are derivedthrough the application of variance fantors, improvement curve slopes and laborrates. m

DD 1473 EDITION OF I NOV 6S IS OUAOLf'E UNCLASSIFIEDSECURITYV CL ASSIFICATION1 OF '16I1 PAGE (11101eo Dat Ef'Oted)

.0.0.

Thi i'(v1w.1 1 l v-Yrtv: ; jjrevirk4 by thc' Ai .-rcrft DiI.sion of Noi ithropj

fl~-~i~ Hi I ,Ai(C.: jtmcL : 1133b 5 -.75-C-31 01 for th2 Ai r rcc Flight [Yy-

ui~j~ Xd)2r~diyAir Iror(cn IldjIaL Ac-ronaatical i L11rat-utw s, Air Porca Sy-iLtIII:2 eurI . i;LPtI Air R'(1co 1Bisn, Ohio. Mr. WrHic'hw J. Ilirt e

? ~ 11- i . o. h reI'.i1L covers the p'riod I rurn

1 April 1975 to 31 Ri'rch 1976.

Illi woxrk do,,cr~IU-xx in tho rejxaxt was carried out by Northrop Corporation,

Aircraft Diviin, 1). J. Le~lanc, P'ECXrUTI DjircItor7. Principz'l contributorsto the lbrthrcp Lctivitios dascriLWa in this rep-ort and their areas of respo~n-

RiIbility ZIY-e .1iSted xl:

J. Itrcnzwiaa Principal Cost Investigator

A. Kokaiwa COst Analysis4T. Tt nzCost Anal~ysi~s

F. TiiiLon Cost Anlysis

J. Proctor Cost Analysis

H. J. Bechrens Industrxial Fmincering

L. Lyle Detail Enqineerinq

M. I1kx: Coff~iptecr lroqramminc

L. 13,,rnhatrdt Design wnd Analysis

low

be UA

N,*gTh'I0. AVY1; IMTU? c'o8

S*S= I.ANCiT *_i ZIAL

Pzor CcRnIUs'

A cCmwV1E P1Rawl LISTING

aPE1ANEr iNpuT I)NTA sms1 42c ~ 'JoS C=~RDL LANXJAX AA 48D ' 4SAMPLE ESTn%?TW 5

tamR ILmFO 50

IOAEfl FUSEAC1 Pi i 74

UPPER ra UMER SKINS - ILING MM~ FL 99

HATr STrFF1L.W PANEL 123

FIMEDING PA L.A1IC.NT IM

APPENDIX A. COMfPUTER PROGRAM LISTING

The ACCF. computer program listing consists of a main program vhich calls

four subroutines. Each section performa a particular function of the e4ti-

mating methodology, as identified below.

ACCEM

FUNCTI ON COMP"TER PROGRAM

* FACTORY LABOR STANDARDS ESTIMATING

- LAYUP

- CORE PREPARATION

- PART CONSOLII)ATION

- FINISHING TT T1 P

* SUPPORT FUNCTIONS ESTIMATING [-AIN

* COST PROJECTION TTLCO MPO NEN'II

The program listing contains instructions only. Calculations ar - de using

constants from the Permanent Input Data Sets and informaLion froi the Variable

Input Data Set (keypunched from Input Forms.)

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'41

APPENDIX B. PERMANENT INPUT DATA SETS

The constants used in calculations performed by the program as well as some

of the identifying labels printed in the output are contained in five

Permanent Input Data Sets. The organization of Data Sets allows convenient

access for reference purposes, or in case changes need to be made. The

constants or the labels may be changed by editing the Data Sets, without dis-

turbing the program instructions.

Four of the Data Sets provide the data for Factory Labor Standards Estimating

in each of the subroutines; the fifth provides data for Support Functions

Estimating and Cost Projection in the main program.

J

4 2

1AYUP DAIR SETI

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0 APPLY RELEASE ACGENI 0.000009 100TRIANS Tfl CLIING timOL 0.00C14b C*6711

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CORE PREPARMOTNt DATA Si~P

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11 SCA0a CUT PqANOLNt 0.002057 0.50::

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I MI1 UP V.05 00 o5 0 02 APPLY :::cbl:& 00000055 0 03 HiANDLING 0000150 006311 0 0

5 PtFlT 1:14ILS 0.001326 0*522 5tAPPLY ADHESIVE 0.00005517AS SE ME EII 0004 0671b5F #PDPLV PORUFI~tLM~ 000002oo 1000000011APPLY VFNI CLOIH 0.00002 100cV12 INSTALL VACLOM F76S co00e2 2 CD

13 INSALL 1hERIOULPL.4 0.016? 2 ?14 APPLY SkAL IIII0.00016 3 ()15 APPLY 1.1SPOSAPLE bAC 000000(4 1.000000 64 0It 4VAL EDG0E! 00000!0 3 017 APPLY k'tVSAPLI: HAG cootol0j 100000 0 'k16 CLAMPAOC( 5 040002 3 Ci 314 CUNNFCT VhCkjUP LINES 0.0061 0.0061 1 120 Ss'iCf'Ig0 PAG E-OWN ,.O0cj(ob 1.Clicouo 44ZI1 CHiELK StALS 0.00(11 3322 KLPM0VP VALUUM LINI 066(031 09.l. IP '. CHECK LMANI'fk INI. cl.0.s 0.0(31 1i4 LVAtD LAYLIP IN O'ViN 0.0L'011. 0*8! bt C f;S LLIA,' LA~vU IN AU10. U*000145 0.6111 0.0is0 4 (s26 C(NNkCI VACUUM LIN-.$ 0.0ohl 2e27* CE'%NfLy I.C. LFALJ, 6*00CVZ 4IF CtkC.K PF'I. LEAKS 0.000006 0.(jO0k7 0.00to A24 CLOSE POOuR 01019? 0. (%1 S2 113c, Wo kIc0LEPS 0.014v 00COJIS 1131 CYCLE CtiELK 0.0800 000800 1132 $HUT CIc'WN 0.00332 0.0001:3 11?? REkMOVE CHAIS 0.00J32 06COC43 I I34 OPIN LC-OR 0*01402 o.ci'r2 I31 PELEA*. 1.L. L JAO4 000035 2236 RILtLA5E VAC. LINES 0.0031!I kfMOVF lPAIk Ptk OVL. 0.00(C-114. 0.bS*6 0 436 IkIM0VE PART1 FR AUICIj. 0.000145 0.611 0,0120 4 0%40 R[LWAF CLAMPS 0000007 0. 1 l0 0 340' AE4OVf RELS. BSAG 0100000e 1.000000 0 '.41 REPOVE LU1SP. BAG 0,000003 1,000000 4 04? REMOVE IHERMOLOUPLES 0.00'V5 2 24)3 PFMnVL VACOUM F1t6S 0.0029 2 044 REMOVE PPRCESS MAIL 0.000019 1.000000j 0.000014 4 '45 PFMOVE tANUP L ASiI 0.00G006 1.000000 4 446. ELEAN 700CL 0.000006 1.000000 4 447 Sf1 UP 0.45 0.05 1 14P FIT LAYUPS INTO MOLDi 0,00237 0.0608? 0000160 !o b44 ChFCK OVEN IN1ERIOk ~ osy , CIi0C3 0 1SC0 LOAD CAC~k INICI OVIkN 001114 0.6566 0 3

52 CU-RF IN *i4AIING ELLM 0.0020,4 0.3207

b3SET1b-~el(40b OO!, YL 1,EK7000 000S5~~~~~ ~ ~ SHTDW .0I 00.

56 ~ ~ . d.EIOO&w L4.D@ Go03 003C57 IPN vos 00S.r .010 0l' 1

FINISHING DPLTPL SL

I PIANUL) -A ~ING1 0606#47 0."V211* 0.012MAC.NRNF RO)UTING 0.0013 Do. 0.203 mANu SAwINf. 0.0046 0.6624. 0.U%PACMNe SAN 0.0002 00.41 0.00

5 "AeN SANIN. 000005 uso. 046 PoKls IOUlL SAC)!Nto 0600dO1.0 Is.sti7 AH SANUiING 0.000046 0. a.p$I UPkINING 0.000 to. 0.01

10 DRILLINGI 0.02b'q3 0. 33?( (0..5&92 (06400(. 00It AFAMIN6 (o.01k1S 0.21'.? 00153 0*0006 000

12 CtiUNlkKSINKIN~. 0.00-45 0025VU 0 0.000 006b!3 C0QNTI~enR1NG 060014 00!096 02756 0.OO06 0.05146 ~I(ME SAWING ~ 6.01Z93 C.. 1010151 080006 000b

14I ('.L71 0.21IN ass 00.(0'006 6016 (.00014S O.#711~

IQ (CCC.A10 067lCoI

46

CO~ST PJCX7MIONct DATA\ SM

3 e.'V4 3403 230?4 #~1%a1 .6?howco4F m( COREt PREP 1.3970 15 *4359 0.0 000

'1 PART CflN~tLIDAYIUN J6.40 25.06 bb7 654 FIN1SgtING O~PAINS 35619 23.8g. LVJ*62 ?t?5 TfVIAL FACIMYS LAI'Wk 0. 0.6 FAICTOkY LAOORI 1. 04 0: 0. 10.

%MFG kNcGINtERING 1 0.722Y -0.1026 I.0Cjb2 -00425b 10.10 tNGINSERIN, 6 .3S4 -00Z22 0.352.. -0.3713 10.11 C.RAPh1C I VLr' 0.nb?% -0*2?b C0032 -0.164.o 10.1? PAOMUCIUN MA1PR1AL at I .013 SUPPOR~T %A1t1A~L 7 0.30 0.14 "P- ALLOWANCE 0.021! 1050

17 loso

114 10At

70 1.7021 (o.

47

APPENDIX C. JOB CONTROL LANGUAGE

The Job Control Language (JCI,) for the ACCEM cc'mputer progrin provide.

allocation of several data sets. The files which are required are described

be Nk..

FILE NO. DESCRIPTION RECORD LENGTH

1 ..4 Perma'iient Input Data Set - May be read in from 80cards oi 43

//ACCEM EXEC FORTXCLG,REGION.GO-100K

//FORT.SYSIN DD

PR#GRAM LISTINGI

//GO.FTOlFOOl O

jACCEM 1 LAYUP DATAj

//GO.FTO2FOOl DDO

IACCEM 2 CORE PREPARATION DATAj

//GO.FTO3FOOI DO

1ACCEM 3 PART CONSOLIDATION DATAj

//GO.FTO4FOOl DO

ACCEM 4 FINISHING DATAI

//GO.FTO9FOO1 DDO

ACCEM 5 COST PROJECTION DATAI

//GO.FTlOFOOl DD UNIT=SYSDA,SPACE=(CVL,(1,1))

//GO.FT11FOOl DD UNIT7SYSDA,SPACE-(CYL,(L.L))

//G0.FTO8FOO1 DD SYS0UT=A

//G0.FTO6FOO1 DO SYS0UT=A

//GO.FTO5FOO1 DD*

IINPUT DATAJ

491

APPENDIX D. SAMPLE ESTIMATES

Four sample estirates have been prepared to demonstrate the employment of the

ACCI'H computerized system. For each estimate, a sketch of the part and a

manufacturing plan supply the part, material, and fabrication process data

necessary to fill out the forms. The completed forms and the resulting

computer outputs are included to represent complete execution of the esti-

mating cycle.

LOWER LONGERON (SR-001921-19)

DESCRIPTION

The lower lonperon component consists of two graphite/epoxy 20 ply thick "L"

shaped legs with a moldline contoured 20 ply thick graphite/epoxy strap. Also

included in this structure is a wedge shaped precast epoxy filled assembly

which acts as a tooling aid and becomes an integral part of the finished lower

longeron component. The total longeron structure is formed in one operation

through the cocuring of both "L" shaped legs and the graphite strap in one

curing cycle as outlined in the detail manufacturing plan, and discussed in

the following paragraphs.

The tooling concept utilized in the fabrication of the lower longeron elements

consisted of: (1) a thin steel brake formed curing (moldline) surface welded

to a steel carriage frame; and (2) two brake formed angle tools for laying up

and curing of the "L" shaped leg components. One of the brake formed angles

incorporated a top flange to prevent longeron distortion during the cocuring

cycle.

50

51%

paw,4

of -Alp

The 20 ply "L" shaped graphite/epoxy components were laved up in the flat in

five ply books, subsequently draped and formed over the brake formed angle

tools with each succeeding book being layed and formed over the preceding bonk

until the tntal 20 ply component was layed up. The 20 ply graphite/epoxy

moldline strap was then layed up on the contoured moldline cocuring tool ard

formed to this shape. The precast epoxy assembly was located on the graphite

strap and resin tacked in place. The "L" shaped graphite assemblies were

positioned on either side of the epoxy casting making intimate contact with

this casting and the graphite strap assembly providing a "T" shaped component.

No structural adhesive was required between these assemblies as resin bonding

was accomplished in these areas during the cocuring operation. The completed

assembly was then vacuum bagged using a reusable rubber vacuum bag and cocured

in one operation in an autoclave at 50 psi (full vacuum + 35 psi autoclave

pressure) for two hours at 300* F with no resin bleeding being accomplished.

The asvembly after the cocuring cycle exhibited excellent dimensional toler-

ances and configuration stability. The components were then net trimmed,

subjected to quality assurance evaluations and set aside for subsequent joining

operations to the lower fuselage and equipment deck assemblies.

}HJNIFACTURING PLA!N

1. The following list of detail parts makes up the lower longeron assembly.

a. Upper composite angle (-77).

b. Lower composite angle (-77).

c. Composite strap (-79).

2. Materials

a. Thornel 300/SP288 graphite/epoxy - per NAI-1332.

52

Sa Ap.---~~h.J

- * " "~- "" ° #

" ".. .. " "

• w "

%, -" .. , ; ,. , , .| .

3. Lavup and Cocure of Graphite/Epoxv Lower Lonugeron

a. The 20 plies required by drawing SR-0019k1 shall be layed up in five

books. Each book shall be transferred to the brake-formed tool, and

layup shall continue until the buildup of all plies is completed

and the two composite angles have been laved up.

b. The -77 composite angles shall be set aside for subsequent cocuring

operations.

c. The No. 1 composite ply (0') of the composite strap (-79) shall be

layed up on the previously released kFreKote 33) lower longeron

cocuring tool per drawing SR-001921, This operation shall be

repeated until the buildup of all the plies is completed.

d. The fiberglass reinforced filler casting shall be wrapped with a

layer of structural adhesive (FI+-123-5), positioned on the -79

composite strap and adhesively tacked in place.

eo The -77 composite angles shall be positioned on either side of the

fiberglass reinforced epoxy filler casting and on top of the -79

composite strap and resin tacked in place. No structural adhesive

is required between the -77 composite angles and -79 composite strap

as resin bonding is accomplished during the cocuring operation.

f. Apply a laver of non-porous armalon over the entire layup and drape

to shape of componert.

C. Apply two layers of Osnaburp breather cloth over the layup and drape

to shape. Do not resin bleed the composite longeron.

53

IL~ ~ ~ ~ ~~~ ~~~~~~~~~A W t , .... O- , ; ,,,,, :,

h. The component shall be vacuum bagged using the reusable rubber

vacuum bag, and cocured at 50 psi (full vacuum + 35 poi autoclave

pressure) with a cure temperature of two hours at 300°F as monitored

by thermocouples.

i. Upon removal of the component from the bag, it will be exposed and

checked for conformity to previously determined dimensions; my

discrepancy shall be recorded.

J. The component shall be n:-t trimmed to final dinensions and delivered

to Quality Control.

k. Quality Control shall map all detectable voids and retain this record

as part of the inspection record.

54

X,- W AX W,.. . . . . . . . . . . . . . . . . . .. .

ACCEM-O IMPUT CHECKLiST

C ESTIMATOR NAME I' .. U D,. I

ESTIATE NUIBER 1 aM- 2

PART NAiE --

PART NUMBER 1" -,,oI"I

C 2 ItPUT FORMS QUANTJTY UEDACCElI- I LAYUP

ACCEM-2 HONEYCOMB CORE PREPARATION

ACCEM-3 PART CONSOLIDAION

7ACCEM-4 FINISHING OPERATIONS

ACCEM-5 COST PROJECTION

55

14 4

ACCIM- I LAYUP

CAMRD PART NAMC RT :10111 QTY

LAVUlP IB~ SAME AS (i. 4G TOOL (LtCik J4II N

KIULK114G ;jg or otcumomiEL$- 0TVPi 01 ItAG (CIfCLI ODA DISPOSABLE 4L REUSAVLtL J.

QWQ 2 (BLANK)WHITE11 110111GIAMS

1l Afvr TAP( 0001

cmO 31cosl IS/it)2AOCNIY (L11kCJ -A)

KEYPUNCH CARD 4 AND CARD 5 ALTERNATELY

LAST EN4 ON11 CAD5I 99' ATETYO AD5I 00

TV9 BEND~' I..CI 1O PL DESCRIPTIO

LAYLI' K~~i~h I * t~ttL, I!~fl-'~L~I 4 ~tt~ AUT IMEN O~A U1~A(RAAII~ UClNI)C RETNUA * r!Y.TANHULAo

1 s It w~u IAId RCEIN.)IA (IN.) 1EGI w I~ AREAtA ~~.UIIRIAL~~~(N. (IN.) 'I 0N.)~li 2*rDO: vr, 5

ACCLM- I LAVUP

COMOD I 111614 NAMI H~tTltu T

tII AI OA4C( A INI

tAYU#, IVA ~M A% LU111( TOML (CIRC~t 0110 It NO

ot UL r 146 of OrtCURAINIS IurLCD~ 2 BLAK)IVP( 01 LAG (CIA(LL 4 01 00AMO~S J-.. RIUSABLEL *..

TIL t ~ r 'Ati w1vtIICARD3 COST to) ~ ~ .Z77~ 7

KEYPUNCH CARD 4 AND CARD 5 ALTERNATELY

THOD OVID IISCkIPTIQN PLY DESCRIPT&cO

R!I"A RECTANGULAR NONRECTANGULAR

BriJ 14D 01 LANGE1, OST H URVATUR[ WIDTH

LINGTH WIDTH AREA DISTAICE

LAST ~ ~ ~ i (NRINCR 4I I99S.LS NRN. (AIN (IIN.OOLrSQ. IN.

1 1tV t( -U~P A , A A

AIl:A~Il! * l A~htI\. A. A. A~~. 41 A/ I

.4-4-A -A-i-~~~~~~..' AA-4 --.. . . ..J...4-4 *A- . --A

ACCEM-3 PART CONSOLIDATION

CYCLE NUMBER

CooI JAT NAK IAR NUMER ATY

COMPONENT DETAIL PARTSlMBER OF LINES USED:0)

PART NAME IRT NI4BER TITY

CONSOLIDATION OF DETAILS

CAM 3 ADHESIVE (CIRCLE ONE) APLIAIO 0AE: YES:_______ I_

___O A. S IN.

ADTIONAL OPERATIONS I

(CIRCLE IF APPLICABLE) BONDING: 1 SPLICING:

CURING PROCESSVACUUM BAGGING 12

TYPE OF' BAG: (CIRCLE ONE) DISPOSABLE: I1 REUSABLE:

RESIN BLEED: (CIRCLE ONE) NO: 45 YES:

PLY-TO-BLEEDER RATIO: Ai

BAGGING AREA: L Q N

SEALING/CLAMPING PERIMETER; , A I.

THERMAL EXPANSION NOLOING

EXT RNAL MOLD CAGE DIMENSIONS: LENGTH: 4 A- IN.WIDTH: W IN.

DEPTH: l .,A IN.

7'CURING TOOL: (CtRCLE ONE) AUTOCLAVF: I

HEATING ELEMENT: 3

58

• .,,J .-, '" -. , ' + , ,. I : + , -.'+ =,; : i ,: -', , .,,+. ' ' ' u m m ' +

ACCEM-4 FINISHING OPERATIONS

PART NAME 2 JPRT NUMBER

CARDI

PART AREAIJ SQ. IN.

(RD 2 (OMIT IF LEFT BLANK) CAR 4 (OMIT IF LEFT BLANK)NET TRIM OPERATIONS HOLE OPERATIONS

AVERAGE TRI L HOLE HOLEHICKNESS LENGTH TY. DIAMETER DEPTH

CARD) 0 CARDS 0

LEGEND LEGEND

OPERATION: I HAND ROUtING OPERATION: 1 - DRILLING2 =MACHINE ROUTING 2 - COUJNTERSINKING3 - HAND SAWING 3 - COUNTERBORING4 - MACHINE SAWING 4 a REAMING5 HAND SANDING 5 w HOLE SAWING6 - PORTABLE TOOL SANDING 6 - HOLE PUNCHING7 -MACHINE SANDING FIXTURE. 0 - NO

FIXTURE: 0 = .NO, I - EXTERNALI - YES 2 - INTERNAL

TEMPLATE: 0 nNO TE14PlATE: 0 - NO1- YES Ia YES

INSERTS: 0 - NO1 - YES

59

a *1

ACCEM-S COST PROJECTION CAM I

UNIT MNER~aJboo~AVE, LOT SIZiTYPE OF ESTIMATE

UNIT COST aL. 21 NO ..L. YES (CKICLE ONE)CUMULATIVE AVERAGE COST COL. 2 NO _Q. YES0(CCICLE ONE)CUMULATIVE TOTAL COST 0. 3 NO . YESQ (CIRCLE ONE)

CP FACTORY LABOR PROJECTION FACTORS 24

LEARNING CURVE: LOG-LINEAR UNIT% CUM, AVE. _L (CIRCLE ONE)OATA INPUT OPTIONS cmO 3c D 4(CIRCLE ONE) CTL VARIANCE LEA

N"( W oL () LAYUP

95tw(I) b) CORE PREPARATION(c) PART CONSOLIDATION M(d) FINISHING OPERATIONS

41 41(0) TOTAL rACTORY LABOR = ,..., .., • • ..1, ...4DATA INPUT OPTIONS(CIRCLE ONE) 2 LABOR RATES C a

(a) FACTORY LABORcd (b) QUALITY CONTROL /HR

(c) TOOLING /MR

(d) NFG. ENG. /iR(e) ENGINEERING

/HRf) GRAPHIC SERVICES /MR

DATA INPUT OPTIONS(CIRCLE ONE) 3 SUPPORT FUNCTIONS C ls c0 I CAM O CA0. BASE BASI UNIT FACTOR LABOR NRS/MAT'L S'S

CM ) Q OUALITV CONTROL10OL INGNFG, ENG,

ENGINEERING Aj.GRAPHIC SERVICES ISUPPORT MATERIAL J "VU

SASE: t - FNA.TORY FACIUCATION. 2 QUALITY CONTROL, 3 - TOOLING,NG, (N.G ING (NGINEERING, 6 GRAPHIC SERVICES. I M DWCUCTION HATLDATA INPUT OPTIONS SASE UlT: I -HOURS. 2 -n.LLAS(CIRCLE ONE) 4 OVERHEAD RATES c le

ITIIM (a) - (C) (Z) (a) FACTORY FABRICATIONITtES (1). (). (3) (b) QUALITY CONTROL

c) TOOLING(d) NFG. ENG. E weAC) ENGINEERING(f) GRAPHIC SERVICES am v

(1) TOTAL LABOR

(2) PATERIAL

(3) ADMINISTRATIVE

60

"" ,it1 " "' * ." '-. : .z",.xl-.._ - * ' -- *- ,.

I.,

10 4A

§!

o IL

0e I~t61

g coooooo

a .oo

IC **0 ,

000tjl 00

I O~O- I O0%

4

14 0a .4-'

'' I I 4.0

& zti - -UIm

*17

.,,., ,,-z 62

8 hi

e * -

iII

00

iv

0004

azL

I i) 81 O

l oc

63

-~ 'f *,.~%- ~*-- *~*. -- .*

10 0

- I cooo°° Q

3I 1000

OO O

Sa. 1.

WI 00

Wj

!0 °°°°°° a

OIOIOOO

a' 00

NO 00

0. ~~ ~ 14514NU

64t

• a. , 3 .C. , -O,.,O,, .,,-. _ o.. . ' ° , , " '" ,-- , . . i " ...lnl ~ -.O,.,,,., -, WU0NO., ,,, , .. II . . . '

r . . ,i i i

: : - .'. .. : L r _.':-: _- - o. - " '' ' '' .'"" .....' ... " " . ". , _- .,.. ? . -.

a IL

I

00

C- 'IQj

~I Oc~ .AL

* aat

CL )1. 4

65

C14 P

800

UIxK

I w

0.*0

4.10N

ao 4A h

vtQ C) CQOL 0 P

wj P"

5.44A*at I- *

A IL at 0 A.1 1 1 J 4) WMA1 00 o"wb.A 4L W0-A 30at W W 941w .1;x I, "1"4 31 O O

hw ~ ~ ~ 0 TI 4JF.'

67

7-7A

% 9ot

4.4

GoU

30- 04 -6

zn z, woO

41 4 l 0--IL a. AL68

I%64L

I l

0 0 g

'AA 0

69

xllOQ 0

COST PROJECTION

PRODUCION COST WSIMATE AT UNIT NO.3 1000AVERAGE LO1 S1ZL: 10.LINEAR UNIT CURVE

PROJECTION FACIL'WS T1oVAR CURVE SLOPE

LAYUP 1.35 ?Q40 2

HONEYLUMB CURE PREP 7*b2 85e60 2VAkT L(INSULIDA71ON 1l,63 80020 tFINIHING OPIkATIONS 21.93 76.20 x

LAbOR RATES &/HR

FACTORY LABOR 10,00

QUALITY CONTRGL 12.50TOOLING 14.00

MF(G ENGINEERING 15.00ENGINEERING 11.75

bRAPhIC SERVICES 9.00

SUPPORT IUN(.TIONS BASE FACTORS

44UALIIY CONIKOL I 1 0.201O0L1Nb 1 1 0.12MFC. ENGINEERING 1 1 0.14

LNGINE 1NG I 1 0.10

GRAPHIC SEkVICiS 1 1 0.05bUFPURT MATERIAL It 2 0.25

UVIRMEAUi RATE$

FACTURY LAeOK 1 .900

OUALITV EONTROL 1.20VTOOLING I .5Cc

IFG L.GINtERING 10100&NGIN t R INC 1.750CRAP IL SERVICES 1 .loMATER! AL 00200ACMINISTRATIVE 0025(

70

.s 16•m '

COST PROJECTION

UNIT COST ESTIMATE AT T 1000

LOST ELtKENT STD. MRS T 1O MRS DOLLARS

FACTORY LAbOkLAYUP 9. • 59 12.b5 12.*47HCJNLYCCJMB CtRS PREP 0.0 00 0.0PART CON4ULIDATION 1.2 1.60 22.34FINISHING OPERATIONS 0.80 1.1o 1705(TOTAL FACTORY LABOR l1.63 15.61 183.46

SUPPOkR LABORSQUALITY CONYRt;L

3o12 39.03ICOL IN l.b? 26e2314FG FNG|IFEE KING 2o19 311.?9ENGINEkRING 1056 18.35

GRAPH IC SkRVICtS 0076 7003TVTAt SUPPOkT LABOR 123o42

LABOR CVfRNEADFACICRY LABOR

348*51WALITY C.ONTROL 44 * 87 0 0 L I N G , 4 6 o 8 €

T~t'LING39,35MFG ENGINEERING

369 -07ENGINkEkING 3211GRA00-IC SERVICES 7..3

C TAL OVER14LAD 510.66

TOTAL LABOR 017.54

MATEk|ALPRODUCTION MATERIAL

3'5o.GSUPPUQI MATERIALMFG. ALLOWANCE

16o??OVERHMAD 119.TTTUIAL MA1kRIAL

717.32

AD4INISIRATIVE OVERPiEAD 363.72

TUIAL CCJT 1918.8

WLJ6MT

LAYUP 17*2b

HONEYCL.U8 LORE PREP O::

K0 TAL 17.2b

71

COST PROJECTION

(.UMULA'ilVE AVLRAGkI EO$T EST1MATI AT T 1000

CUST ILEMENT $10. "RS 1 1000 HRS DOLLARS

FACTURV LAeUkLAVUP 9059 19.14 191.36HONEYCOMB CORE PREP 0.0 0.0 0.0PAR1 CONSOLIDATION 1.24 2 e.4 3 32,60

FINIS.SING OtERATIUNb GO0 1.91 2860TOTAL FACURY LABOR 11.63 23.37 274.61

bUPPURT LABORSOUALITY LONIKC1 L 4.67 58.43T.LOL IN EA 2080 39.26MFG ENGINEEPING 3e2? 49*08khGl hFEENING 2 •34 27*46GkAPHIC SERVICES I17 10952

TOTAL SUPPORT LABOR 164*,Tb

LA60 R O)VERHEAD

FACVIPY LAhOR 52L.75QUALITY CONTkg(L 70.11700L ING 58089MFG kNGINELKING 53.99ENGINEER ING 48.066GRAPH C SEkV! CtS ||•S7

TUIAL OVERHEAD 764a37

TOTAL LABCR 1223.72

MATERIALPRODUCTION MATERIAL 34*5.60SUPPORT MATLkIAL 86.40MFG* ALLOWANCE 167.59OVERsEAD 119.92

TOTAL MATRIAL 7190s1

AOMINISTRA71VE OVERK4AD 485.81

TOTAL CITh 2429.03

WEl 3 GH1

LAYUP 17.28"UNEVcO948 LORE PPEP 0.0

TCTAL

72

IP• tN • " . -

4r" ."-' I~alP *m ' 4 mS ' - ''" - ZiL •"

COST PRUJFCEILN

LUMULATIVt COST LSTIMATE AT 1 1000

COST ELEMENT 51D. HRS 1 1000 HRS DOLLARS

FACTORY LABORLAYUP 9.5V 19135o95 191359o44HONEYCOMB C('Rk PREP coo0 0.0 00

PART CUNSOLIDATION 1.24 ?32L031 32597.27FINISHING UPERAT IONN0 030 1906044 26596.56T0TAL FACTORY LABOR 11.63 23370.76 ??406o37

UPPOkA LABOR AQUALITY CONTRL 4674e 5 58426986TOOLING 2880489 39262.087

MFG ENGIN*ERING 327le91 49078.58ENGINEERING 2337008 2746064GRAPHIC SERVICES ll6es54 10516.84TUAL SUPPOR LABOR 12741.69

LABOR AVERAOFACI0RY LA TRA 521752900

SUALRITY CONTROL T013219IALWIN NC 5889430MFG ENGNEERING 5396.46ENqGINEERING 40056*12GR APHI]C SERVICES 1156U*$3

TOTAL MVAERIHEAD 76369950

TOTAL LABOR 1223721.00

MATE RIA LPRODUCTION M4ATERIAL349,1

SUPPVRT MAIERIAL 863999HFG, ALLOWANCE 5654*22;

OVERHEAO 8753007TOTAL MATERI|AL 52518469

ADIISTRA71 VE OVERHElAD 437226e2b

TOTAL COST 21861319000

WE iC(HT

LA VUPd 17279o98

M'ONEYCOMS COKE PRE:P DOD

TOIAL 17279.96

73

r ,, ~~~~~~~~~~~~~~~~. . .. .. .... , .,) r. ,:,. .- .......... :. :

LOWER FUSELAGE PANEL (SR-001921-15)

DESCRIPTION

The lower fuselage panel is a relatively simple structure composed of thkree

ply (o" /90" /+45" ) graphite-fiberplass/epoxy hybrid skins with localizedGR GR -- L T

fiberplass/epoxy buildup areas along the edges of the panel with a honeycomb

core substructure. The tooling selected for the fabrication of this structure

consists of a "brake formed" steel curing surface mechanically attached to a

fiberglass/epoxv honeycomb sandwich base, This concept allowed one to obtain

excellent heat-up and cool down rates while maintaining the weight and cost

of the tool at a cost competitive base as compared to total metal or plastic

tooling.

The hybrid skin assemblies for the lower fuselage panel were layed-up in the

flat, with the ouLer skin being draped into the release coated (Fro-Kote 33)

"female" tool. The fiberglass/epoxy localized buildups were then located and

resin tacked in place. The localized fiberglass buildups were then located

on the honeycomb core assembly and the inner skin assembly was draped and

formed to the honeycomb core. No structural adhesive was required between the

skin assemblies and honeycomb core as resin bonding was accomplished in these

areas through the fiberglass/epoxy adhesive preprep of the hybrid composite.

The assembly was then vacuum bagged using a reusable rubber vacuum bag and

cocured in one operation in an oven at vacuum pressure (15 psi) for two hours

at 300"F with no resin bleeding being accomplishid, After the cocurinp cycle

the lower panel exhibited an excellent aerodynamic surface on the outer mold-

line skin, with the tbtal assembly displaying good dimensional tolcrances and

configuration stability. The panel was then net trimmed and subjected to

74

Quality assurance evaluations with no out-of-pattern readings bhinp recorded.The panel was then set aside for subsequent joining to the lower lonFerons

and equipment dock.

MANUFACTURING PLAN

1. The following list of detail parts makes up the lower panel assembly.

a. Composite skin - upper (-69)Sb. Composite skin - lower (-67)

33c, Hloneycomb core - 3.1 lba/ft (-65)

2. Haterials

a. lthornel 300/SP288 graphite/epoxy - per NAI-1332

b. Narmco 3203 fiberglass/epoxy

c. Aluminum honeycomb core - per NAI-1171, Class I

3. Machining of (-65) Honeycomb Core

a. The honeycomb core shall conform to NAI-1171. Use 0.0007 foil,3

O.125-inch cell, 3.1 lbs/ft density, 5056-1139 aluminium alloy

(CR III coated) per specification 00-A-250/8.b. Machine honeycomb core per drawing SR-001921 (-15). Note ribbon

direction.

c. Roll form core to shape of lower panel cocuring tool.

4. Layup and Cocure of Craphite-Fiberglass/poxy Hybrid Skin Assemblies

a. The No. 1 composite ply (0' - graphite) of the lower skin (-67)

shall be draped and formed to the lower panel cocizring tool.

75 i1

b. The No. 2 composite ply (90 - graphite) of the lower skin shall

be draped and formed over the No. I composite ply (ply-on-ply).

c. The No. 3 composite ply (+45' fiberglass) of the lower skin shall

be draped and formed over the No. 2 composite ply (ply-on-ply).

d. The -6 honeycomb core which has be~n previously machined and roll

formed shall be positioned on the lower skin. No structural

adhesive is required between the honeycomb core and lower skin

assembly as resin bonding is accomplished through the fiberglass/

epoxy adhecive prepreg ply during the cocuring cycle.

s. The No. I composite ply (+45* fiberglass) of the upper skin shall

be draped and formed over the -65 honeycomb core. No structural

adhesive is required between the honeycomb core and No. 1 composite

ply of the upper skin as resin bonding is accomplished through the

fiberglass/epoxy adhesive prepreg during the cocuring operation.

f. The No. 2 composite ply (90* - graphite) of the upper skin shall be

draped and formed over the No. I composite ply (ply-on-ply).

g. The No. 3 composite (0' - graphite) of the upper skin shall be

draped and formed over the No. 2 composite ply (ply-on-ply).

he Apply a layer of non-porous armalon over the entire assembly. Do

not resin bleed composite skins.

i. Position fairing blocks around periphery of assembly to prevent

core crushing during cocuring operation.

J. Position rubber tooling aids in core transition areas of assembly

to prevent core migratiorn.

k. Apply two layers of Osnaburg breather cloth over the entire assembly.

76

A.~

'.4

~ ~.\.

!t 4. 6 % j I * * " " , , a : t ,. ,

N j. . , ., . . . ,'' , - ,

1. The component shall be vacuum bapged using the reusable rubber

vacuum bap, and cocured at vacuum bag pressure (15 psi) only, in

an oven with a cure temperature of two hours at 300*F as monitored

by thermocouples.

77

1 . ..

ACCEM-O INPUT CHECKLIST

CaoI ESTIMATOR NAME __"T__l_.. _ ___",__________

ESTIMATE NUMBER 1 I41PART NAME

L_ _4_w_ M MO__ _______________,___,,

PART NUMBER I_ ' .Ce!,,("I , I

cA 2 INPUT FORMS QUANTIITY USEDACCEM- 1 LAYUP

ACCEM,2 HONEYCOMB CORE PREPARATION

ACCEM-3 PART CONSOLIDATION I5

ACCEM-4 FINISHING OPERATIONS

ACCEM-5 COST PROJECTION

78

* . .

6".**,~~ ~___"_______________________________,.

. "' ' "I " .C" ." . .. . .- ." " -,. . " -

ACCEM- I LAYUP2

CAM~ I'AR i NAE ~ ART UMBER QTY

TRIM ALLOACE 51

IN.

LA' dP TOOL SAME AS CuRI:,G TOOL (CIRCLE OK)E3 NO 0__

TEBULKING NC -' 3CCURREINCES .

CARD 2 (BLANK) EST LS.N. TPE TYPE OF SAG (CIRCLE ONE) OISTOSASLE _1 EUSASLI .1

C M3COST (SILS) A_____________________7 __________

KEYPUNCH CARD 4 AND CARD 5 ALTERNATELYCAROD4CA5

\ETHOD SEND IESCRIPTION PLY DESCRIPTION

RAISRECTANGULAR NONRECTANGULAR05

FENGTH URVATURE WIDT hf

(N)LENGTH WIDTH ARA DITNE

(IN.) IN.) SQ.tN (IN.)

~AA. A..~

A.' A. ~ -A

~~~~~~A A..LA-AL4 4 A ~

A. ~ ~ AA L--&LA A. .&

T~~flOA ENTR ON CAR 4 Is .9 " LAS ENR ON CAR . "0.

HA~C'LIA, ATOO T, AIEL, IEC.M

LATP ETCO: 1 MNUL. *HAn-ASIT,4 COIV ATO A . A12 .P) . .ONA A .MYC(6 PR

MA'I'GMTHD PHEEP OXY, 2 - DI RERGLAS/EPOIT 7

LAU EHD 1 MNA,- HAnASS,4-c-% UOAI 10IM.i-CNA UOAI 301"XPOSIION ECHNQUE!I P0 0-00 2 PY-ONM'L.

e-a

ACCEM-1 LAYUP

CAM~ I fPART NAME fART UMBER QTA

TRIM ALLOWANCE LLJ.AL IN.LAYLUP TOOL SAME AS CURING TOOL (CIRCLE O1E) YES MO 0

DEBULKING ;4u;:c!Or OCCURRERCES

63 43TYPE OF BAG (CIRCLE ONE) DISPOSABLE _L REUSABLE

CARD 2 (BLANK)GRAPHITE FIBERGLASS

TAPE OVEN TAPE WOVENCM COST (SILS) F___jg_____&___________M______-A.____la.____A

DENSITY (LB/SQ.Ifi.) ILAA

KEYPUNCH CARD 4 AND LmA.D 5 ALTERNATELY

THOO BEND IESCRIPTION PLY DESCRIPTIUN

RADIUS RECTANGULAR \ NONRECTANGULARBEND OF FLANGE eiENGTH UP.VATURE WIDTH

LENGTH WIDTH AREA DISTANCE

-2&A A,.&L .4--4AL

A-- A, A,4& 'A .

LASTENTR O?~CAR 4 I "999";LASTENTR ONCARD525 000A.E-tLD

MATOLIG IVFTOO~ 1 PRE-, 2*DRC-RTOLAVUP M(R ~ I* ~iA L ', I ' A .ASII . . ..RCATMTI 751M . .OPCATMAI 3D1M

DEPOSITIO A.NIUE A, A. A..NPY *PYO-YA

TYPE Of END: A. -L-RAIG4T SAP AE TAGT HRFML;3*SRII.RDA A

A. "A

*~A *fK, A.~pU.

LATENR O AD S 999;LSTETR N AD5 S1101

ACCEM-2 HONEY^OMB CORE PREPARATION

.M PART NAME PART NUMBER TY.

CA IATERIAL DESCRIPTIONCELL SIZE: A_ _, .__2,,16. IIN.

DENSITY: •LB./CU. FT.THICKNESS: IN.

AREA: I SQ. IN.C O S T : ! m ± , ' . 5 , , , , ! / P A R TOPERATIONS

SAWING LENGTH OF CUT: I . , ., , IN.Cl ;IACHINING IFLAT LENGTH OF CUT: . , , , A. * IN.

M.AXIIMUIM WIDTH: IN.CONTOUR LENGTH OF CUT: - 1A, , IN.

MAXI4UM WIDTH: A IN.STEP LENGTH OF CUT: IN.

WIDTH OF CUT: !IN.SCARF LENGTH OF CUT: ,IN.

WIDTH OF CUT: )1 IN.

BLEND LENGTH OF CUT: I i, A 1IN.CUTOUTS QUANTITY: in A

HANDFORMING (CIRCLE ONE) YES: &L.A NO: 1

BRAKEFORMIING RADIUS OF CURVATURE: A • , N.(CIRCLE ONE) DIE LENGTH -e6 FT: >1 ,X . >

NO. DIE CHANGES:NO. DIE REPOSITIONS:

LIQUID POTTING VOLUME FILLED: ,A, CU. IN.

TAPE FOAMING VOLUIIE FILLED: I. . A..,_ ICU. IN.

81

.,, . " , ',-.- . " . " • ,. '.: " ,'.;.-., ,.,, 3: . ." "

- .,,- ', ' . . .. ' ' ':: :: i. -.""' : : :.: - L : " : t: ':'":' : , : _--- . ! ,,:, ', ,! : . ,, - ,: - , , . , ,-- ,," , . . . . . . ...":: :- ' : : :: . : .. . .f . ..v

ACCEM-3 PART CONSOLIDATION

CYCLE NUMBER

"IART NAM PAAT MAUER IU 7TI

COMPONENT DETAIL PARTS

NUMBER OF LINES USED a (MAXIMUM 10)NAE RT NUMBER

CNO 2 &CL *4 _ ___

i i

CONSOLIDATION OF DETAILS I I

CAD 3 ADHESIVE (CIRCLE ONE) NO: YES: 1

APPLICATION AREA: ...... A. SQ. IN.

ADDITIONAL OPERATIONS II II

(CIRCLE IF APPLICABLE) BONDING: 1 SPLICING: 2

CURING PROCESS

VACUUM BAGGING 12

TYPE OF BAG: (CIRCLE ONE) DISPOSABLE: REUSABLE:

RESIN BLEED: (CIRCLE ONE) YES:PLY-TO-BLEEDER RATTO: . -TO-I

BAGGING AREA: A,. S IN.

SCALING/CLAMPING PERIMETER;

THERMAL EXPANSION MOLDING

EXTERNAL MOLD CAGE DIMENSIONS: LENGTH: IN .. A. . *

WIDTH: IN.

DEPTH: .. &. IN,

71

CURING TOOL: (CiRCLE ONE) AUTOCLAVE: IOVENIj>

HEATING ELEMENT: 3

8Z

-. , ,. .q - . ,-.w' -.- ,-- , -. ,,o

, -- -z, ", '. -;-

ACCEM-4 FINISHING OPERATIONS

PART NAME RT NUIBER %CMI _00 tDwi..f0 0l

PART AkEA 1SQ. IN.

CARD 2 (OMIT IF LEFT BLANK) CARD 4 (04IT IF LEFT BLANK)NET TRIM OPERATIONS HOL 3PERATIONS

AVERAGE TRIM HOLE HOLEHICKNESS LENGTH TV. DIAMETER DEPTH

Eli I!j.Jk, . I-.A., A- . -..

A.

CARD 3 0~ wA 6

LEGEND LEGEND

OPERATION: 1 HAND ROUTING OPERATION: 1 - VILLING2 zMACHINE ROUTIAG 2 - COtJNTERBORING3 - HAND SAWING 23 -REAM1ING4 aMACHINE SAWIN64 COUNTERSINKING5 =HAND SANDING 5 -HOLE SAWING6 x PORTABLE TOOL $ANDING 6 - HOLE PUNCHING7 - MACHINE SANDING FIXTURE: 0i - NO

FIXTURE: 0 =.NO . I - EXTERNAL1 =YES 2 -INTEIMAL

TEMPLATE: 0 =.NO TEMPLATE: 0 - 10I1= YES 1 - YES

INSERTS: 0 - r NOI -YES

83

010 0O.

2 =MACIN ROTI-G ,=CUTEBRN

ACCEM-5 COST PROJECTION C I

UNIT NUMER J.I QQ 1AVE. LOT SIZE: .__. jD,

TYPE OF ESTIMATEUNIT COST COL. 21 NO _Q_ YES (CIRCLE ONE)CUMULATIVE AVERAGE COST COL. 22 NO -0 YES (CIRCLE ONE)CUMULATIVE TOTAL COST CO 23 NO 0 YES (CIRCLE ONE)

C FACTORY LABOR PROJECTION FACTORS 24

LEARNING CURVE: LOG-LINEAR UNIT . CUM. P, .1- (CIRCLE ONE)DATA INPUT OPTIONS COO 3 4(CIRCLE ONE)c T1 VARIANCE LEARNING CURVE SLOPE

..- - I ( a ) L A V U P , ..;A_ l . _ .Ift"l 0,) -,& I L_ -1 AITtM (.) 2, (b) CORE PREPARATION

(c) PART CONSOLIDATION r7 -,AA(d) FINISHING OPERATIONS

AI TOTAL FACTORY LABOR J

DATA INPUT OPTIONS(CIRCLE ONE) & LABOR RATES

ME (a) FACTORY LABOR /H5IT(m (a) - (b) QUALITY CONTROL . A_ /HR(c) TOOLING /HR

(d) NFG. ENG. /HR(e) ENGINEERING /HR(f) GRAPHIC SERVICES

DATA INPUT OPTIONS(CIRCLE ONE) SUPPORT FUNCTIONS CARD CARD7 CA 0 CARO I)

d) BASE BASE UNIT FACTOR LABOR HRS/MAT'L $'SCARS (6)- (8) , I, I I IcU (9) 2, QUALITY CONTROL j ,

NFG. ENG.

ENGINEERING -GRAPHIC SCRV ICES +6+ " I- &

SUPPORT MATERIALBASE: I •FACTORIY FACRICAITION, QU ALITY C ONTROL. 3 - TOOLING,

DAA P T P IO S4 M FG. ENG. 5 - ENGINEERING. 6 • OIPNIC SERVICES. 7 PIOUCTION M4T'L(CIRCLE ONE) BS 4I:IHUS OLRON ,! , OVERHEAD RATES CA 0

IT11% (a) - if). (2).0) (a) FACTORY FABRICATION AITEMS (1). (2). (3) (b) QUALITY CONTROL

WC TOOLING . .

(d) MFG. ENG.(e) ENGINEERING

(f) GRAPHIC SERVICFS

(1) TOTAL LABOR

(2) MATERIAL(3) ADMINISTRATIVE

84

.

~04

!N

C,,

I-!

ginim- A

Wi 4

z ,

06 * @ bi. 04004%A 49 9

gg

41C 49 zd 49 .

(. 4L. i I

85

I / do . .. . . ... . . . . . . . . .. ... - ..

0 w 01 tb3fflQ6

06 0@SS S S

Ku

A 04p COQOQ.)we Ail fAIe 0

44 1 jIj%

al I i-000000000

z Q

.61 P- ZA. ot I i

0- ~ ~ I ps- -cc 09 a

86

wi 49 Iein

po 4 044 z

II~A 9L4. ~Oi @4 K

.JIS

I jK

d0CLNo0

871AJ

V ~coo

coo

I 4mO2 o

coo.

n Am P.

0- 0 onoIII I~so coo 4 ow

Jo en 1N C4

-ii *

ujI

00 w 2 . N I

Z ' Q (qu, t* 4 1 (q

in to.A%

dc*

ci~

j

.3

hu I J I89

Ii.Q 0

4c so

0 -0

I.

4c4a. I JZ La A C

0.9

IL x

6d.

09

S,0

0-0aC

So

N

9j 'L iab

0O -0UA.

-It

-J91

Qs v"* OO.vO Ai: & I- w 04 20 A.~ I O ~ ~ cc04

bi wi SI .~

)o 4 Iw- 49MC . uoI M 12 uI A wd -0 . c * 'L * ' I %

W ~~ a. w %C' t b4

92

00

NL

Wg 4JS4

c 00*

wi 0 *aa ac *

0.4 j , j* i

I -

31 93

Af- 1', I

21I

0 X

94

COST PROJEC1IOW

PRUDUJC71UN COST FSlIMATE AT UNIT NO*& 1000AVkIkAGE Ll bIZ~l logkPIBEAR UNI5T CURVE

PRC'JkLC71t' FALU*~S TIeVAR CUk%7t SLCIk

LAYUP ;e3e2* 76063 %olt4EYCemb C.ORF PRtEP R..t3 0.0 %P.Ak7 (,UNSLLILATI1jN "15.06 76052 T'

LALOR PATE.1 HI

IFAC7URV LAtOfR Waco.0LUAL17N (.ONTkUL lueo0700L I N6 10.00MFL, EtNC'NLFRINC, 10000iNGINEEINC 0LGRAPHIC S5VICES Ito i E

SUPIUR FUNCTIONS ASL FACTORS

QuALIY CDNTKLVL 1 3 1.4117JOLIftL- 1 1 4o22M9FC, ENC3NEkRMNG 1 12e&-5LNGINfrCRINC 1 1LRAPHIL SERVIEFS 1 1 0.455UPPU47 MATERIAL 1 2 003C

UVLI4MtAU 'RD1ES

tACYORY LAtbOR1* (I

LNGJNEfR!Nt 1.700GRAPHIC SukVICLS 10700MATER IAL U.ZO(iOMINI SIRAVIELO

95

COST PROJECTION~

UN17 1.151 FS11MAIE Al 1 1000

LOST UL1MENT STOO 14RS 1 1000 HRS DOLLARS

FACIPY LABRLAYUP .?.2 .5MflNkVEO(MIA CCRE PRFP 0J.31 0.4. 4o4J

PART CEINS1LLIATION 0.72 1.20 12.61IANJ!11P4G UPEkATIONS 094,? 0.?2 7.1% IIVIAL FALICkV LAbOR 2.22 3.673.7

WUPP93R7 LAFUCRb16UALIIY LAJN1R[IL 0.?7 1o1UI. INc. G 013 1.26MFG, FNINkkldNu 0.20ENC RNIERING 0J.10 1.uoL(AtPHIC StRVIC.I S V.04 0.45

VAIAL tUPPOR7 LAb'0f 7.36

LAP(jk uvr~ktiALFAL1(CRY LAP'R 1QUAL1''. CIJNlkt'L .0lP(UL If~ 1.9MFG LNCINEEKINC( 2.,93

GRAP'HIC SERVICtS 0.7t,TPITAL OVLI~hLAD b6.'.'

TUTAL LABL;R 110.55

MAURIALPRLIDUCTIC14 MAI RIAL 353.11SUPPOII 4DIkkIAL 105041iMFL.. ALLOWANCI 4.4 *73flvkRI'k Au 100.76

IJIIAL MA7iHIAL 604.53

#UINSTkAIIVL OVER14FAU 112

1(.1AL LU01 b2Z.34

LAYUPH'0NEVLUM' LOft~ PREP' 0.b!

YITlAL 3.3t

96

4k .

COST PkOJLCTIO

CUMULA11V0 AVkRAGb WSI ESTIMATL AlT 7 IDCO

COST ELEMEN~T SIDS. MRS I 1000 MRS DVLLARS

FALIClky LAE1JRLAYLIP U97? 2.03 20.33MONEYCUME CORE PREP 0*131 0.47 4.71PART CLI4NUL3IUOVIDN 0.?2 2.05 it.46FINI~m1NG OPFI4A10h$ U.42 1.16 11.60

TOTAL IAC1QkY LABCA io 5.71 .1*3

4UPIPLkl LAPCJbKSQUALITY COq4TRt1L Cot 60'TOOLINMG 00lu 4.98MFG iNGItEERRM 0.77 7075ENGINFEI1NG 0.34 3e4C(RAPHIL SERVICE~S 0.10 0of

IL:lAL SUPPORT LABOR 23.63

LAbOR CVEkHEALFACTORY LAFOR "5.69CUALI7Y CONlROL 907b'TOOLINMG 7*4*7

f'GENGINeERINC, 11.62tKNC i RING 5 0 ?1GRAPHIC SERVICES lots

TOTAL OVtRHEAD 12O

TUTAL LAbCA 20? .7t

MATERIALPRO01UCTION twAILRIAL 353.11

SUPPORT MATERIAL 105.93MFG. ALLOWANCk 4*14

L'VERMEAC) 100 * 4

TOTAL MATERIAL 650

AUM1NISTRA7IVk OVERI*AC 121.17

TDlAL COST92 *#

WEIGHT

LAYUP 2.51HEINEYCOMS (.ORt PKEP 0.65

ILTAL 3 *36

97

CUMULATIVk CCI-T kST1NATE AT 1000 -

COST IkLEK&IN7 STDs MiRS *1 1000 MRS, DOLLARS

LAVUP 0.1? 2033.19 20331.8?MONEYLUMS LCORE PREP 0.31 4.1.21 471202?PARI C.LJPSULIVAION0t .oelz "eo..'', 20484.93F1IIHING OPERATIONS5 0*42 1159082d.1V821t)1AL FAL7O4Y LASCJP 2.22 5712 *t 57127077

SUPPUftT LASORSIQUAL17Y CONIRUL 651*7b 51i7TOUL 1N( 49800 49DIS

ENWdR k%L 339991 '399014CRAPhIC SfkVICLS 9b*60 9tbol1

Tt07AL SUPP'ORT LABOR 23631.71

I )OR OVtERHIAPIAC1(1NY LABOR 0~691 .62QUALI7Y CON4TRt IV776065I OULINGMFG ENERINC 11622*36ENG1NMERNG 5?7?6S3GRAPhIC SERVIUtS 167629"

TOIAL OVEKHEAV 122016006

TOTAL LABOJR 20277505(0

MAYER RALl'ROUCTIU% MAIERIAL 3'198SUPPORI MA'kRIAL O324MPG. ALLCWANCE It.UVLQ~iLAL 9204bo81

TOIAL MATERIAL t52?50.6

ADMIN157RAIIVt OVFR14EAD 113257*56

IL!TAL COSI 6381

LAYUP kL.8.oc04O1EYL'ME CORE P9kEp h7

1 (AA 1 t AL6

98

-,,Poo.j.

UPPER AND LOWER SKTNS _-TRAILING EDGE FLAP

OT 0*

00

o/z 'ts-/?

MANUFACTURING PLAN

1. The following list of details makes up the skins for the trailing edge

f Cap.

a. Composite skin- upperb. Composite skin - lowvr

2. Hatvrals

a. AS/3501 - 3 prt-prog 12" wide

99

IL-,YT : q -~-

3. LaY and Cure of _Sriint e y i Assemblies

a. The composite skin to composed of 15 tapered plies. Ply orietnta-

tion and stacking sequences is established by using mylar tooling

aide. After the mylars are stacked the sequence is inspected

and checked against the engineering drawings.

b. Hylars are then covered with 3501 prepreg to the proper orientntion

and again stacked prior to final layup.

C. The mylars are keyed to two tooling holes along the main spar

element line. The tool is prepared by first applying a coet of

release agent (Fre-Kote 33) and covered with 1 mill thick Teflon

separatok film.

d. After the tool is prepared the first ply is orientated to the two

tooling holes, smoothed down, and the mylar removed. This pro-

cedure is then repeated until all 15 plies have been pliced on the

tool.

e. An excess of approximately one inch is left on the preplying for

resin content, fiber volume and void content determinarions.

f. The layup is then covered perforated release .11m, 120 fiberglass

bleeder cloth applied in a ratio cf 1:3, and the layup closed out

with a non-perforated release film and a disposable nylon vacuum

bag. Leak tests are then performed to insure proper bag closeout.

g. The skins are autoclaved cured using the followintg cure cycle

listed below:

1. Apply full vacuum

2. Heat at 225 F; add 85 psi pressure

3. Continue heating to 350 F

4. Cure at 350 F for 30 minutes

5. Cool below 150 F before releasing pressure.

h. Upon removal of the component from the bag. it will he expost-d and

chpeked for conformity to previously determined dimensions and

aerodynamic smoothness requirements; and discrel:vncy will be recordt.d.

1. The component war net trimmod to final dimvnsionp anid fiber volume,

resin content, voids and density determinations made.100

s +%":.. . ,. ! + .i. +_ + . +.?, m ~ -.. . . + - . , .

ACCEM-O INPUT CHECKLIST

CMO I ESTItATOR NAME ___ __._._ I

ESTIMATE NUMBER ___________- _-

PART NAME . . . . . ...

PART NUMBER ______L_ ___

CN 2 Il4PUT FORMS QUANT0,TY USEDACCEII. 1 LAYUP A, OA

ACCEM-2 HONEYCOMB CORE PREPARATION LO01J

5ACCEM-3 PART CONSOLIDATION L,...LI

ACCLM-4 FINISHING OPERATIONS

ACCEM-5 COST PROJECTION 0.2.,

I0

A M- 1 LAYUIP

CAM emD111a

LAYWI I tiitjMq AS (nlil iG . Y ((lA ( tLL (Wit) 4

6241111If I . ((INC11 0,4) 0ILPOSADLI .. (C~I J

CARD I (BLANK)

______ wovr I API UOW(4

KEYPUNCH CARD 4 AND CARD 5 ALTERNATELY

TIJOD IE40 ILSPIPTIO4 PLY DESCRIPTION

RADIUS RECTANGULAR NfRCTANGULAR

LENGTH URVATURE WIDTH LNT ITLEGT WITH AREA DISTANCE

11 AlI

LAS ENRYON AR 4 s 999"~LAS UTRYONCARISIS W'O(IN.

HA'.'ICPtI~.( * I.CP.1, 2 *II~ElOATA-

NAYLIA. .C~ . ...1uIIhA .AE

PAI~l~ (P A- r.AII~rI~, 2*rS~~~,I~(

ACCEM-3 PART COtSOLIDATION

CYCLE NUMItLR .1 .PART NAME PWQT .'IMBLR

CAMDI _Yrotg& -2ATIY

COMPOiNT Of TAIL FARTS U

NUM LFR OF LINES US[D j.. (MAXIMUM 10)

PART NAME RT NUMBER ANTITYCAM 2 v

I

CONSOLIOATION OF LTAILS

C*O13 AWESIVL (CIRJLE ONE) NO: 0 YfS: I

APPLICATION AREA: A- SQ. IN.

AODITIONAL OPERATIONS Ii

(CIRCEL IF APPLIC,"'[) BONDING: I SPLICING: 2

CVRING PROCESS

VACUUM BAGGING I2

TvPI OF tlAG (CIRCLE ONE) DISPOSABLE' R[ISArLE: 2RESIN PLEED): (CIRCLE ONE) NO: on ES: IS)

PLY-,O-Ph.{FUER RATIO: Ir T'

RAG1I14G AREA: ,t-L , .ADSQ. IN,

S[,LINGiCLAMPING PrRl T(R. A, IN-

TWkMAL EXPA:,SION 1-,LOING

EXTIHNAL "OLD CAGE DIN[iiIONS: L! tiGT4: 41 A IN.

WIOI: " - _A. IN.

DEPI: A IN.

CURING TOOL: (CIRCLE ONE) AITOCLAVE:

OVEN: 2

HEAT IC, ELLIMENT: 3

S- -.--. .--.

ACCEM-4 FINISHPJG OPERATIONS

PART NAME 2,ART NUMBER OTY

CARDS I Fk~j S~k&A l

PART AREAI SQ. IN.

CARD i (OMIT IF LEFT BLANK) CARD 4 (OMIT IF LEFT BLANK)NET TRIM OPERATIONS HOLE OPERATIONS

AVERAGE TR,11M ,OLE HOLELE\GTCKJES-" ' \I OLDI.,ET RICKNESS AMETER DEPTH

( , _

-'d r.

CARDS 3 2 CRD 0L.EGENID LELGEN D

OPERATION: 1 HAND ROUTING OPERATION: DRILLING2=MACHINE ROUTING 2 -COUNTERBORING

3 - HAND SAWING 3 -REAMING4zMACHINE SAWING 4 - COLIZJERSINKING5rHAND SANDING 5 =HOLE SAWING

6 =PORTABLE TOOL SANDING 6 HOLE PUNCHING7 -MACHINE SANDING FIXTURE- NO

FIXTURE: 0 NO, 1 = EXTERNAL1 YES 2 =INTERNAL

TEMPLATE: 0 NO TEMPLATE: 0 =NO1 YES 1=YES

INSERTS: 0 =NO1 YES

104

. to

-- I

ACCEM-5 COST PROJECTION CARD I

UNIT NUMBER,"O, o,0.*

AVE. LOT SIZEL-1 ,

TYPE OF ESTIMATE

UNIT COST COL. 21 NO f1 YES Q (CIRCLE ONE)CUMULATIVE AVERAGE COST COL. 22 NO 0 YES Q(CIRCLE ONE)CUMULATIVE TOTAL COST COL 23 NO 0 YES . (CIRCLE ONE)

CARD 2 FACTORY LABOR PROJECTION FACTORS,2 24

LEARNING CURVr: LOG-LINEAR NITb CUM. AVE. -L (CIRCLE ONE)

DATA INPUT OPTIONS CMO 3 CARD 4

(CIRCLE ONE) T1 VARIANCE LEARNING CURVE SLOPE_CRL NE O I I

ITCH ()- WI A"Wi~t(, , (al LAYUP

A, .-"- "-.V I -, .- 1ITE( ) 2 b ) CORE PREPARATION

(c) PART CONSOLIDATION(d) FINISHING OPERATIONS 3. A,'.A...,-

41 41

(e) TOTAL FACTORY LABOR , ,

DATA INPUT OPTIONS CNfD 5(CIRCLE ONE) 2 LABOR RARES I

( Ca) FACTORY LABOR i . .SHRIt~MS (,) -(f I t) QUALITY CONTROL .S/HR

(c) TOOLING $/HR

(d) MFG. ENG. A $/HR

(e) ENGINEERING Al ..... HR

(f) GRAPHIC SERVICES A . A ___$/HR

DATA INPUT OPTIONS(CIRCLE ONE) 3 SUPPORT FUNCTIONS CARD 6 CARD 9

WK BASE BASE UNIT FACTOR LABOR HRS/MAT'L S'S

CAROS I) -8) I I T )coMo () 2, QuLT CONTROL Il .'1

TOOGLING . 3 AMFG. ENG. "' = - ""l. . '

ENJGINEERING '5 IGRAPHIC SERVICES - 'SUPPORT MATERIAL _ J,.. _... . , .,-

DATA INPUT OPTIONS(CIRCLE ONE) COVERHEAD RATES C D

ItIMS . , ,I ) W I , (a) FACTORY FABRICATION

ItEMS [1). ), 1) , (b) QUALITY CONTROL ------

(c) TOOLING

(dI) mt. ENG. 4

(e) ',GINEERING C 11(f) GRAPHIC S[RVICES .

(TOTAL IlABOR-

C)MATERIAL

Ci) ADMINISTRATIVE L L-

IO

/ . -.- 'P i p "iA

ACCEM-5 COST PROJECTION C I

UNIT NUElP.*~J OAVE. LOT SZE,

TYPE OF ESTIMATE

UNIT COST C . 2t NO -a- YESQ (CIRCLE ONE)

CUJLATIVE AVERAGE COST Cl. U NO -L. YES (CIRCLE ONE)

CUNULATIVE TOTAL COST COL U NO .. YES T ( CIRCLE ONE)

S2 FACTORY LABOR PROJECTION FACTORS 24LLEARNING CURVE: LOG-LINEAR UNIT -.. CUM. AVE 'CIRCLE ONE)

DATA INPUT OPTIONS CAD3 4(CIRCLE ONE) caL TI VARIANCE LEARNING CURVE SLOPE

-- o (a) LAYUP .

(b) CORE PREPARATION

(c) PART CONSOLIDATION

C.) TOTAL FACTORY LABOR

DATA INPUT OPTIONS(CIRCL ONE) 2 LABOR RATES

-L .) (a) FACTORY LABOR A /MR

1e ,W) (b) QUALITY CONTROL /MR

(c) TOOLING /MR

(d) MFG. ENG. -A /MR

(s) ENGINEERING A /MR

(f) GRAPHIC SERVICES 0/14R

DATA INPUT OPTIONS(CIRCLE ONE) 3 SUPPORT FUNCTIONS CAIRD CAM ? CA I C O S

,0...BASE BASE UNIT FACTOR LABOR HRS/MAT'L SS

,,) ~ QUALITV CONTROL ,*TOOLING

MFG. ENGS. t- b,

ENGINEERING A

GRAPHIC SERVICES

SUPPORT MATERIAL r - A

USt: i - FIrTOR¥ FAISICATION, QUALITY CONTROL. 3 TOOLING.4 • mF. (g .IS - ENGIN:ERING, 6 GRAPHIC SEIVICES. 9 * PROOICTION VT'L

DATA INPUT OPTIONS USEU6T: i I *i411S. I • OLLARS(CIRCLE ONE) 4 OVERHEAD RTES-i

I~U'I ( (a) FACTORY FABRICATIONttM 1)1 (2). 1) (b) QUALITY CONTROL A.

(c) TOOLING

(d) MFG. ENG.

(e) ENGINEERING ,

(f) GRAPHIC SERVICES We II

(1) TOTAL LABOR

(2) MATERIAL

(3) AOMINISTRATIVE

106

• -. :"+ ",-. _"Y'a_ :'-,w ,.-, r y': . ""' -. ,', . ......

'i ~ ' 'A .

41 - 2

4K f

wc Lw04

4 4 Z W i

~g ~ ~ 1 -107

o~~~~p It 04 ~~Q4Q(0.0

,o 4$QQQOQQ000QQC0

ZZ0 0 0S

V- kNMU NM4

4'0 I 00ku .030

09 ~~ 6 0 O 000 t 30Q34-f"I N

l~ J3000

0 IA ~~I 0 0 0 O 00

to j

ib) 0C 0 0 1 0 O *

L C W UA V4 IX04P -404040 04 4P

49 pq. 015000"

Qi NNNNNNNNNNNN

108

W~ a..

ILI

Ge Iat 4 04 A

I. 0

ILQ0 30 0 inlb -4 M

8 -

at 44149 -zW . 0 -m

j 491 4 1-a. P" o448

6) IL W IL 4.

109

I S0

49

IAI

0 bh

Ga.

0O -A

PART CONSOLIDATION

FACTORY STANDARD HOURS skT-UP RUN

SE I UP i. 0?0

SEFORr CUREAPPLY POROUS FILM 0.061APPLY BLEEDER PLIES 1.113APPLY NONPOROUS FILM OlbIAPPLY VENT CLOTH 0.136INSTALL VACUUM F7GS ooze-INSTALL THERMCICPLS 0.O5APPLY SEAL STRIPS 0.0T0APPLY DISPOSAbLE bAG 0.041SEAL EDGES G.o53CONNECT VALUUM LINES 0.U12SMOOTH BAG DOWN Cb0d01CHECK SEALS O.u08REMOVE VACUUM LINE 0006CHECK CHAMBER INT. 0,060LOAD LAYUP IN AUTO. 0.1lbCUNNECT VACUUM LINES C0024CONNECT T.C. LEADS 01,037CHECK FOR LEAKS 0.202Z.LOSE DOOR 0.038

DURING CUKESET RECORDERS 0.02bCYCLE CHECK 0.160SHUT DOWN 0007REMOVE CHARTS 0.00?

AFTER CUREOPEN DOOR 06038RELEASE T.C. LEADS 0.014RELEASE VAC. LINES 0.012REMOVE PART FR AUTO. 009ZREMOVE DISP. BAG 0.020REMOVE THERMOCUUPLE S 0e036REMOVE VACUUM FTGS 0.012REMOVE PROCESS MATL 0224REMOVE LAYUP 9 ASIDE 09041CLFAN TUOL 0.041

TOTAL HOURS 0.070 3,103

111

_ _ ___ '

IC.

0O0

in oey1

em"

OA~ di

Igoeg

Lu

112

- 00.. 4.4~

000000

8

I atI

113

! w

0: 0 14 0 .2oi

OcOA

44

114

COST PROJ I ION

PAODUCTION COST ESTIMATE AT UNIT W.t 1000AVkRAGk LOT SIZ1I 20LINEAR UNIT CURfV

PROJCTION FACICORS TI.VAR CURVE SLOPE

LAYUP 23.24 76.3 1MONEYCO1b CORE PREP 1|,b3 0.0 •PART CONSOLIDATION ;fS.06 76obZ IFINISHING OPkRA1ION& z3.1b4 76077 x

LAbOR RATIS

PACTIJRY LAROR I*UoUQUALITY CONTROL 10.j0TOOLING 10.00MFG ENGINEERING 10.00ENGINkERING 10.00GRAPHIC SERVICES 10.00

SUPPORT FUCTIONS BASk FACTORS

QUALITY CONINOL 1 1 1641TOOL ING 1 1 4022MPG ENGINEERING 1 1 2.55ENGINEERINC 1 1 1:6,4GRAPHIC SERVICES 1 1 0.40SUPPORT MATERIAL 7 2 0.30

OVERHEAO RATES

FACTORY LAbOR 16500QUALITY CONTROL 1.500TOUL ING l SucMPG L NGINFEKING 1500ENGINEERING .10O0GRAPHIC SERVICES 1.700MATERIAL 0200ADMINISTRATIVE 0•150

115

q -

.. .. ... .. . .. ..... . .. .. ... . .. . .. . . .. .. .: . .:. ,, _ .," "% ., ,. " .,_ ,,' . ' ._, ' ... . .. .. .

COST PROJECT ION

UNIT COST kSTl04ATE AT T 1000LOST ELEMEENT TO. MRS T 1000 HRS DOLLARS

FACTORY LABORLAYUP ?.99 12.43 124,26HUN&YCOMB CURL PRkP 0.0 0.0 0.0PART CONSOLIDATION

3.19 S.ss 55.46FINISfHING OPEk'AT1IOS 0.1B 1.90 39.00TUTAL FACTORY LABOR 11.65 19047 1I4.'4

SUPPORT LAbORSQUALITY CONTROL 1.42 14.23TOOLING O.oS 077MFG ENGINtENING 1.04 10.36kiWNUMERING 0053 $06GRAPHIC SERVICES 0.24 2.3TOTAL SUPPORT LABOR

3039000

LABOR OVERilkADFACTORY LABORQUALITY CONTROL.

21.34TOUL ING

10 .16MFG ENGIN&ERING 10.16ENGINEERING

1*.S4GRAPHIC b|RVICtS 4.09

TOTAL OVERAD 3s4*01

TOTAL LABOR 565,118

MATERIALPRODUCTION MATERIAL

23*6)SUPPORT MATERIAL 23.6

MF. ALLOWANCEOVERHEAD 563019

TENTAL MATEPIAL 4336 54

ADMINISTRATIVE OVERHEAD 73.36

TOTAL COST

WEIGHTLAYUP 26.97HONEYCOMB CORE PRp 0.0

TOTAL 26.9?

116

, .

., -" . , .w. . ,

tuMqULAU'Iv AviskAGE C0&I k~tIMATL AT 1 1000

COST [L&ML#4T ilos mis .7 1000 "R& DOLLARS

FACTCRY LABOR7.~ 20.13 201e33

"OP4EYCOMP CORk PREP 0co0 0.0 0.0

P~ALt F.PC1ORLASO 3.19 9.01 90.12

FZIISHING OPERATIMU Us.es 31.5? 315.b

SUPPORT LAbOftNWUAL11 Y (.OPTRUL

3.45 4g?

TOOLING~ 2o66 26,63

MFG EP4GRN RING 4.14 4142

ENGINEERING 1.82 18.:16

GAAP~InC SERVICES 063Sa

TOTAL SUPPORT LAOOK 1269 24

LAPOR OVERHEADFACYCORY LABOR 2I

QUALITY COTROL.5.?TOOL ING

39,9%

MFG ENG1INEERING 21

EKNERINC 30.67

4RAP'iIr SERV1LtS b9

TOTAL tCVERHrEAD 661.53

TOTAL LABOR~ 1109o43

MA IfRI ALPR0OUCTIO% MATERIAL

2340 * 6

5IJPPECRY MATERIAL 760.9

MFG* LLE ANCL723o24

TOTAL MATERIAL4394

ADM1NlSTRAIM Ov VERHEAD 81703

ICIAL C-CSI 6266.20

LAYUP269"ONEYCO"b CORE P'REP

00

IOTAL 26.9"

117

COST PROJKTION

CUMULATIVt CUST iSTIMAT& AT T 1000

LUST ELEMNLT SID. HRS T 1000 NRS DOLLARS

FACTORY LABORLAYUP 7.59 20133.43 20334.2-iONYCUMB CORE PREP oo 0.0 040PAKT CONSULIDATIIMN 3.19 9012.01 0120.06IRINISHIC OPERATIONS fiSo8 2420.93 24209.29TOTAL FACTUkY LABOR 11.65 31566%36 315663o56

SUPPORT LABOkSQUALITY CONTROL 3476o96 34769o57TUOL NG 2662.67 26626.6SMPG ENGINEERING 4142o32 41423.16ENGIPNEERIN G 1016.12 18161.23CAAPHIC SERVICES 525.65 5256.9O

TOTAL SUPPORT LABOR 12623700

LAeCJR UVERNEADFACTCKY LABOR 473495.31

QUALITY CON1ROL 521-4e36

TOOL ING 39939.98MFG ENGINEERING 6213475ENGINEbR ING 30074.09GRAPHIC StRVICES 0936*04

TOTAL OVERHEAD 667534.31

TOTAL LABOR 1109434.00

MAYERIALPRODUCTION MATERIAL 2346613.00SUPPORT MATERIAL 7039#3087MFG. ALLOWANCE 6872 . 6OVERH EAD 611493.56

TOTAL MATERIAL 3668Q61000

ADMINISTRATIVE OVERHEAD 716799.12

TOTAL COST 5495154.0

WEIGHT

LAYUP 26972.56HONEYCOMB CORE PREP 0.O

TOTAL 26972.5

118

-I-..

09

ly 0

4

N jnEp~qI- Q. u P" 0 M'A -K I.. 0u 0- w Wogo of ~ Z.E tI 4

'4. I- Z z u " Z I w 7*gjw04 4 1" A a U4 x

K~~~ "A " oa

00 a0 0 @31~~ ~~ a in 0 ~ ~ ' 0

II'Ott49u0ijI

m

IL at

jI. -j Jb iu.

"" :: !x b- - 4

Kz C9 0

* U 13ev cc0 6)

120

I0 C -A §~ 0 0W -Ae NN rN O wO Q ? -S CYt 4A

"0 .0 W% el S 0

AA N

49 a c0 tz 4 " 3 psA 0

3 .t 9 4UA

06- ionI.4 4 z

uin N~

* N 0EV~acig4, i

ki-

-4 &

HAT STIFFENED PANE~L ASSF2MLY

MANUFIACTUJRING PLAN

1. The following list of details makes up the hat stiffened lower panel

F assembly.a. Composite lower skin

b. Composite hat stiffener (2 required)

2. Materials

h. Narmnco 320.3 fiberglass/poxy pc

123

3. LatiVp and Cocure of Skin and Procured Hat Stiffeners

a. The composite skin is composed of 6 ply (0 GR/90 GR/+4 5 GL)S

layed up in the flat with the outer skin being draped into the

release coated (Fre - Kote 33) female lower panel cocuring tool.

b. The No. 2 composite ply shall be draped and formed over the No. I

composite ply (ply-on-ply), this sequence shall continue until

the build-up of all plies is completed.

C. The layed up composite skin shall be set aside for subsequent

cocuring operations.

d. The No. 1 fiberglass ply of (+ 45L) is layed up on the rubber

curing tool utilized in thermal expansion molds. This procedure

continues until the build-up of all plies is completed. The

layup is then transferred to the elastomeric mold cage.

e. The encaged stiffener is subsequently placed in an oven for curing.

f. Upon removal of the component from the mold it shall be checked

for conformity to previously determined dimensions.

g. The precured compo!iAte stiffener shall be positioned on the pre-

vlously layed up skin assembly and resin tacked in place. No

structural adhesive is required between the composite stiffeners

and composite skin as resin bondi' g is accomplished during the

cocuring operation.

h. Apply a layer of non-porous armalon over the entire layup and

drape to shape of component.

i. Apply two layers of Osnaburg breather cloth over the layup and

drape to shape of component.

j. The component shall be vacuum bagged using a reusable rubber vacuum

bag and cocured at vacuum bag pressure (15 psi) only, in a oven

with a cure temperature of 300 F for two hours as monitored by

thermocouple.

IZ4

AV W

t ~ t

h. Upon removal of the component from the bag, it will be exposed and

check for conformity to previously determined dimensions and aero-

dynamic smoothness; any discrepancy will be recorded.

1. The component shall be delivered to Quality Control for NDT. All

dctectable voids shall be mapped and retained as part of inspec-

tion record.

m. The component shall be net trimmed to final dimensions and set

aside for subsequent assembly operations.

125

A*.-. 4' P" " "Z'

ACCEM-O INPUT CHECKLIST

CAADI ESTIMATOR NAME

ESTIMATE NUMBER I A 1 .

PART NAME VF,

PART NUMBER i. | 2' " (a I

CA/ 2 INPUT FORMS QUAN EDACCEI1-1 LAYUP

ACCEM-2 HONEYCOMB CORE PREPARATION

ACCEM-3 PART CONSOLIDATION

7ACCEM-4 Fit 1SHING OPERATIONS

ACCEM-5 COST PROJECTION

126

rp, • ,. ".

ACCEM-1 LAYUP

CfOI PAR NAME ,2 fANT IUMiN 1ITY

ININ iLWAICI L AJ I

LAVUP 1mEL VAY A. 0111:14 TOOL (LIKfttC~)Y WE J* N

WYPI 01 lS (CIWULI O.40 01.EOAaLI -.L RASt 4J.CAMD 2 (BLANK)

IMP4tL FIRSITAPE W I YAP( WOIU

CAM 3 cosl t 1O) ______________SoOmli mLisq.IU4.) q.AA..

KEYPUNCH CARD 4 MND CARD 5 ALTERNATELY