advanced composite cost estimating manual · /7 dcnald j. leblanc, t. /bettner /.'...

AFFDL-TR-76-87Volume 1I

( ADVANCED COMPOSITE COST ESTIMATING MANUAL

NORTH1IROP CORPORATION C#-AIRCRAFT DIVISION

~ HAWTHORNE, CALIFORNIA 90250%di-

AUGUST 1976

TECHNICAL REPORT AFFDL-TR-76-87FINAL REPORT FOR PERIOD APRIL 1975 - MARCH 1976

Approved for public release; distribution unlimited:]

AIR FORCE FLIGHT DYNAMICS LABORATORY

AIR FORCE WRIGHT AERONAUTICAL LABORATORIES

AIR FORCE SYSTEMS COMMAND

WRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433

.... .I-Aw l

NOTICE

when Government drawings, specifications, or other data are used for any purposeother than in connection with a definitely related Government procurement operation,the United States Government thereby incurs no respor ibility nor any obligationvh;troever; and the fact that the government ray have formulated, furnished, or inany way supplied the said drawings, specifications, or other data, is not to be

regarded by implication or otherwi$e as in any manner licensing the holder or anyother person or corporation, or conveying any rights or permission to manufacture,us*, or sell any patented invention that may in any way be related thereto.

This technical report has been reviewed and is approved.

Project EngineerVehicle Synthesis BranchAeromethanics DivisionAF Flight Dynamics Laboratory

FOR THE COMANDER

OBCo SAFChiefb Aeromechanic l ii sionA.P Flight Dyiamics orator y

This report has been revieve,! and cleared for open publication and/or public releaseby the appropriate Office of Information (01) In accordance with AFR 190-17 and DODD5230.9. There is no objection to unlimited distribution of this report to the publicat large or by DDC to the National Technical Information Service (NTIS).

Copies of this report aht'udd not be returned unless rettur Is required by securityOonsideratioj, contractual obligations, or notice on a specific document.

AIR FO~FL - 23 WACH 77 - 100

UNCLASSIFIEDSECURITY~ CLA.SSIFICATION OF THIS PAGE (WN-nData Ft,~.r.d)

)7 REPORT DOCUMENTATION PAGE R~)iSRCIN________ BEFORE COMPLETING FORM

RCPOR 2 GO'.T ACCESbION NO 3 RIECIPIENT'S CATALOG NI)MSER

y AFFDL LTR-76-87w Lo-; -__._TITLE ___(___dWitig____5L TVPE_ PQF_ aj PERIOD COVE14ED

SFinal epptJ DVANCED fOMPOSITE COST ESTIMATING 1 UA AprII75 4031 Mar 076,VOLUMEn 4&6 PERFORMING DOG. RIEPORT NUMBP.

17 AUTHO R11 s) CONTRACT OR GRANT NUMBER(s

/7 Dcnald J. LeBlanc, T. /Bettner /.' F33615-75-C-3103VJ. /Lorenzana, F. /Timson

9. PIER7ORMtNG ORGANIZATION NAME W 55VMS 10 PROGRAM ELEMENT. PROJECT. TASK

Northrop Corporation, Aircraft Divisionv AREA AWORK 141TN MARS

3901 West Broadwa 10l 7 2Hawthorne, California 90250

11. CONT ROLLINC OF FICF N AME AND AD,'nESS upa ~rAir Force Flight Dynamics Laboratory .4 ' Aug 76,JAir Force Systems Command - 13, NMBR OF PAGES

Wright-Patterson Air Force Base, OHI 45433 534 MONITORING3 AGENCY NAME & ADORES'(II different from Controlling Office) IS SECUR17TY CLASS. (of 11113 rOpoVI

UNCLASSIFIED

*iSs I'CLASSIFICATIO4 DOWNC-.0INGSLHEDULE

'--TION STATEMENT (of thl. R.'prir

Approved for public release; distribution unlimited.

**' iT IIUrl N STATEMENT (of Ill. bh.tra:f .tered in Block 20, It -Iffetet ('oS fPortI 100F O

a "LPM~TR NOTES

19_. KEY WORDS (Continue onI rever*se it f necessit, and Identl Iv by blckr number)

Advanced Composite Materials, Detailed Parametric, Cost Estimating,Methodology

20. ABSTRACT (Continue on, reverse side It naecexsecy and Identify 01v blo-It ntimb-)This program concentrated on the development of a computerized system thatestimates the recurring costs associated with the fabrication of advancedcomposite detail parts and components. The system employs Industrial Engineer-ing Standard equations developed in the program to calculate standard houra forthe detail composite fabrication operations of layup, core preparation, partconsolidation and finishing. With these standards as base, recurring costs arederived through the application of variance factors, improvement ctrve slopesand labor rates.

DD I 'J'," 7 1473 ED)ITION OP; 1 NOV GS IS O3SQLF-E UNCLASSIFIEDSECURITY CLASSIFICATION OF THIS PAGE (ftyn Data Entered)

PREFACE

This Technical R,.xrt. ..xias prj iedr by the Aircraft Division of Northrop

Coqxoration tuincr Co.Lract ':j. F33615-75-C-3103 for Uh Air Force Fliqht Dy-

nirmics liaboratory, Air Force 1right Aeronautical Lboratorics, Air Force Sys-

tans Ca-mund, Wright-PattCr1on Air Force &ise, Ohio. Mr. Richard J. lirt,

A'IT, ,a. the Air Force Pro,;raar N.:tnacjcr. This report covers the period froin

1 April 1975 to 31 MaUrch 1976.

The work described in the report was carried out by Northrop Corlpration,

Aircraft Division, D. J. LeBlanc, Program Director. Principal contributors

to the Northrop activities described in this report and their areas of respon-

sibility are listed below:

Oontributor Responsibility

J. Iorenzana Principal Cost Investigator

A. Kokawa Cost Analysis

T. Bettner Oost Analysis

F. Timson Cost Analysis

-. Procto-: Cost Analysis

H. J. Behrens Industrial Engineering

L. Lyle Detail Engineering

M. woo Caputer Programming

L. Bernhardt Design and Analysis

i hi ie' i CIo ) [

. 'i , Pr jr "i Dii'L.,!5 ctorl ...............................

............................... ..................: 1 P .. . .. ............ . . .ITUD PAW P'AVtAIIT l ,S'

Jon•,t- " " ,L L'BIH PGEEZ-ICZ."~IU

SECTrION PAGE

.0 IROUCTION 1

2.0 3

3.0 *KEYPUH1TNC DTA CAIWE.L) 24

4.0 'ESTTIMNG 'J TIONS, 27

4.1 LAYUP STANDADS' 28

4.2 CORE PREPARATION STAINDS 31

4.3 PART CONSOLIVtkTICN STANDAq3S 32

4.4 FINIIHING SIMvAMS 37

4.5 FACORY LABOR VARIAN 38

4.6 SUPPORT 2.14rIONS 41

4.7 LABOR AND OERHEAD RATES 46

5.0 cumm 48

,' ",,4¥ , " " B Q RRE EDI O P E NOT JrILRED

I ,

1.0 INTROL TION

The objective of the "Advanced COuposite Cost Estimating Manual Pro-

gram," Contract No. F33615-75-7-3103 was to develop a omputerized method-

ology for estimating the recurring costs associated with the fabrication

for advanced composite parts, and to fully document this methodo].ogy for

use by Governmnt and Industry. This program wes conducted by Northrop

Corporation, Aircraft Division, from April 1975 to 31 March 1976. A cozm-

prehensive description of the development of the computerized methodology

is provided in Volume I of this report.

The User's Manual describes the inplementation of the computerized

estimating system developed in the "Advanced Cznposites Cost Estimating

Manual Program." This volume contains instructions for completion of the

input forms, instructions for keypunching data cards, estimating equations,

and description of the outputs. This constitutes a caplete explanation of

the procedures to be followed in using the system.

The master diagram on the next page illustrates the flow of the esti-

mating process. I* identifies the various input and output ocunents pre-

pared and generated as well as the operations, processing, and calculations

performed to arrive at the desired cost estimates. Detailed discussions of

the subject areas of this diagram are contained in the denoted sections of

this volume.

N+

w , -.

Opi

Ila z

414

2.0 INPUT FORMS

Six (6) Input Forms have been designed for this systcm. ACCEM-O gives Kenerq1

informlation about the user and the part to be estimated. In addition, this

form serves as a checklist chat the computer uses to determine thle type and

quantity of the subsequent input- forms submitted by the user. ACCIE-l (ILayup)

provides detail information on the part or parts layed tip, specifying thle

layup methods and techniques used and the tyne and form of advanced composite

materinl layed up. It also provides information on supplementary layup opera-

tions such as debulking and trimming as required. ACCEM-2 (Core Opecations)

describes the processe,; performe~d to prepare aluminum honeycomb, core accord-

ing to specificatioriv. ACCEM-3 (Part Consolidation) defines the proce.,scs

performed in joining and/or curing composite and detail parts. When co-

curing. this form identifies the various composite and core elements that are

to be cured sim~ultaneously. In addition, this forn covers thle splicing and

bonding of core. More than onie curing/joining cycle is available via this

form, thereby accomodat ing pre-cur ing and secondary bonding operations.

ACCEM-4 (finishing) identifies and provides detail informiticln on the various

tritmming and drilling operations that are performed on cui-ed composite parts.

ACCEM-5 (Cost Projection) specifies the factors and rates that are used in

calculating final cost estimates.

To aid the user in filling out the ACCEM input forms, descriptions/instructions

have been provided. Examples of completed input forms for sample estimiates

are contained in the Appendix.

3t

GENERAL INSTRUCTIONS

1. The user must follow a specific format when filling the data In the

proper fields. Particular care should be exercised in positioning

Integers. In order to avoid confusion, all the spaces of the data

field for the element must be filled in. For example, "l" is written

"001," as illustrated below;

10 -1OO~ .1LALO

The input elements for which this rule applies are identified in the

description/instructions for each form.

The computer program has been designed with four levels of data require-

ments. Some of the data must be inputted by the user for program

execution; some is computer generated; and some is for documentation

purposes only. The data requirement for each input element is identi-

fied in the description/instructions for each ACCEM form. The defini-

tions of the data requlrements are as follows:

UNCONDITIONAL REQUIREINT- Absolutely necessary for program ext-cution.

CoNDITIONAL REQ'IREIMENT - Necessity dependent upon other conditions

being present. (For example, if an operation is performed, then the

accompanying parameters must be filled in)

SYSTEM. GENERATA) - If data is not inputted by the user, then specified

default values will be supplied.

DOCUMENTATION - Data input is voluntary and in generic to the user only.

4

ObI

ACCEM-O INPUT CHECKLIST

OBI"CTI VE

ACCEM-O identifisz l he types and quantities of data contained in the Itiput

Package. This information is used by the computer in determining the processing

sequellc le.

ACCEM-O is unconditionally required for computer program operation.

DESCRIPI'TON OF EII:NFNTS DATA REO

ESTIMAT3 NUMBER - Name of person supply data D

ESTIMATE NUMBFR - Identification number of estimate D

PART NArIE - Name of part D

PART NUMBER - Identification number of part D

INPUT FORMS - List of form nanets

QUANTITY USED - Amount of each form included in Input Package(I NI1 E(FR)

ACCEM - 1 LAYUP

ACCEM - 2 HONEYCOMB CORE PREPARATION U

ACCEM - 3 PART CONSOLIDATION U

ACCEM - 4 FINISHING OPERATIONS U

ACCEM - 5 COST PROJECTIONS U

LEGEND

DATA REQUIREMNT: U - Unconditional RequirementC - Conditional RequirenentS - System Generated (Value Specified)

D - Document ati on

5

- i

ACCEM-O INPUT CHECKLIST

CARD I ESTIMATOR NAE II

ESTIMATE NUMBER 1

4'PART NAME __ _ _ _ __ _ _ _ _ _ _ _ _ _

PART NUMBER I I

CWV, 2 INPUT FORMIS QUANT EDACCEI1- 1 LAYUP

3ACCEM-2 HONEYCOMB CORE PREPARATION

ACCEM-3 PART CONSOLIDATION

ACCEM-4 FINISHING OPERATIONS

ACCEM-5 COST PROJECTION

6 '

- gw~ ~ ~

ACCEM - LAYUP

OBJECT IVE

ACCEM - 1 provides the information for the description of the material and

the processes used in the layup operation. Data supplied in this form will

be used in calculating the standard houss and material costs for the layup

operation, as well as part weight. Codes are provided for some of the Inputs.

It is necessary to have one Layup Form for each non-identical layup.

It is an unconditional requirement that either ACCEM - I or ACCEM - 2 be

included in the Input Package for computer program operat ion.

DESCRIPTION OF EI.EMENTS IATA RE..

PART NAME - Name of part layed up O

PART NUMBER - Identification number of part layed up U

QUANTITY - Amount of identical parts layed up (INTEGER) U

TRIM ALLOWANCE - Unit of excess added to part dimensions to provide

for trim, in inches S 1.00

LAYUP TOO], SAME ASCURING TOOL - A lay,.p may be layed up and cured on the same tool,

or it may be transferred to another tool for curing. S - 0

DERULKING - Process of densifying plies

NO. OF OCCURRENCES - Amount of debulking operations performed (INTEGER) S= 0

TYPE OF BAG - CaLegory of material used in debulking C

COST - Cost of material in dollars per pound

GRAPHITE - TAPE S 1 37.00

- W(.'EN S 93.00

FIBERGLASS - rAPE S - 8.70

- WOVEN S - ).30

DENSITY Weight of material for a given unit of surface area,

in pounds per square inch

GRAPHITE - TAPE S - 0.0004

WOVEN S- 0.0008t

FIBERGLASS - rAPE S = 0.O0o

- WOVIN S 0.0010)4

7l

T ." *t= "

-7 t *"

, , . % . ,,-. Al'-vW ~ r" ,#"

-;

DESCRIPTION OF EI.E MEINTS DATA RE q.

METHOD - Procedures and tec',niques used to deposite com-pCsite material or tool (If HANDLING METHOD I 1,then information must be filled out for first lineof prep]y. If HANDLING METH1OD = 2, then information

must Do filled out for each ply)

HANDLING METHOD S =2

PREPLY - Stack of plies which are layed upon a flat surface

and ther transferred to the la:,up tool.

DIRECT-ON-TOOL - Deposition of composite material one ply at a time

on layup tool

QUANTITY OF PREPLIES - Amount of identical stacks of plies (INTEGER) C

LAYUP METHOD - S = 1

DEPOSITION TECHNIQUE - S = I

PLY-ON-PLY - Layup directly on previously layed up ply

PLY-ON-MYLAR - Each ply is layed up on a template (mylar) and

then transferred to the stack or layup tool.

BEND DESCRIPTION - Parameters which define layup complexity of non-

flat parts. (If HANDLING METHOD = 1, then aseparate entry for each type of bend must beginon the first line of the preply description. IfHANDLING METHOD =- 2, then a separate entry foreach type of bend must begin on the line of the

ply description)

TYPE OF BEND - A bend is characterized by a combination of factors. C

The surface along which the bend extends may be

straight or curved. The change in the surface ofthe part which determines the bend is defined by theradius of curvature. If the radius is less than orequal to two inches, the bend is sharp. The bendis radial if the measurement is greater than twoinches. A male bend is external to the tool surface;a femal bend is internal. Curved bends may beclassifi , d according to flange type. A stretchflange ft one In which the outer edge expands awayfrom the center of curvature. A shrink flange is

one in which the outer edpe contracts toward thecenter of curvature (See illustrations on next page.)

LENGTH OF BEND - Length of .ne bent surface perpendicular to the bendangle C

.... .. .- .-, ..- - . -- - - - -. , ' v ..- -- :, . . "r,' i, 9 ' .,-4 , %V1:¢L~ lI,* ,

Lb =BEND

BENDLINELb BEND LENGTH LENGTH

BEND R = RADIUS OF CURVATURE

SHARP. MALE RADIAL, MALE

R = RADIUS OF CURVA TURE

BENDLINE

BNLb BEND LENGTH Lb BEND LENGTH-

SHARP, FEMALE RADIAL. FEMALE

SITRAI Gfr BENDS

R = RADIUS OF CURVATURE

L BEND LENGTH Lb

Lb BEND LENGTH

=FLANGE WIDTHF FLANGE WIDTH

R =RADIUS OF CURVATURE

SHRINK FLANGE STRETCH FLANGE

LUIWED BfIA-S

9 ... .... . LA"

DESCRIPTION OF ELMENTS DATA REq.

RADIUS OF CURVATURE C

For Bend Codes 3-4: Radius of circle perpendicular to bend length

For Bend Coden 5-7: Radius of the circle formed by the bend length

FLANGE WIDTH C

For Bend Codes 5-6: Distance from the bend angle to the edge of thef lange

PLY DESCRIPTION - Defines each ply that composes the part. (IfHANDLING METHOD - 1, then a separate entry foreach ply type of the preplied stack must be filledouL. If HANDLING METHOD = 2, then a new entrymust be supplied for each ply having a uniqueLayup Method, Bend Description, or Ply Description.)

RIORIENTATTON - Angle which material is layed up. The 0 plyorientation is always in the lengtn direction.

U (INTEGER) U'COUNT - Number of plies (INTEGER) U

SDIMENSION (Whre the patto be layed uphas a crvedi bend,

dimension can be measured by taking the flat equi-valent of the layup. To do this, extend the we-,width to cover the flange width.) For a rectaLi-gular p-irt, the dimensions are length and widthFor non-rectangular parts the necessary dimensionsare area and distance (greatest length ac :oss tile

part perpendicular to orientation).NOTE: Dimensions must be filled in for either therectangular or non-rectangular category. U

MATERIAL - Defines the composite material used in layup

FORM S = 1

TYPE- S = I

WIDT1 - (in inches) S . 3.0

NOTE: AFTER FILLING THE LAST LINE OF DATA, THE USER MUST ENTER "9999" IN

THE FIRST FOUR COLUMNS OF CARD 4, AND "000" IN THE FIRST THREE

COLUMNS OF CARD 5.

IE(;'ND ')

DATA REQUI REMENT: U Unconditional RequirementC = Condi ional "t-quirementS lSystem Cent-rated (Value Spec i fIed)D - Ihotniontation

10

-.. .

ACC[M- I LAYUP

CARD I PART NAME A UMUER ,41 ()Q

51TRIM ALLQ4J4(t LAL F1

61 611AYIJP IDOL SAME AS CLIRI-4G TOOL (CICLE OI41 YES 1_ '40 0-_

1 62OLBLx,*-n or~Z' DI CCUR2[L.'CIS tw j64

TYPE 01 DAG MAUQCL 041) 0NSPOSAL I fltL5A1

CARD 2 (BLANK)GRAPHITE I RiS

TAPE 41011 TAN ~ WOVEl4

CARiD 2 OST IT/LB)

KEYPUNCH CARD 4 AND CARD 5 ALTERNATELYr ARD 4 CAD5

ETHOD BEIMD ESCRIPTION PLY DESCRIPTION

- AIUSRECTANGULAR ORETNLA

BEND OF FLANGE 0e

LENGTH WIDTH AREA DISTANCE

~ &a~~L .. 4. (IN.)

A 7A.A 17,

LAST~~~~~~ ENR ON---- CARD 4454994; A'ETYO CR s'LEGAO

KA'i.t'I ATO: 1*PlPO, 2 I:r1O~Ol

1'A -A -AA. 0 I-A ~TRA

A-~

ACCEM - 2 HONEYCOMB CORE PREPARATION

OBJECTIVE

ACCEM - 2 provides the description of the part, material, and processes used

in aluminum core prepart ion operations. Data supplied in this form will be

used in calculating the standard horus and material cost for core preparation

as well as part weight. It is necessary to submit one form for each non-

Identical piece of core.

It is an unconditional requirement that either ACCEM - 1 or ACCEM -2 be in-

cluded in the Input Package for computer program operation.

DESCRIPTION OF ELEMENTS DATA REO.

PART NAME - Name of part 1)

PART NUMBER - Number of patt U

QUANTITY - Amount of identical parts involved in operations(INTEGER)

MATERIAL DATA - Characteristics of core material

CELL SIZE - Width of one cell, In inches U

DENSITY - Weight of material for a given unit of volume,

in pounds per cubic foot U

AREA - Surface area of core piece, in square inches U

CORE THICKNESS - Depth of core, in inches U

COST OF MATERIAL - Cost of core in dollars per square foot

OPERATIONS - Techniques used to alter the surface or shapeof core

SAWING - Cutting the periphery of the core-

LENGTH OF CUT - Total distance that is sawed C

MAC111NING - Altering shape and dimensions of core

FLAT - Cut made perpendicular to the cells across the

core surface

LENGTH OF CUT - C

WIDTH OF CUT - C

e. 4.

DESCRIPTION OF ELEMENITS DATA REQ.

CONrOUR - Curved or angular cut across core surface

LENGTH OF CUT - C

WIDTH OF CUT - C

STEP - Removal of section perpendicular to cells alongside of core

LENGTH OF CUT - C

WIDTH OF CUT - C

SCARF - Removal of angular section along side of core

LENGTH OF CUT - C

WIDHT OF CUT - C

BLEND - Removal of surface material to match structuralelement to which core is bonded

LENGTH OF CUT- C

WIDTH OF CUT - C

CUTOUT - Hole cut in core

QUANTITY - Amount of cutouts made in core C

HAND FORMING - Manual bending or shaping of core C

BRAKE FORMING - Machine assisted bending or shaping of core

RADIUS OF CURVATURE -Radius of circle to which core is formed C

DIE LENGTH - Size of initial die used in forming core C

NO. OF DIE CHANGES - Amount of times different dies is installedin machine C

NO. OF REPOSITIONS - Amount of times a particular die is shifted C

LIQUID POTTING - Strengthening core by filling cells with mixturewhich is hardened by application of heat

VOLUME - Measurement of area to be filled, in cubic inches C

TAPE FOAMING - Strengthening core by applying tape which expandswhen heated to fill cells

VOLUME -- Measurement of area to te foamed, in cubic inches C

LEGEND

DATA REQUIREMIENT: U = Onconditional RequirementC = Conditional RquirementS = System Generated (Value Specified)I) = Documentat Ion

13

W'.:. "V

ACCEM-2 HONEYCOMB CORE PREPARATION

PAD ART NAMIE P'ART NUMBER TY.

cARO2 MATERIAL DESCRIPTIONCELL SIZE: IN.

DENSITY: __________- ___ LB./CU. FT.THICKNESS: I__ _N.

AREA: S Q. IN.COST: u.. .,, , Iq.Fr.

OPERATIONS S

SAWING LENGTH OF CUT: , , , . .IN.

FLAT LENGTH OF CUT: . A , IN.IIAXIN.UI$ WIDTH: " . ._.A IN.CONTOUR LENGTH OF CUT: .I .,- IN.MAXI1Ull WIDTH: ..... .. IN.STOP LENGTH OF CUT: A . IN.

WIDTH OF CUTA ,, IN.SCARF LENGTH OF CUT: AA IN.

CARD4 WIDTH OF CUT: , , IN.

BLEND LENGTH OF CUT: A ,IN.CUTOUTS QUANTITY: P A I

21HANDFORIING (CIRCLE ONE) YES: NO: I.LLAJ

31BRAKCFORNG RADIUS OF CURVATURE: __,_,___ .A._ ,11iN.

(CIRCLE ON[) DIE LENGTH <_S FT: f.J > .A jNO. DIE CHANGE':

NO. DIE REPOSITIONS:

LIQUID POTTING VOLUME FILLED: ,A IN.

TAPE FOAMING VOLUME FILLED: 160 A. , ICU. IN.

14

.. .. ,t,,,. , . . ' .. " .".,' "'

• .". .- '' ,e - . -"" -"M ,,' "+

. . ;--, ,.. . .

ACCEM - 3 PART CONSOIIDATION

OBJECTIVE

ACCEN - 3 describes the methods and processes of joining and curing elements.

Data supplied in this ferm will be used in calculating the standard hours

for part consolidation. It it necessary to submit one form for each joining/

curing cycle.

It is an unconditional requirement that either ACCEM - 1 or ACCEM -2 must be

included in the Input Package if ACCEM -3 is to be used.

DESCRIPTION OF El.EMENTS DATA REQ.

CYCLE NUMBER- Identifies the sequence of consolidatiot, D

PART NUMBER - Name of the part resulting from consolidation D

PART NUMBER - Number of the part resulting from consolidation D

QUANTITY - Amount of identical parts (INTEGER) U

COMPONENT DETAIL PARTS- Identification of elements to be consolidated(Elements must have been previously identifiedin ACCEM - 1 or ACCEM - 2)

NO. OF DETAILS - Quantity of line items (INTEGER) U

PART NAME - Name of element D

PART NUMBER - Number of element U

QUANTITY - Amount of elements (INTEGER) U

CONSOLIDATION OFDETAILS - Information identifying processes and methods used

in joining elements (either bonding or splicing,and/or a curing process msut be selected for con-solldatioa of details)

ADHESIVE - Chemical agent used to adhere elements C

APPLICATION AREA Surface area in inches on which adhesive is applied C

ADD IT] ONA).OP1ERAT IONS

BONDING- Joining surfaces of detail elements C

SPLICING - Joining edges of detail elements C

15

- e..a.".s.- ,.A- ..- ". .-: -. . -, - -- .>~ .._ . ,l.9 . .. *-- y , .-o • • .. . .. - -"-"" . . ... : 4 -' 'L , , .

DESCRTPTION OF EI.IEENTS DATA REq.

CURING PROCESS - Application of pressure and heat (eithervacuu.i bagpging or therma) expansion mold,

and one of the curing tools must be selectedfor the curing process)

VACUUM BAGGING - Application of vacuum pressure to advanced com-

vosite material.

BAG MATERIAL - Type of material used C

RESIN BLEED - Removal of excess resin from composite material C

PLY- TO- BLEEDERRATIO - Proportional relationship of composite plies to S-3.O

bleeder plies

BAGGING AREA - Surface area covered by bag material, in square

inches C

SEALING/CLAMPINGPERIMEIER - Distance around bag that is sealed or clamped,

in inches C

THERM1AL. EXPANSION

MOLD - Elastomeric tool in which composite material

is contained

MOLD CAGE DIMEN-

SIONS (EXTERNAL)- Outcr surface dimensions of mold cage, in inches C

CURING TOOL - Method of applying heat an( additional pressure Ufor curing.

AUTOCLAVE - Chamber which supplies additional pressure as

well as heat to vacuum bagged material

OVEN - Chamber which supplies heat by convection tomaterial enclosed in either a vacuum bag or

thermal expansion mold

HEATING ELMEN'r - Tool which transfers heat by conduction to materialenclosed in thermal expansion mold

LEGEND

DATA REQUIREMENT: U - Uncondilonal RequirementC - Conditional Requirement

S - System Generated (Value Specified)

D - Documentation

16 'A

- -.- 4 .41~


CYCLE NUM8ER

cwI IPART N.AME PkRT NUMBERANTITY 1CARDI

COMPONENT DETAIL PARTS 51

NUMBER OF LINES USED , (MAXIMUM 10)

PART NAME HRT NUMBER TITYCRD, 2

CONSOjLIDATION OF DETAILS

CARO . AI)HESIVE (CIRCLE ONE) NO0: 0 YES: 1

APPLICATIOR AREA: I Q N-

ADDITIONAL OPERA~TIONS gg

(CIRCLE I APPLICABLE) BONDING: 1 SPLICIG: 2

CURING PROCrSrvACUUM AGING 12 12

|T|O OF BAG: (CIRCLE ONE) DISDOSABLE: I REUSABLE: 2

RESIN ,LEDE (CIRCLE ONE) NO: 0 YES: "T

PLY-tO-BLEEDER RATIO: AT-

BArGING AREA: 6 ~S . IN.

SEAL Ifl/'LAMWING PER.M . I t

.A.. $q.IN.

THERMAL EXPANSION MO..ING _ .

E TERNAL MOLD CAGE DIIEISIONS: LENGTH-IIDITH:

DEPTH:

CURING TOOL: (CIRCLE ONE) AUTOCLAVE:

OVEN: 2

HEATING ELEENT: 3

17

EH 1- ... t

ACCFM - 4 FiNIS1N OPi.RATIONS

011.1 I:CT I VI"

ACrE - 4 provi de, the part description and process idit. if iat lon for the

finishing operations performed on a cured composite part. Mata supplied in

thIs form will be used in ('alculating the standard hours for finishing. Codes

are provided for identifving each operation. It is necessary to submit one

form for each non-Identical part.

It is an unconditional requirement that either ACCEM - 1, or.ACCEM - 2, aI

ACCIM - 3 be included in the Input Package if ACCEM - 4 is used,

DES.CR-PTI.0N Of E"LrMENTS DATAjs.oz

PART NAME - Name of part finished D

PART NU'BEF, - Number of part finihled D

QUANTITY - Amount of identical parts (INIEGER) D

PART AR:A - Surface area of part, in square lncihe U

NET TRIM OPERATIONS - Processcs In which material Is rkemoved from Lhe

edges of l.he cured part.

TYPE OF OPERATION - lde:ntiflcation of net trim operatliol

AVERAGE Ill ICKNESS - Mean depth of area to be tirimmed, in inches C

TRIM LENT(;ll - Total distance trimmed, in inches C

FIXTURE"- Stationary tool on which operation is perlornmed C

TEMPI.ATE- Guide tool for trimming C

HOl.E OPER.\TIONS - Processes used to cut holes in cured parts

(1IERA'I 1ON CODE - I dent ificat ion of hole cut t ilg operation C

QUANTITY - Amount of identical holes cut in part (INTEGER) C

HIOLE I)IAMETIER - Meanl width of holes, in inches

HO1.1' DI'"Fi - Mean depth of holes, In inc-es

FIXTURE - Stationary tool on which operation Is performed C

TEMPLATE - Guide tool for cutting holes; C

INSERTS - Removable bushing used to giuide hole operations C

IEtGNIi

DATA RFQUIRE1' MINT: tl = Umconditloioal Requirement

C - Condti lonal IVitqultementS - Sybtem Ccnt-rait id (Value Spicifi(lid)

, fl• D I" ~)',,m,o,nl .a i~

18

'Q., , : . ,, ., . , , - ' , • ,=..- .. .''


PART NAME 0 ;PRT NUMBER QTY

CAlkD 1 4 41

PART AREA SQ. IN.

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

AVRG RMHOLE HOLEHICKNESS LENGTH ,TY. DIAMETER DEPTH

A..

-... \ l _ 4

CARD 3CAR~D 0 U

LEGEND LEGE-ND

OPERATION: I = HAND ROUTING OPERATION: DRILLING2 MACHINE ROUTING 2 = COU"ER!ORING3 =HAND SAWING 3 =RE:AM ING4 =MACHINE SAWING 4 =COU;ITERSINKING5 =HAN SANDING 5 =HOLE SAWING6 =OPORTABLE TOOL SANDING 6 = OIPO PUNCHING7 MACHINE SANDING FIXTURE: 0 = NO

FIXTURE: 0 = NO, 1 r EXTERNALI = YES 2 = INTERNAL

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

INSERTS: 0 = NOI YES

19

- " "-. -. "rj , ;' ./ "' < 'l ' 9 - > < :i - - I .

I

ACCIM - 5 COST PROJECTIONS

OBJECTIVE

ACCEM - 5 provides the rates and factors to be used in Support Fun( Ion tst im t in)

and Cost Projection. Dta supplied In this form will bo applied to the results of

Factory Labor Standards Estimating in order to arrive at total component costs in

hours and dollars. Codes are provided to Identify certain data input options

which allow rmaximum flexibility.

It is an unconditional requirement that either ACCEM - I or ACCEM - 2 mnst be In-

eluded in the Input Package if ACCEM - 5 is to be used. ACCEM - 3 and ACCEM -4

are not necessarily required if they are not applicable to the estimate.

DESCRIPTION OF ELEmi.ENTS DATA REQ.

UNIT NUlMfBER - Number of production unit at which cost is U

estimated. ( 1 NTE(ER)

AVERAGE LOT SIZE - Mean number of units in each production lot. U

TYPE OF ESTIMATE - Unit Cost is estimated for the specified unit U

number. Cutnulativtu Average Cost is the meancost per unit.; Cumulative Total Cost is the sum

of the unit costs.

PROJECTION FACTORS - Factors which are applied to the standards to com-

pute component total factory labor hours.

DATA INPUT OPTIONS -Cods are provided to Indicate whether factors in Uthe program are to be applied, or whether datawhich have been entered (either in detail or in

total) will override these value,. The input re-

quirement for this Sect ion is dependent upon the

option that is selected.

LEARNING CURVE - Indicates type of le-irning curve slope S - 0

T VARIANCE - Mu'tiplicative factor applied to standards toarrive at total hours fo, first unit. C

IEARNINGCURVE Sl.OPE-Progress iv,, relationship of values expressed asa ptercentage. C

z0

__ .- o ................

DESCRIPTION OF ELEMENTS DATA RP(9.

IF DATA INPUT OPTION - 0, THEN THE FO.LOWING BASIC RELArlONSPll'S ARE,APPLIED: LEARNING CURVE= 0

FOR, NN5

T VAR. SIOPE UNIT VAR.Fj'N

LAYUP 34.03 65.80% 34.03N-'60 37

15.4359CORE PREP 16.8 3 1.397 + 1_ -N . ....

PART CONS 36.48 65.77% 36.48N- '6 0 4 4

FINISHING 35.19 65.82% 35.19N-6 0 3 5

FOR N !?6,

LAYUP 23.24 76.63% 23.24N 3 8"

0

15.4359CORE PREP 16.83 - 1.397 + 14

PART CONS 25.06 76.52% 25.06N- 3 8 6 0

FINISHING 23.84 76.77% 23.84N 3 8 1 3

SUPPORT FUNCTIONESTIMATES - Calculattm of costs of support labor and material

DATA INPUTOPTIONq Codes are provided to indicate whether relation- U

ships in the program are to bh appli, d, or whetherdata which have been entered (eithor as a multipli-cative relationship or as a direct inlput) willoverride these values. The Input requirement for

this Section is dependent upon the option selected.

BASE - Cost element which is the basis of the estimating

relationship C

BASE UNIT - Category of value of the cost element C

FACTOR - Multiplier which is applied to base cost element

value. CLABOR HRS/MAT'L $'s - Direct estimate of support function cost C

IF DATA INPUT OPTION 0 0, THEN THE FOLLOWING BASIC RELATIONSHIPS ARE APPLIED:

BASE BASE UNIT FACTOR * FACTOR *

QUAL. CONT. 1 1 O.4243N- 0 1 7 3 7 S "0.4196

TOOLING 1 1 0.7030N 0.2594 0.6313N 1

MFG. ENG. 1 1 0.7227N- 1 8 2 6 1.0062N

0 .4 25 6

ENG. 1 1 0.3540N- 0 .2 2 2 3 - O.3524N

0 3 7 1 3

GR. SERV. 1 1 O.0824N-O . 2 2 9 8 OO 4 3 2 N

-O. 18 4 (l

SUP. MAT'L 7 2 0.30 0.30

*Applicable if Learning Curve - I**Applicable if Learning Curve - 0

2I

- ( S' A.'" - :" "

DFSCRIPTION OF ELEMENTS DATA REQ.

LABOR RATES - Factors applied to labor hours to calculatelabor cost in dollars.

DATA INPUT OPTIONS - Codes are provided to indicate whether rates in Uthe program are to be applied, or whether datawhich have been entered will override these values.The input requirement is dependent upon the optionthat is selected.

RATES - Cost of unit of laboe in dollars per hour C

IF DATA INPUr OPTION - O, THEN THE FOLLOWTNG VALUES ARE APPLIED:

FACTORY LABOR $10.00

QUALITY CONTROL $10.00

TOOLING $10.00

MFG. ENG. $10.00

ENGINEERING $10.00

GRAFRIC SERVICES $10.00

OVERHEAD- Costs incurred in doing business, regardless ofparticular goods produced, which are allocatedto'dost categories.

DATA IVIUT OPTIONS - Codes are provided to indicate whether rates in the Uprogram are to be applied or whether data whichhave been entered (either in detail or in total)will overriJe these values. The input requirementfor this Section is dependent upon the optionselected.

RATE - Factors which are applied to cost category dollarsto generate overhead costs. C

IF DATA INPUT OPT1ON = 0, THEN THE FOLLOWING VALUES ARE APPLIED:

FACTORY FAB, 1.50

QUAL. CONT. 1.50

TOOLING 1.50

MFG. ENG. 1.50

ENG. 1.70

CR. SLRV. 1.70 LEEND

MATERIAL, .20 DATA REQUIREMENT:

ADMIN. 0.15 U - Unconditional RequirementC - Conditional RequirementS - System Generated (Value Specified)D - Documentation

•. ... -..... .o A A.A. . "' .C. . . . , , ' . , -+, .t- t,

ACCE'!-5 COST PROJECTION C I

UNIT NUMBER .AVE. LOT SIZE ,

TYPE OF ESTIMATE

UNIT COST COL. 21 NO .l.. YES .1.. (CIRCLE ONE)

CUMULATIVE AVERAGE COST COL. 22 NO -0- YES I (CIRCLE ONE)

CUMULATIVE TOTAL COST COL 23 NO 0 YES I (CIRCLE ONE)

CARD 2 FACTORY LABOR PROJECTION FACTORS 24 24

LEARNING CURVE: LOG-LINEAR UNIT _.k CUM. AVE. J_ (CIRCLE ONE)

DATA INPUT OPTIONS CAD 3 CARD 4(CIRCLE ONE) Cot.. I T VARIANCE LEARNING CURVE SLOPE

NOE (a) LAYUP 1

IC(M) ,, (b) CORE PREPARATION

(c) PART CONSOLIDATION -A. %

(d) FINISHING OPERATIONS .41 41

(e) TOTAL FACTORY LABOR , A. .

DATA INPUT OPTIONS(CIRCLE ONE) 2 LABOR RATES CA4IlD 5

NONE .0. (a) FACTORY LABOR Ak .• ,/HR

IEMS (f) (b) QUALITY CONTROL

(¢) TOOLING F S/HR(d) MFG. ENG. . .$/HR

(e) ENGINEERING A1 , "$/HR

(f) GRAPHIC SERVICES A - IHR

DATA INPUT OPTIONS(CIRCLE ONE) 3 SUPPORT FUNCTIONS CARD 6 CARD 7 CARD 8 CAID

WNEO BASE EASE UNIT FACTOR LABOR HRS/MAT'L $'S

CARDS(6) - (8) ,I, I I I . |

CARD (9) ,Z, QUALITY CONTROl.fOOLING Nj.. 1...jL _ ,_ ZIL. . _.J, _,

MFG. ENG. --

ENGINEERINGGRAPHIC SERVICES

,7*

SUPPORT MATERIAL 5L GLNO0

BASE: I - FACIORY FACRICATI04, • QUALITY (ONTROL, 3 • TOOLING,4 • MfG. ING. .5 , NGINIERING. 6 ' GKAPHIC SERVICES. I • PRODOCTION WII'I.

DATA INPUT OPTIONS BASE U;.r: H - OURS. 2 • DOLLARS(CIRCLE ONE) 4 OVRHIEAD RAlES WID 10

LQ~J I

IEMS (a)- (f), ')3) (a) FACTORY FABRICATION

ITEMS (1). (2). 13) 12, (b) QUALITY CONTROL

c) TOOLING

(d) MFG. ENG. . A , ,

(e) ENGINEERING(f) GRAPHIC SrRVICES CAM If

(1) TOTAL LABOR h t...

(2) MATERIAL

(3) ADMINISTRATIVE

? 3

- .777,

* :' ~&-

• " "# ' -" " . " "" ' - . ;-f'''w,.< , -: " .. . . . T, '__

3.0 KEYPUNCHIINC DATA CARDS

The ACCEM Input Forms have been designed so that the data can be keypunched

directly from the forms. General instructions, as well as additional notes, by

card, for each ACCEM Input Form have been provided. This information has been

described in sufficient detail to serve as a guide for the user to keypunch

data.

GENERAL INSTRUCTIONS

1) The card and column number where input data is to be keypunched has

bean identified on each input form. For each data field, inputs

should be left justified.

2) All of the data inputs start in Columns 1, 11, 21, 31, 41, 51, 61,

and 71. For convenience in keypunching. keypunch program cards

(11M1 029) can be set to these columns.

3) Skip those items where data has not been entered..

ACCE!4-0 INPUT CHECKLIST

Card I - one per page

CarJ 2 - one per page

ACCEM-1 LAYUP

Card I - one per page (except as noted below)

Card 2 - one per pare (except as noted below)

Card 3 - one per page (except as noted below)

24

24 ;9

a.,

Card 4Keypunch alternately, i.e., two cards per line. Cpntinue

, Card 5

sequence to the end of this data. The last entries should be:

Card 4 9999 (Col. 1-4)

Card 5 000 (Col. 1-3)

NOTE: More than one page of ACCEi-I may be used to continue

data on Card 4 and Card 5 for a non-identical lavup.

For these continuation pages skip Card 1, Card 2, and

Card 3, and resume sequence for Card 4 and Card 5.

ACCEM-2 IiO EYCOIIB CORE PREPARATION

Card 1 - one per page






Card 2 - one per line of input (maximum 10 lines)



Card I - one per page

Card 2 - one per line of input. Omit this card if lines are blank.


Card 4 - one per line of input. Omit this card if lines are blank.


25

t 4 ~ V -. -'

Y , ' ' ' : °"•" .-" " k '" ,""•:

N ACCII-5COST PROJECTION







Card 7 -one per page




~ 26

F4

4.0 ESTRIATING EQUATIONS

The computerized estimating system is composed of equations which are

used to calculate the elements of total recurring cost. These equations

are provided in this section for the user's reference. In addition, manual

cost estimates can be made by solving the appropriate ecuations.

The standards estimating relationships (Sections 4.1-4.4) fom the core

of the ACOC4 cmputerized system. They are used to calculate the basic work

element of factory labo-r.

7b develop estimates of total recurring cost, the user has the option

of either entering nis ocn relationships and factors or using those supplied.

The variance equations (Section 4.5), support function estimating relation-

ships (Section 4.6), and labor and overhead rates (Section 4.7) which are

generated by the computer are surmAraized herein.

27

..- ....

4.1 LAYUP STANDARDS ESTIMATING RELATIONSHIPS

B3ASIC DEPOSITION_

DETAIL ELEMENTS SETUP RUNTIME

CLEAN LAYUP TOOL SURFACE 0.000006A (Li)

APPLY RELEASE AGENT TOLAY1IP TOOL SURFACE 0.000009A (L2)

POSITION TEMPLATE (MYLAR) 000 0 A 77006 (3ON TABLE AND TAPE DOWN0.017()

PLY DEPOSITION

MANUAL - 3" TAPE 0.05 0.00140L0.6018 (L4)

- 12" TAPE 0.05 0.001454L08 4 (L5)

- WOVEN MATERIAL 0.05 0.000751A 0.6295 (L6)

HAND-ASSIST - 3" TAPE 0.10 0.000368L 0 8446 (L7)

- 12" T'APE 0.10 0.001585L 0 5580 (L8)

CONRAC AUTO. (720 1PM) 0.15 0.00063L 0 4942 (L9)

(360 1PM) 0.15 0.00058L 0 5716 (LIO)

TRANSFER PLY FROM TEMPLATE 0004A 6 1 LiTO STACK OR LAYUP TOOL 0004A061 Ll

TRANSFER STACK TO LAYUP TOOL 0.000145A0.6711 (L12)

CLEAN CURING TOOL SURFACE 0.000006A (L13)

APPLY RELEASE AGENT TOCURING TOOL SURFACE 0.000009A (L14)

TRANSFER LAYUP TO CURING TOOL 0.000145A0.6711 (015)

WHERE:

A =Area of ply, or greatest ply area of stack or layup, in squjare inches

L =Length of ply strip, in inches

28j

LAYUP COMPLEXITY__INCREMENTS

BEND TYPE BEND FACTORS NOTES

STRAIGHT BENDS

SHARP, MALE 0.00007L b (SHARP, FEMALE 0.00016L b (82)

RADIAL, MALE 0.00007L b WHEN R 2" (B3a)

NO FACTOR APPLIED WHEN R > 2" (B3b)

RADIAL, FEMALE 0.00016L b WHEN R s. 2" (B4a)

[0.004R- 13585Lb When R > 2" (B4b)

CURVED BENDS

TAPE

STRETCH FLANGE [0.015R* 5 3 F* 15 )Lb (85)

SHRINK( FLANGE [0.0064R- 5 7 F' 7 ]L b (86)

-0.5958WOVEN [0.00444R- + 0.0007]L b (87)

WHEE: Lb Length of bendlineR =Radius of curvature

F =Flange Width

NOTE: The additional increment of runtinme is added as follows:

Ply-On-Ply/Direct-On-Tool (14)O (16) Ply Deposition

Ply-On-Ply/Pre-Plying (112) Transfer Stack toLayup Tool

Ply-On-Mylar-/Direct-On-Tool (I0l) Transfer Ply toLayup Tool

Ply-On-Mylar/Pre-Plying (L2) Transfer stack toLayup Tool

SUPPLEM1ENTARY LAVUP OPERATIONS

DETAIL ELEMENTS SETUP RUNTIME

DEBUL KING

DISPOSABLE BAG 0.02 0.00175A06 1 (L06)REUSABLE BAG 0.02 0.000557A 08 ' (117)

TRIMMING 0.00011P (118)

L WHERE:A = Area of layup, in square inches

P = Perimeter of layup, in inches

30

th,. - r%

ri

4.2 CORE PREPARATION STANDARDS ESTIMATING RELATIONSHIPS

DETAIL ELEMIENT SETUP RUNTIME

SAWING

HANDLING H = 0.000453A 0 3810 (HI)

SAWING 0.05 H = (O.000663T 04230)L (H2)

MACHINING

POLYGLYCOL 0.02 H r 0.00257A0 "6175 (H3)

HANDLING H = 0.002657A 0 5051 (H4)

FLAT 0.50 H = O.0002(W/I.5)(L +6) (H5)

CONTOUR 0.60 H = O.00005(4W)(L i 6) (H6)

END MILL STEP 0.11 H = 0.O006WL (H7)

END MILL SCARF 0.11 H = O.O006WL (H8)

END MILL BLEND 0.11 H = O.0009L (Hg)

CUTOUT 0.01 H = 0.0120(N) (HlO)

FORMING

HAND 0.05 H = 0.000008A '208 (HIl)

POWER BRAKE H O.0008L0 2 (HI2'

SETUP

IF DIE LENGTH 6 FT. 0.15

IF DIC LENGTH > 6 FT. 0.19

PER DIE CHANGE 0.12

PER DIE REPOSITION 0.03

INCREMENTS

IF C = 0.1250 IN. H = O.0091R (Hl2a)

IF C = 0.1875 IN. N = 0.0065R (Hl2b)

IF C = 0.2500 IN. H = 0.0052R (Hl2c)

IF C -S 0.3125 IN. H = 0.0039R (Hl2d)

LIQUID POTTING 0.05 H = 0.0105V (113)

TAPE FOAMING 0.05 H = 0.0257V (H14)

CLEANING 0.05 H = 0.00046V0 .4257 (HI )

WHERE:

A = Core area in square inches N = Number of cutoutsT = Core thickness,in inches R = Radius of curvature to be formed,L = Length of cut, in inches in inchesW = Maximum width of cut, in inches C = Cell size, in inches

V = Volume to be potted or foamed,in inches

31

43PART CONSOLIDATION STNDRD_ ETIATN RELATIONSHIPS

SPLICING/BONDING

DETAIL ELEMIENT SETUP RU14TIME

APPLY ADHESIVE 0.05 0.000055A (Cl)a

HAMM!N 0.015A~6 1 (C2)

WHERE:

Aa = Adhesive application area, in square inches

A = Part area, in square inches

NOTE: These standards are applicable only if the adhesive which joins the

detail elenments is cured by applying heat with a hand gun.

32

-- 77

VACUUM BAG/AUTOCLAVE CURE

AP PL ICAT!IONDETAIL ELEMENT SETUP RUNTI HEDI.RES

SF.TI'P0.07

GATHER DETAILS, PREFIT, 055DISASSEMBL[ AND CLEAN 0.001326 (A0 522 x x (Vi)

APPL ADESV X x (V2)APPLYADHEIVEO.000055La] 0.6711ASSEMBLE DETAIL PARTS 0.000145 (A0 ) X X (03)

APPLY POROUS SEPARATORFILM 0.0000O9A b x x (V4)

APPLY BLEEDER PLIES 0.00002A r x X (V5)

APPLY NON-POROtJSSEPARATOR FILM ~ 0.000009A b x x (V6)APPLY VENT CLOTH 0.0O002Ab x x (V7)

INSTALL VACUUM FITTINGS 0.0062N f x (V8)

INSTALL THERrIOCOUPLES 0.O162N f X x (V9)

APPLY SEAL STRIPS 0.01Px (Vio

APPLY DISPOSABLE BAG 0.000006Ab X (Vil

APPLY RUBBLR BAG 0.000015Ah X (V12

SEAL EDGES 0.00054PD x (V13

CLAMP EDGES 0.02Px (V14

CONNECT VACUUM LINES &APPLY VACUUM 0.0061 x x (V15

SMOOTH DOWN 0.000006Ab x x (V16

CHECK SEALS 0.007 bx x (V17

DISCONNECT VACU'A l LINES 0.0031 X X (Vi8

CHECK AUTOCLAVE INTERIOR 0.0300 (Al)

LOAD LAYUP IN TRAY 0.000145A0.6711 (A2)

ROLL TRAY IN 0.0250 (A3)

CONNECT THERMOCOUPLE LEADS 0.00 92N f (A4)

CONNECT VACUUM LI NES AND APPLYVACCUTI PRESSURE 0.006111f (A5)

CHECK BAG, SEAL & FITTINGS (0.000006V a 00027 Pb .00388f I (A6)

CLOSE AUJTOCLAVE 0.0192 (A7)

SET RECORDERS 0.0560 (A8)

START CURE CYCLE

q

33~

APPLICATIONDETAIL ELEMENT SETUP RUNTI.ME U-157RE-U.

CYCLE CHECK 0.0800 (A9)

SHUT DOWN 0.00332 (AIO)

REMOVE CHARTS 0.00332 (All)

OPEN AUTOCLAVE DOOR 0.0192 (A1 2)

DISCONNIECT THERMOCOUPLELEADS 0.0035N f (A13)

DISCONNECT VACUUM LINES 0.0031N f (A14)

ROLL TRAY OUT OF AUTOCLAVE 0.0120 (A15)

REMOVE LAVUP FRO14 TRAY C00f0145A 0 6711 (A16)

RELEASE CLAMPS 0007bx (Vig)

REMOVE DISPOSABLE BAG 0.0O0O08A b X (V20

REMOVE REUSABLE BAG 0.000OO3A b X (V21)

REMOVE THERMOCOUPLES 0.0095N f X X (V22)

REMOVE VACUUt FITTINGS 0.0029N f X (V23)

REMOVE VENT CLOTH 0.0O0O07Ab x x (V24)

REMOVE NON-POROUS SEPARATORFILM 0.0O0007Ab x X (V25)

REMOVE BLEEDER PLIES 0.000007A b x x (V26)

REMOVE POROUS SEPARATORFILM 0.000007Ab X X (V27)

ASIDE USED MATERIAL 0.O0O005A b x x (V28)

REMlOVE LAVUP & ASIDE 0.000006Ab x x (V29)

CLEAN TOOL 0.000006A b x X (V30)

WHERE:

A = Area of detail part to be consolidated, in square inchesA = Area of surface where adhesiv.e is applied, in square inches

A =Bagging area, in square inchesArb = Area of resin bleeder plies

k rea of composite material used divided by ply to bleeder ratio,in square inches

Nf Number of vacuum fittings 1, if Ab 432 square inches-2, if A b 432 square inches

Pb Perimieter of bag to be sealed or clamp~d, in inches

NOTES:1. (01) W V) are applicable if two or more component detail parts are

to be joined together in one cure cycle

2. (V4) -(V5) and (V26) -(V27) are applicable if resin bleeding.

34

e--

VACUUM BAG/OVEN CURE

DETAIL ELEMENT SETUP RUN1TI1IE

SETUP 0.05

SEE VACUUM1 BAG/AUTOCLAVE CURE FOR ELEMENTS (Vi) -(V18)

CHECK OVER INTERIOR 0.0300 (01)

LOAD LAYUP INTO OVER 0D00114A b08 (02)CONNECT VACUUM LIAES ANDAPPLY VACUU."I PRESSURE 0.O061Nf (03)

CONNECT THERMOCOUPLE LEADS 0.00O92Nf (04)CHECK FOR LEAKS [O.ODOOOGAb+ .00044P + O.OO88H~ (05)CLOSE OVEN 0.0192 (06)SET RECORDER 0 -2)1 40 (07)START CYCLE

CYCLE CHECK 0.0800 (08)

SHUT DOWN AFTER CURE 0.00083 (09)

REMOVE CHARTS 0.00083 (010)OPEN OVEN 0.0192 (011)

DISCONNECT THERMOCOUPLELEADER 0.O03 5Nf (012)DISCONNECT VACUUM LINES 003N(013)REMOVE PART FROM OVEN O.OQ00 0 .8586 (014)

SEE VACUUM BAG/AUTOCLAVE CURE FOR ELEMENTS (V19) -(V30)

WHERE:

Ab = Bagging area, in square inches

Nf = Number of vacuum fitt-Ings

P 2Sealing/clamping perimeter, in inches

35

THERMAL EXPANSION M0Li,3

DETAIL ELEMENT SETUP RUNTIME

SETUP 0.02

CLEAN MOLD CAGE 0.0008Am (Xl)

APPLY RELEASE AGENT 0.0013A m (X2'

ASSEMBLE LAYUPS INTO CAGE [0.0237 (A06 8 ) + 0.0016 (X3)

APPLY HEAT;

a. OVEN: 0.05 SEE VACUUM BAG/OVEN CURE ELEMENTS (01) -(014)

b. HEATING ELEMENT: 0.43 0.00264 (A0 2 ) (X4)

REMOVE PART FROM TOOL (0.000145 (A06- ) + 0.000253 (X5)

ASIDE PARTS 0.000043 A0' 9 5

WHERE:

Am =External surface a-ea of mold cage, in square inchesA = Area of component detail part to be consolidated, in square inches

36

4.4 FINISHING STANDARDS ESTIMATING RELATIONSHIPS

DETAIL ELEMENT SETUP RUNTIME

MET TRIM OPERATIONS

HAND ROUTING 0.05 (0.00666T 0.29)L (Fl)MACHINE ROUTING 0.20 0.0015L (F2)

HAND SAWING 0.02 (O.0046T0.6624 )L (F3)

MACHINE SAWiNG 0.05 (0.0022T0 .64 )L (F'4)HAND SANDING 0.02 0.0005L

PORTABLE TOOL SANDING 0.02 (0.0012T)L (F6)

MACHINE SANDING 0.25 (O.00046L)P (F7)I

HOLE OPERATIONSO.3370 0.4562DRILLING 0.05 (0.01693D z + 0.0006)Q (F8)

COUNTERBORI;JG 0.05 (0.00514D 0.96z025 + 0.0006)Q (F9)

REAMING 0.05 (0.012180.24 z 0.38+ 0.0O06)Q (F10)

COUNTERSINKING 0.05 (0.00450.75 000) (F11)

HOLE PUNCHING 0.05 (0.0036)Q 1051(F12)HOLE SAWING 0.05 (0.01293 z1105 + 0.0006)Q (F13)

HANDLING TIME

PART HANDLING 0.000145A0.671 1 (F14)FIXTURE - INTERNAL O.0J414A 03 6 (Fi5)

- EXTERNAL 0.00777A 02 9 (F16)TEMPLATE 0.00010/A 0706(F17)CLAMPS 0.000322C (F18)INSERTS 0.0007Q (F19)

WHERE:T =Average material thickness, in inches1. =Trim length, in inchesP =Number of passesD =Hole diameter, in inchesZ =Hole depth, in inchesQ Quantity of holes per partA =Part area, in square inchesC = Part perimeter, in inches

37

'T.1M~ . A

4.5 FACTORY LABOR VARIANCE EQUATIONS

Factory labor hours at a specified production unit are calculated by

applying the solution of the appropriate variance eqpation as follows:

(Factory Labor Hours) N = [(Variance) N (Factory Labor Standards)],

where (Factory Labor Standards) = (Set Up/tot Size) + Rln

LAYUP

Unit Variance

VUL = 34.03 N 6 0 3 7 , for N<-5

VUL = 23.24 N 3 8 4 0 ' for N 6

Cumlative Variance

VCL = [34.03i(i 6 0 37 )], for N*55 N...603 -3840) N

VC, [34.032(i 6 0 3 7 ] +[23.24'.(i 34 for N-6i=l

Cumulative Average Variance

VVCAL = CL

N

38

~1

HONEYCOMB CORE PREPARATION.

Unit Variance

VUHC =1.3970 +15. 4359N

Cumuative VarianceN

Vc = 1.397N + 15.43592

Cumulative Average VarianceVCHV~tI - N

VCAHC N

PART CONSOLIDATION

Unit Variance

VUpC [36.48N-'6044], for N'5

V[, C [25.06N-3860, for N 6

Cunulative VarianceN

V = 36.48 (i-'6044 for N'- 5

5V C = [36.48 (i-6044 + [ 3860

fCCH 25.06c~( J for N 6

Coulative Average VarianceVP-

CIV C N

39

*, 7 W

4 _

FINISHING

Unit Variance

V, [35.19r.6035 ] for N195

VU, [23.34N..- -31 3], for N>, 6

Cmzulative Variance

= 35.19'(i~.05] for N,<5

[ 35.19f (i 6035 ] + N2.4:~ 3813)1 for N>,6i=1 6

Qimulative Average Variance

CAF

40

Oro

4.6 SUPPORT FNCTIONS ESTIMING FUATIONS

. ALITY (awTmL

log- Linear Unit Bnqrovement Curve

Unit Quality Control Labor flours

11aN-Unit = '4 .3542N 0 2 2 8 5 ) (FLUnit)

Cumulative Quality Control Control Labor HoursN

(0.3542Ei0.2235) (FLN..CLn)i=.l

Cumulative Average Quality Control Labor Hours

QM-~nAve =(QcUN.CR) /

Iog-Linear Cumulative Average Improvement Curve

Cumulative Average Quality Control Labor Hours

-0 1737Ave - (0.4243N- ) (FLHN Ave)(QC1N-Cm Av -CL= ve

Cumulative Quality Control Labor Hours

QC NCm = (0.4243N 0 17 37) (FIN.cLu)

Unit Quality Control Hours

VCLHN-Unit = (QCLUNCLm ) - ()CUI(NI)_Cum)

41

200 , ,, .- .. % 4

TOOLING

Liog-Linear Unit Improvement Curve

Unit Tboling Labor Hours

Tnk Unit = (0.6313N-0 4196)

Cumulative Tooling Labor Hours..o = (0.6 13ZNi-0.4196

i=l

Cumulative Average Tooling Labor Hours

nAve - (n-Cm /N

Log-Linear Cnulative Average Improvement Curve

Cumulative Average Tooling Labor Hours

NC Ave - (0.7030N-0 .2594) ( Ave )

Cumulative Tooling Labor Hours

7LHN, = (0.703M4-0. 2 - 9 4 ) (F N_.)

Unit Ioling Labor Hours

TN-Unit =(TilNCum) - (TLH (N-1)-Cur

4Z

%,, , " f. , ,,,, ' . . , ,.wr; . ...., .. -.,.O-

MANUFAC'UIUNG ENGINUI G

Log-Linear Unit Imrovanent Curve

Unit Manufacturing Engineering Labor Hours

Z'_OUnit -- (1.0062N 0 4 25 6 ) (F _N-Unit )

Cumulative Manufacturing Engineering Labor Hours

MrUiN-Cun = (1.0062zi-0 .4 2 5 6) (FUN-Cn)

i-I

Cumulative Average Manufacturing Engineering Labor Hours

( N-On Ave = lUN-Cumn) /N

Log-Linear Cumulative Average Improvanent Curve

Cumulative Average Manufacturing Engineering Labor Hours

-1826IUIN-an Ave = (0.7227N 0 " (FN-Cum Ave )

Cumnlative Manufacturing Encineering Labor Hours

-0 1826'LHN_cum = (0.7227N - ) (FLHNc0)

Unit Manufacturing Engineering Labor Hours

T 1"N-Unit = ('U- Cum) - ('EM (N-i) -Cum )

43

• i

14.ads.

EN1GTNEERING

Log-Linear Unit Improve.ent Curve

Unit Engineering Labor Hours

ELHNUnit = (0.3524N 0 "3 7 1 3 ) (FL _Unit

Cumulative Engineering Labor Hours

~0 371?(F'tINcR)E IMNC m = (0. 3 52 4 i (

Cumulative Average Engineering Labor Hours

ELHN-Cn Ave = (EIHN-Cm) /N

Log-Linear Cumulative Average Inprovement Curve

Cumulative Average Ergineering Labor Hours

EU"-Cum Ave = (0.354N 0 2223 )(FUL .Cum Ave)

Cumulative Engineering labor Hotrs

-. 2223EM = (0.3540NF 2 (u )

Unit Engineering Labor Hours

EIN..nit = (E"N ) - (ELH(Nl)_Cum)

44

GRAPHIC SERVICES

Log-Linear Unit Improvement Curve

Unit Graphic Services Laboi nours

G (0.0432N - " (FIJIN= (F-Unit_Unit)

Cumulative Graphic Services Labor HoursNGS IH _ u = ( .0432 i - 0 . 1 V I) (F

i==

Cumulative Average Graphi c Services Labor Hours

LHN-um Ave = (GSLHN-c~n) ,N

ng-Linear Cumulative Average ,mrovae ent Curve

Cumulative Average Graphic Services Labor flours

GSLN-cm Ave = (0.0824N- 0 "2 2 9 ) (FU'N-ICn Ave )

Cumulative (Graphj c Services Labor Hours

GSLHc.. = (0. 0824 - 0 2 2 9 8 )(F)

Unit Graphi c Services Labor Hours

GS-N-Unit = -(GSLH(N-1) -Cm )

45

4-

4.7 LABOR AND OVEAIEAD IW.P'

LAB3OR RATES

FACIORY LA13OR $10. 00/HCUR

(QIALITY COTRO L $10.O00A1V3R

TOOLING $10. 00/HcUR

MFG. ENG. $10. 00/HOJR,

MNINEEZING $10. OOA-iCER

GRAPHIC SER1VICES $10. 00/qCUR

0VERHED RATES

FAC'IRY LABOR 1.50QUALITY ONROiL 1.50

TCOLING1.50

rlFE-. ING. 1.50

1.70GRAPHIC SERVICES 1.70

MATMIAL0.20

.ALXINISTRATIVE 0.15

46

SUPPORT ?VAflIMAL

(Support Material $) =0.30 (Production Material $)

Manufacturing Allowance

(mfg. Allow. $) = f0.02 (Factory Labor $)+ (Scrap Material $

7 .1 47

~,ci 4

5.0 OUTPUTS

The computerized cost estimating system generates a printing of the input data

in coded form and of the calculated costs of advanced composite part fabrica-

tion. These outputs may be outlined as follows:

* GENERAL

- IDENTIFICATION OF ESTIMATOR AND PART THAT IS ESTIMATED

- OUANTITY OF EACH INPUT FORM.

• LAYUP

- CODED FORM OF INPUT DATA

- STANDARD SETUP AND RUNTIME HOURS FOR DETAIL LABOR ELENENTS

- KATERIAL USAGE AND SCRAP

- WEIGHT AND COST OF NET COMPOSITE MATERIAL

* HONEYCOMB CORE PREPARATION

- CODED FOlRM OF INPUT DATA

- STANDARD SETUP AND RUNTIME HOURS FOR DETAIL LABOR ELEMENTS

- WEIGHT AND COST OF CORE MATERIAL

* PART CONSOLIDATION


- STANDARD SETUP AND RUNTIME HOURS FOR DETAIL LABOR ELEENTS

* FINISHING


- STANDARD SETUP AND RUNTIME HOURS FOR DETAIL LABOR ELEMENTS

SUMUtARY OF TOTAL FACTORY LABOR STANDARD HOURS

48

.....!: -i '-,L." : , ; i.: .: : L A

* COST PROJECTIONS


- UNIT COST ESTIMATE AT SPECIFIED UNIT NUMBER

- CUMULATIVE COST ESTIMATE AT SPECIFIED UNIT NUMBER

-. CUMULATIVE AVERAGE COST ESTIMATE AT SPECIFIED UNIT NUEBER

- WEIGHT ESTIMATE OF COMPOSITE AND CORE MATERIAL

Outputs of sample estimates which illustrate the contents of the above cate-

gories are contained in the Appendix.

49

' U. S. OVERNWNT PRINTING OFFICE: 1971 - 757-001/257

f h

advanced composite cost estimating manual · /7 dcnald j. leblanc, t. /bettner /.'...

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