1. Statement of Work.pdf

16AUG21

STATEMENT OF WORK

FOR

Computer Numerical Controlled Vertical Turning Center

1.0 Scope: This purchase specification provides the minimum requirements for 1 each Computer Numerical Control (CNC) Vertical Turning Center (VTC).

2.0 Applicable Documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of request for proposal shall apply:

U.S. Department of Labor

CFR Title 29, Chapter XVII, Part 1910 – Occupational Safety and Health Regulations

(Applications for copies shall be made to the Superintendent of Documents, Government Printing Office, Washington, DC 20402)

Electronic Industries Alliance

J-STD-001C – Requirements for Soldered Electrical and Electronic Assemblies

(Application for copies shall be made to the Institute for Interconnecting and Packaging Electronic Circuits, 2215 Sanders Road, Northbrook, Illinois 60062-6135)

National Fire Protection Association (NFPA)

NFPA - 70 The National Electrical Code, 1996

NFPA - 79 Electrical Standards for Industrial Machinery, 1997

(Application for copies should be made to the National Fire Protection Association, One Batterymarch Park, P.O. Box 9101, Quincy, Massachusetts 02269- 9101) or the most current version of the International Electric Code IEC 60204-1

Underwriters Laboratories Inc.

UL 508 Standards for Safety for Industrial Control Equipment

(Application for copies should be made to Underwriters Laboratories, Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096 or the most current version of the International Electric Code IEC 60204-1.

2.1 Order of Precedence. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence.

3.0 Salient Characteristics:

3.1 General Requirements: The CNC VTC shall be new and one of the manufacturer’s current models capable of operation in accordance with the requirements herein. The machine will be a Heavy Duty cast or molded frame (not a welded steel frame). The CNC VTC shall be capable of operation in manual, semi-automatic, or fully automatic cycle. The turning center shall use standard ISO programming format for computer numerical controlled machine tools. It will include all required software and hardware necessary to program and operate the CNC VTC from the machine’s control panel. The CNC control will accept programs from an off-line programming system. The CNC VTC shall have box ways which are induction-hardened and Turcite coated on the linear axes. The machine shall have two precision spindle bearings – one thrust and one radial. Included should be a flood coolant system, coolant gun, through tool coolant system, work light, splash guard enclosure, spare parts list, maintenance and instruction manuals, standard set of wrenches and keys for the CNC VTC and its accessories. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Controlled Axes. The CNC VTC shall have a minimum of two (2) controlled axes that can be run in both simultaneous linear and simultaneous contouring modes (2-axes simultaneous contouring). Axes shall be defined as X and Z and shall be programmable in increments as small as 0.0001 inches. There must be an integral torque limiting system on the X and Z axes which electronically senses axis overload which will shut down the machine to an E-stop condition. The position of all axes is to be known by the controller at all times including times of power loss, crashes or E-stop.

3.1.2 Travel. The minimum requirements for axis travels are: X-axis travel minimum shall be a minimum of 22.8 inches. Z-axis minimum travel shall be a minimum of 39.4 inches.

3.1.3 Table. The table shall have a minimum diameter of 40 inches with a maximum load of at least 4,850 pounds (lbs.).

3.1.4 Capacities The VTC shall have a maximum turning diameter of at least 43.3 inches with a minimum of 50 inches swing over bed. The maximum turning height/length shall be a minimum of 39.4 inches.

3.1.5 Spindle Speed / Horsepower. Minimum horsepower (HP) shall be no less than 75 hp intermittent duty and be capable of 4710 ft.-lbs. of torque. The table should be capable of turning up to 850 revolutions per minute (RPM).

3.1.6 Frame Construction. The base and column shall be a of cast iron construction which fully follows the Meehanite process as to provide a machine casting with uniform soundness, consistent physical and mechanical properties and dependable performance in service around the table for maximum support, mass, rigidity and dampening. Welded/brazed or combination of any like processes shall not be used to construct the CNC VTC.

3.1.7 Turret Style Automatic Tool Changer. The Turret Style Automatic Tool Changer shall accommodate BMT-Key shank tools currently used on Anniston Army Depot (ANAD). Machine and turret shall be capable of utilizing up to a three inch diameter boring bar. Turret capacity shall be at least 12 tools.

3.1.8. Ways. The ways shall be integrated box style ways.

3.1.9 Axis Drives. The axis drive motors shall be coupled directly to ballscrews through a gear reduction unit for maximum torque. Feedrate for X-axis and Z-axis shall be a minimum range of 0.0001 inches per minute (ipm) to atleast 78 ipm. Rapid traverse rate for both axes shall be a minimum of 785 ipm.

3.1.10 Coolant System. Coolant through the tool should be a minimum of 85 psi and include the coolant tank with filtering. ChipBLASTER Modular* 1,000 PSI, 2-8 GPM variable coolant system with 100 gallon tank or equal to shall be utilized. A cyclonic filter that filters to at least 2 microns shall be utilized to maximize longevity of coolant life.

3.1.11 Lubrication. There shall be an Auto Lube system for the ways. There should also be an oil chiller for the gearboxes and spindle.

3.1.12 Chuck. The machine shall be equipped 40" HC 3-jaw CLOSED CENTER power chuck. The contractor shall provide one set of both hard jaws and soft jaws for use in the chuck.

3.1.13 CNC Control System. The CNC shall be a FANUC 32i-B Control. Safety interlocks should be included on all doors.

3.1.14 Chip Conveyor. The CNC VTC shall have a conveyor to remove chips from the machine enclosure with a discharge height of at least 42”.

3.1.15 Work Light. The CNC VTC shall be equipped with a work light inside the enclosure of the work area.

3.1.16 Voltage. The CNC VTC shall be supplied configured to operate on 480 Volts, 3 phase, 60-hertz electrical power. The use of an external transformer to match the machine’s power requirements is acceptable and shall be furnished and installed by the contractor at no additional cost to the government.

3.2 System of Units. The equipment shall display all units of measure in the U.S.

Customary System of Units (first) and be capable of displaying both U.S. Customary System of Units and Scientific Units (second) where applicable.

3.3 Equipment Location. The CNC VTC will be located in a typical machine shop environment. When machine is placed it must be kept a minimum of 3 feet from walls.

Aisle ways are 6’ wide minimum. (See dimensions in 5.2.1)

3.4 Electrical Power Requirements. The CNC VTC shall be designed to operate on 480 VAC, 3 phase, 60-hertz electrical power. The electrical system shall conform to National Fire Protection Association (NFPA) 79 or to International Electrical Standard IEC 60204-1. All electrical wiring and components shall be sized for 480 VAC operations. Use of a multi-tap transformer is acceptable.

3.4.1 Electrical Noise. The electrical power at Anniston Army Depot (ANAD) is subject to noise. If the CNC VTC requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the CNC VTC. If the CNC VTC is subject to interference from adjacent machinery, the CNC VTC shall include the proper shielding to prevent malfunctions.

3.5 Safety and Health Requirements. The CNC VTC shall be designed and manufactured in accordance with American National Standards Institute (ANSI) B11.6 or International Machine Tool Standards ISO 230-2. The manufacturer shall ensure that the CNC VTC and all equipment and accessories used on the machine shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910.

If a conflict arises between the ANSI B11.6 and the OSHA standards, the more stringent standard shall apply.

3.5.1 Noise Level. Noise emitted by the CNC VTC shall be no greater than 80 decibels as measured per ANSI S12.23-1989. The 80-decibel limit is absolute.

Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the equipment into conformance with this requirement shall not interfere with visibility needed for safe operation of the CNC VTC. Operators shall be able to use this equipment without the need for hearing protection.

3.5.2 Ergonomics. The equipment shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

3.6 Reliability. Evidence of the reliability of the proposed CNC VTC shall be included with the contractor's proposal. The contractor shall cite at least five similar

CNC Mills sold over the last ten years and include the following information for each CNC mill: customer, contract or purchase order number, and customer point of contact information (phone number, e-mail, etc.). The reliability of the CNC VTC cited will be a factor in the past performance evaluation of the contractor's proposal.

3.7 Maintainability. The CNC VTC shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. The contractor shall provide evidence that repair parts and service for the CNC VTC are readily available. The contractor shall also provide information on the normal maintenance actions required for the CNC VTC including type of maintenance, required interval, mean time to perform maintenance and number and skill of people required to perform the maintenance actions. The CNC VTC maintainability will be a factor in the past performance evaluation of the contractor's proposal.

3.7.1 Construction. The CNC VTC, equipment and accessories shall be constructed of new material (i.e. not remanufactured or used parts).

3.7.2 Components. The components used to manufacture this CNC VTC shall be the manufacturer’s latest make and model. The contractor shall only use components that will be readily available for a minimum of 10 years after installation or can be easily replaced with newer components of the same type. This includes not only contractor-manufactured items but also those supplied by sub-contractors.

3.7.3 Warranty. The CNC VTC shall be covered by the manufacturer’s standard commercial warranty for a period of two years – parts and labor. The warranty shall be written in the name of the Anniston Army Depot. During the warranty period, the contractor shall be responsible for the repair of any defects in equipment parts or workmanship. The contractor shall respond to requests for service within 48-hours after the request.

3.8 Nameplate. A nameplate shall be attached to the CNC VTC and shall contain, as a minimum, the following information:

a. Nomenclature.

b. Manufacturer’s name.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Short-circuit/over current rating.

g. Contract number or purchase order number.

h. National stock number (if applicable).

i. Date of manufacture.

3.9 Lubrication Plate or Chart. A lubrication plate or chart shall be attached to the CNC VTC. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of (s) with SAE number or lubricant identifier.

3.10 Environmental Compliance. The CNC VTC provided under this contract shall meet all applicable Environmental Protection Agency (EPA) restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user’s health and shall be adhered to during the manufacture, service, transportation, storage and operation of the CNC Vertical Turning Centers.

3.10.1 Recovered Materials. The offeror / contractor is encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR). In this case raw materials shall be recycled to produce new castings, forgings etc. (Refer 3.7.1)

4.0 Acceptance Testing & Verification

4.1 Conformance. The CNC VTL shall meet the requirements of this specification and conform to the manufacturer’s own drawings, specifications, standards, and quality assurance practices. The Government reserves the right to, at any time during the contract period; require proof of such conformance or to inspect the CNC mill to determine compliance with the requirements of this specification.

4.1.1 Test Setup and Conditions. Unless otherwise specified, ANAD shall supply all tooling and material(s) as outlined in 4.2 and 4.3. The contractor shall conduct all tests required by the Government. The government will provide test instruments and equipment with calibration traceable to the National Institute of Standards and Technology (NIST) and will provide certification of calibration as specified.

4.2 Operational Test. Upon completion of the CNC VTC installation, the CNC VTC shall be operated in accordance with the Manufacturer’s standard operating procedure for a period of one (1) hour. During these tests, the contractor shall demonstrate proper operation of all CNC VTC’s controls, functions and features. The government will provide the materials necessary to perform the tests. All tests must be witnessed by the ANAD Contracting Officer or Contracting Officer's Representative. The proper operation of all controls and features shall be verified during this test period. Should a malfunction occur during any test, the contractor shall correct the problem and repeat the test(s).

4.3 Performance Test. Unless otherwise specified, the performance test shall consist of the tests listed in ASME B5.57. The Government reserves the right to specify any of or the entire test listed in these standards.

4.4 Acceptance. The Government will accept the CNC VTC only after the contractor successfully completes the requirements of paragraphs 4.1, 4.1.1, 4.2 and 4.3 herein.

Final acceptance will be at Anniston Army Depot. Failure of the CNC VTC to meet the performance requirements specified shall be cause for rejection.

5.0 Installation and Delivery

5.1 Delivery. The contractor shall complete the installation of all equipment and acceptance made within 120 calendar days after award of the contract.

5.1.1 Shipping, Handling, and Storage. The contractor shall be responsible for all shipping, storage, and handling of the CNC VTC and all materials. The Government shall not be responsible for furnishing any labor, equipment or warehouse space, for the loading, unloading, and storing of any materials. The Government will make available, if possible, space for a contractor furnished trailer or van for the storage of the materials.

Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area. Should the contractor not wish to furnish a trailer for equipment storage, then the contractor shall coordinate with the Contracting Officer, a date at which time the contractor may deliver his equipment to the building.

5.2 Installation. The contractor shall be responsible for installing the CNC VTC to include all labor and materials required. The contractor shall be responsible for insuring that the installation is compatible with existing facilities. The contractor will provide along with the bid, all of the installation requirements for the proposed offering, in this case, a (CNC mill). This documentation is to include as a minimum, the following:

a. Floor plan drawing of the CNC VTC showing the floor space requirements.

b. Space required around the machine after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate weight of the machine with accessories and attachments.

f. All utility requirements, including capacities of required utilities and approximate locations of utility connections to the machine.

g. Industrial waste disposal requirements, if any.

h. Ventilation requirements, if any.

A site layout for the equipment is included with this specification for reference. Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours. The area near where the equipment is to be installed is an active working area. The contractor shall not interfere with on-going Government operations and production unless authorized by the Contracting Officer or the Contracting Officer’s Representative.

5.2.1 Layout. Ceiling Height of 13’ 6”

Width of 13’ 2” Length of 10’ Concrete beneath location of install is minimum of 9 inches thick

5.2.2 Electrical. All electrical work shall comply with American National Standards Institute (ANSI) Publication C2 – National Electric Safety Code and with National Fire Prevention Association (NFPA) Publication No. 70 – National Electric Code or the International Electric Code. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings or equivalent International Electrical Code Standards for Machine Tools. Workmanship shall be in accordance with standard commercial practices. Runs shall be installed perpendicular and parallel to existing facilities and the equipment to be installed. When equipment is installed near existing power lines, equipment shall be located for proper clearances in accordance with ANSI C2. New equipment shall not be connected to Government power without prior approval of the Contracting Officer or the Contracting Officer’s Representative [COR] assigned to the project. No high voltage work will be accomplished without prior approval of the Contracting Officer or the assigned COR. All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

5.2.3 Trades. Coordination of trades installing the equipment shall be the responsibility of the contractor.

5.2.4 Foundation / Hardware. All foundation hardware and foundation requirements as determined by the machine builder shall be furnished by the contractor and included in the bid price.

5.2.5 Utilities. The Government will provide utilities within 20 feet of the equipment installation site. The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor in the installation manual noted above.

5.2.6 Electrical. The Government will connect power to all contractor furnished fused disconnect device. The contractor shall furnish and install a main fused disconnect device separate from the equipment. The fused disconnect device shall be the correct size and type required the equipment voltage and comply with the requirements of paragraph 5.2.2. The Government will furnish only one voltage to the site.

5.2.7 Equipment Protection. The contractor shall protect surrounding equipment and shop area from damage due to dust, debris etc., during the installation.

5.2.8 Site Cleanup. The contractor shall remove all debris, scrap material, trash, etc.

from the job site daily. The depot will furnish a dumpster for all trash and all construction materials at the job site, and will be responsible for emptying said dumpster. ANAD will provide an outdoor location for the cleanup of contaminated material if requested by the contractor. No equipment will be provided by the Government to perform any of the work performed by the contractor.

6.0 Documentation. The contractor shall provide documentation to the government as listed below. Three copies each of the following technical data shall be provided as specified on the attached DD Form 1423 with the CNC VTC. The contractor shall also provide three compact discs (CDs) that each contains copies of the delivered documentation.

6.1 Content. The manuals shall include electrical, hydraulic, and pneumatic schematics, as applicable; parts list, troubleshooting procedures, preventive maintenance requirements, lubrication schedules, calibration procedures, etc. Catalogs shall fully describe optional tooling, fixtures, and attachments available for the equipment furnished. In addition, any other technical data normally furnished with the equipment shall be provided. All technical data shall be furnished in the English language and be IAW with the following data item descriptors (DIDs):

Operator' Manual CDRL A01 DI-TMSS-80527A Engineering Support Manuals CDRL A02 DI-TMSS-80527A Engineering Drawings CDRL A04 DI-SESS-81003B Equipment Manuals CDRL A05 DI-TMSS-80527A

7.0 Training – On-Site. The contractor shall provide as a minimum training to the following type of personnel on-site at ANAD:

Operator and Programming – 5 days

Maintenance Personnel – 1 Day

Training shall be provided for the operation, programming and maintenance of the equipment. Training shall be conducted at Anniston Army Depot during normal Depot working hours. All training costs shall be included in the total bid price.

8.0 Scope Changes. The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.