1. STATEMENT OF WORK for Milling Machines (Conventional)- March 24, 2020 (1).pdf

DESCRIPTION/WORK STATEMENT/SPECIFICATION

1.0 Scope: This purchase specification provides the minimum requirements for 1 or more vertical knee type milling machine. (10 each requested)

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)

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

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 milling machine shall be conventional and motorized with manual controls no (CNC). The milling machine shall be one of the manufacturer’s current models. The milling machine shall be a vertical knee type, milling machine. The milling machine shall have an R8 spindle taper with power draw bar, variable speed head with power quill feed, variable power feed on the X, Y axis, antifriction bearings, and 50 degree angular chrome plated ways with adjustable gibs, chrome plating shall meet MIL Spec QQ-C320 Class 2-A, metered lubrication system. The Milling machine shall include a digital readout (DRO) system. The DRO shall be capable of displaying positional units in English and Metric units for 3 axis of travel. The milling machine shall include one set of R8 collets 1/16” to ¾” in 1/16” increments, a Collet tray (installed) Vise 6” with Swivel base and step key set and all tools wrenches typically supplied by the manufacturer for this type equipment and its accessories as required.

3.1.1. Style. The milling machine shall be a floor model knee type vertical.

3.1.2. Major Components. The milling machine shall as a minimum be comprised of the major components as follows: Column Base, Knee, Saddle, Table, Turret, Ram and Machining Head.

3.1.3. Load Size. The milling machine shall have a work piece capacity of 750 lb.

3.1.4. Table. The Table shall be casted ribbed construction precision ground and have precision ground angular ways. The table size shall be a minimum of 48” inches by 9” inches. The Table shall have as a minimum three (3) T-slots on 2.5 inch centers. The size of the T-slots shall be .625 inch. The Table shall be capable being moved manually using feed handles attached to both ends of the Tables lead screw with inch dials graduated for .200 inches per revolution. The milling machine shall have as a minimum controlled variable speed servo motorized drive (Power Feed) on the table defined as longitudinal travel X–axis. The table shall be equipped with as a minimum a graduated scale with reader head to provide positional feedback along the travel distance of the X-axis to a digital readout device. The table shall have as a minimum two (2) manual locking mechanisms to secure the X-axis movement.

3.1.5. Saddle. The Saddle shall be casted construction with precision ground chrome angular ways. The Saddle shall be capable being moved manually using a feed handle attached to the Saddle lead screw with inch dials graduated for .200 inches per revolution. The milling machine shall have as a minimum controlled variable speed servo motorized drive (Power Feed) on the saddle defined as Saddle travel Y-axis. The Saddle shall be equipped with as a minimum a graduated scale with reader head to provide positional feedback along the travel distance of the Y-axis to a digital readout device. The saddle shall have as a minimum one (1) manual locking mechanism to secure the Y-axis movement.

3.1.6. Knee. The Knee shall be casted construction with precision ground chrome angular ways. The Knee shall be capable being moved manually using a removable feed handle semi attached to the Knee lead screw mechanism with inch dials graduated for .100 inches per revolution. The Knee shall be equipped with as a minimum a graduated scale with reader head to provide positional feedback along the travel distance of the Z-axis to a digital readout device. The knee shall have as a minimum one (1) manual locking mechanism to secure the Z-axis movement.

3.1.7. Turret. The Turret shall have the ability to rotate 360 degrees. The Turret shall have as a minimum a scale indicating 180 degrees along the turret’s circumference.

The zero point of alignment shall be the center of the column ways.

3.1.8. Ram. The Ram shall as a minimum have the ability to extend out to achieve the maximum throat distance defined in the Range paragraph below. The Ram shall have a lever operated rack and pinion gear to move the Ram into position along precision machined dovetail ways of the RAM and Turret. The Ram shall be manually secured by a minimum of two (2) clamping bolts. The Ram shall support the machining head.

3.1.9. Range. The Milling machine shall have as a minimum the following: table travel X-Axis 33.5” inches, saddle travel Y-Axis 12 inches, quill travel 5 inches, knee travel Z- Axis 16 inches, Ram travel 12 inches, Throat Distance (Min.) 6.75 inches, Throat Distance (Max.) 18.75 inches, Table to Spindle Nose Gage Line (min.) 2.5 inches, Table to Spindle Nose Gage Line (max.) 18.25 inches.

3.1.10. Machining Head. The Machining Head shall as a minimum be of a type that is motor driven with a belt and geared infinitely variable speed control the machining head shall have two (2) speed ranges defined as low gear and high gear. The low gear range shall as a minimum permit 60 to 500 revolutions per minute (RPM) and the high gear range shall as a minimum permit 500 to 4,200 (RPM). The machining head shall have as a minimum a hand lever for shifting between the high and low ranges. The machining head shall be designed to allow it to be tilted in two (2) directions. The machining head shall be positioned using worm and gear controls. The head shall have the ability to be set for angular positions 90 degrees left and 90 degrees right of vertical and 45 degrees front and 45 degrees back of the vertical position. The machining head shall as a minimum be secured using four (4) clamping bolts for angular movement right to left.

The machining head shall as a minimum be secured using three (3) clamping bolts for angular movement front to back. The machining head shall contain feed and control mechanism for the power quill. The machining head shall be equipped with an adjustable depth micrometer to control the range of quill travel. The machining head shall have a cooling system that maintains the operating temperature of the machining head within twenty (20) degrees Fahrenheit of the ambient temperature. The machining head shall have external lubrication ports for access by the operator.

3.1.11. Quill. The Milling machine shall be hard chrome plated and hand lapped have as a minimum a quill diameter of 3.375 inches. The quill shall as a minimum have both manual and built-in power quill feed with minimum of three designated feed ranges the lowest being .0015 inches per minute (IPR) and the highest .006 IPR. The power quill feed shall be engaged or disengaged by a hand lever. The quill will have a removable hand wheel for fine manual hand adjustment of quill position. The quill feed will be controlled by pressure release using a micrometer depth adjustment. The quill shall have as a minimum one (1) manual locking mechanism to secure the quill movement.

3.1.12. Spindle. The milling machine shall as a minimum have a chrome-nickel alloy spindle that is heat treated and ground with precision bearings that are preloaded and spaced for maximum radial and thrust capability. The bearings as a minimum shall be ABC Class 7 bearings. The Milling machine shall have as a minimum a spindle diameter of 1.875 inches.

3.1.12.1. Spindle Taper. The Milling machine shall have an R8 spindle taper. The spindle taper shall be precision ground true with the spindle bearings.

3.1.12.2. Spindle Speed. The Milling machine shall have as a minimum a duel range infinitely variable spindle capable of 500 – 4200 RPM in high range and 60 – 500 in low range.

3.1.12.3. Spindle Motor: The Milling machine shall have as a minimum an AC spindle motor power rating of 3 HP for a 30 minutes duty cycle and 2 HP rating (continuous).

3.1.13. Digital Readout: The Milling machine shall include as a minimum a digital readout (DRO) system. The DRO shall be capable of displaying positional units in English and Metric units for three (3) axes of travel, the table, cross feed and knee.

3.1.14. Lubrication: The Milling machine shall include as a minimum a manual system for lubrication. The machine shall have a centralized lubrication system to provide metered lubrication to the machine ways and lead screws assemblies of the Table, Saddle and Knee.

3.1.15. Work light: The Milling machine shall include as a minimum a work light that is adjustable with a flexible mount that allows the operator to position the light as needed.

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 Milling machine will be located in a machine shop area.

3.4 Electrical Power Requirements. The Milling Machine shall be designed to operate on 208/230/460 VAC, three phase, 60-hertz electrical power. The Milling Machine shall be shipped configured for 460 Volts 60Hz 3 phase electrical power. The electrical system shall conform to National Fire Protection Association (NFPA) 79.

3.4.1 Electrical Noise. The electrical power is subject to noise. If the Milling machine requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the Milling machine. If the Milling machine is subject to interference from adjacent machinery, the Milling machine shall include the proper shielding to prevent malfunctions.

3.5 Safety and Health Requirements. The manufacturer shall ensure that the milling machine and all equipment and accessories used on the machine shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910.

3.5.1 Noise Level. Noise emitted by the Milling machine 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 Milling machine. 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 Safety Guards: The Milling machine shall be designed to allow the use of guarding that protects the user from rotating tooling.

3.7 Warranty: The Milling machine shall be covered by the manufacturer’s standard commercial warranty for this type of equipment and shall be for a period of not less than one year. The warranty shall be written in the Anniston Army Depot’s name. 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 request within 48 hours after the request.

3.8 Nameplate. A nameplate shall be attached to the Milling machine 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 Milling machine. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

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

3.10 Environmental Compliance The Milling machine 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 Milling machine.

3.10.1 Recovered Materials The offerer/contractor is encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

4.0 Acceptance & Verification

4.1 Conformance. The Milling machine 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 Milling machine to determine compliance with the requirements of this specification.

5.0 Delivery

5.1 Delivery The contractor shall complete the delivery of all equipment within 120 calendar days after award of contract.

5.1.1 Shipping: The contractor shall be responsible for all shipping of the Engine Lathes and all materials to Anniston Army Depot, Anniston Alabama.

5.1.2 Equipment Decommissioning and Removal: The contractor shall be responsible for the decommissioning and removal of the old equipment.

5.1.3 Installation: The contractor shall be responsible for installing the new equipment.

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 Milling machine.

6.1 Content The manuals shall include electrical, hydraulic, and pneumatic schematics, as applicable; parts lists, trouble shooting 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)

Equipment Manuals CDRL A01 DI-TMSS-80527A Electrical Drawings CDRL A02 DI-TMSS-80527A