10_Equipment Specification - CR Onsrud X Series.pdf

EQUIPMENT SPECIFICATION

C. R. ONSRUD X-SERIES

5-AXIS CNC GANTRY MILL

DATE: 23 APRIL 2025

PREPARED BY

David McDonell

PROJECT ENGINEER

AFLCMC/EZPAA

FA860425RB027

Attachment 1

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page ii

TABLE OF CONTENTS

1 SCOPE

2 BASE MACHINE

3 MACHINE FEATURES

3.1 CONDTION

3.2 WORK ENVELOPE

3.3 CONTROLLER

3.4 SPINDLE AND HEAD OPTIONS

3.5 LUBRICATION

3.6 LUBRICATION REMOVAL

3.7 MATERIAL HANDLING

3.8 ISOLATION TRANSFORMER

3.9 MACHINE LUBRICATION SYSTEMS

3.10 TOOL CHANGER

3.11 SINGLE POSITION AGGREGATE STATION

3.12 ELECTRICAL CABINET COOLING

3.13 CHIP REMOVAL

3.14 MACHINE STATUS DISPLAY

3.15 COMMISSIONING

3.16 AIR KNIVES

3.17 TOUCH PROBE

3.18 ALLIGNMENT EQUIPMENT

3.19 SPINDLE ENCODER

3.20 PNEUMATIC MATERIAL STOP

3.21 TOOLING MAINTENANCE PACKAGE

3.22 TOOLING STARTUP PACKAGE

3.23 TOOL SETTER

3.24 TOOL LENGTH TOUCHPAD

3.25 SOFTWARE

3.25.1 GENERAL

3.25.2 LICENSING

3.25.3 DATA IMPORT

3.26 MODELING

3.26.1 MACHINE CODE AUTOMATION

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page iii

3.26.2 MULTI-PART MACHINING

3.26.3 MULTI-STEP MACHINING

3.27 WARRANTY AND SUPPORT

3.27.1 SOFTWARE SUPPORT

3.27.2 MACHINE WARRANTY

3.28 TRAINING

3.28.1 MACHINE TRAINING

3.28.2 SOFTWARE TRAINING

3.28.3 TRAINER

3.29 ACCEPTANCE

3.30 SHIPPING

3.31 INSTALLATION

3.32 DOCUMENTATION

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page 1

1 SCOPE

This purchase description (PD) describes the specific features and capabilities to be supplied to the government as part of a gantry mill purchase.

2 BASE MACHINE

Manufacturer: C. R. Onsrud Model Name: 5-Axis X Series CNC Router Model Number: F401X24

3 MACHINE FEATURES

3.1 CONDTION

All components of the machine shall be fully functional and new, not used, refurbished, or salvaged.

3.2 WORK ENVELOPE

The work envelope shall be 401” x 21” x 28” and be configured for use with mechanical clamping (not a flat table system).

3.3 CONTROLLER

The controller shall be a FANUC 30i machine controller system with an integrated PC interface.

3.4 SPINDLE AND HEAD OPTIONS

• Power shall be rated for 18 kW (24 hp) in S1 (Continuous duty rating) per IEC 60034-1.

• Maximum speed of 24,000 RPM or greater

• Rotation (5-axis milling) o Spindle and head assembly shall be capable of rotation in two axes.

o At least 360° of total rotation about the C-Axis (vertical axis rotation of the head) o At least 220° of total rotation about the A or B-Axis (vertical-horizontal rotation of the head)

• Be fully programable, reversible, variable speed and capable of synchronous feed tapping

(rigid tapping).

• Capable of milling, routing, drilling, and reaming with programable feed rates with override capability.

• Liquid cooled

3.5 LUBRICATION

The machine shall use automatic oil mist lubricant from a pressurized tank that provides continuous metered lubricant.

3.6 LUBRICATION REMOVAL

The machine shall include a mist extraction system to remove oil mist form the enclosure environment.

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page 2

3.7 MATERIAL HANDLING

The machine shall have ten (10) servo adjustable pneumatic clamps. Each clamp shall have a quick pin system for making large adjustments to clamping depth and pneumatic actuation for part holding.

3.8 ISOLATION TRANSFORMER

The machine shall be equipped with a 34kVA isolation transformer. The transformer shall be a 6-tap, 60 hz, non-compensating transformer that is selected specifically to interface with the power at the installation facility to be compatible with the machine.

3.9 MACHINE LUBRICATION SYSTEMS

The machine shall have an automatic grease lubrication system.

3.10 TOOL CHANGER

The machine shall have a fully servo controlled, twelve (12) tool, dynamic, automatic, rotary tool changer.

3.11 SINGLE POSITION AGGREGATE STATION

The machine shall have a separate, large saw blade tool changer to hold a blade up to 400 mm in diameter.

3.12 ELECTRICAL CABINET COOLING

The electrical cabinet shall be cooled via air conditioning.

3.13 CHIP REMOVAL

The machine shall be equipped with a chip conveyor to remove debris to one side of the machine.

3.14 MACHINE STATUS DISPLAY

The machine shall be equipped with a stack light for machine status.

3.15 COMMISSIONING

One or more authorized C. R. Onsrud representative(s) shall perform machine setup and integration at the installation facility. Prior to commissioning, the machine will be permanently placed with all necessary utilities accessible by the government.

3.16 AIR KNIVES

The machine shall have one set of air knives on each of 2 linear guides (front and back of motion).

3.17 TOUCH PROBE

An RF touch probe system (Renishaw RMP60 or equivalent) and an RMI-Q RF Receiver shall be included with the machine. It shall be capable of wirelessly measuring holes, planar surfaces, centers between holes, and outputs points & coordinates.

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page 3

3.18 ALLIGNMENT EQUIPMENT

The contractor shall provide any specialized alignment equipment required for final machine calibration. The contractor shall be responsible for shipping charges associated with such equipment.

3.19 SPINDLE ENCODER

The spindle shall be equipped with an encoder to allow rigid tapping and orientation commands.

3.20 PNEUMATIC MATERIAL STOP

The material stop shall be pneumatically actuated and retracted via M-Code.

3.21 TOOLING MAINTENANCE PACKAGE

The contractor shall provide a tooling maintenance package which shall include the parts below.

All parts shall be compatible with the machine and HSK63F tool holders to the fullest extent possible, as applicable.

• 5-axis calibration bar

• Collet torque wrench

• Tool holder clamp stand compatible with all tools in the rotary tool changer

• Spindle wiper

• Two tool clips

• Collet and tool holder cleaning kit containing Rust Free, T-9, (or equivalents) and a collet brush.

• Spanner collet wrench

• Open end collet wrench

3.22 TOOLING STARTUP PACKAGE

The contractor shall provide a startup tooling package which shall include:

• (2) HSK63F high speed balanced standard tool holders, ER25

• (2) Thrust bearing chuck nuts

• (2) Standard ER25 ½ inch collets

3.23 TOOL SETTER

The machine shall include a digital bench-top tool setter.

3.24 TOOL LENGTH TOUCHPAD

The machine shall include an automatic tool length touchpad digitizer.

3.25 SOFTWARE

3.25.1 GENERAL

The contractor shall provide a 5-axis CAM software designed for the machining of extrusion type products and parametric programing of features.

3.25.2 LICENSING

In addition to any software on the controller, the contractor shall provide the 5-axis CAM software to be installed on multiple, separate Windows 11 PCs. A single, perpetual, floating

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page 4 license housed on a removable media stick will hold all license access to the CAM software. Any software provided shall not require recurring costs including but not limited to software license renewals and maintenance fees.

3.25.3 DATA IMPORT

The software shall be capable of receiving imported STEP files and DXF files to be used as models for part and stock extrusion geometries, respectively.

3.26 MODELING

The software shall be capable of hosting dimensionally accurate renderings of key machine work area components including but not limited to clamps, tools, tool holders, and the spindle assembly.

3.26.1 MACHINE CODE AUTOMATION

The software shall be capable of automatic recognition of machined features and generate toolpaths for those features.

3.26.2 MULTI-PART MACHINING

The software shall be capable of programing the machine to cut and machine multiple unique components on five (5) sides from the same extruded stock length in a single operation.

3.26.3 MULTI-STEP MACHINING

The software shall include automatic positioning and optimization features for the pneumatic clamps (multi-step machining).

3.27 WARRANTY AND SUPPORT

3.27.1 SOFTWARE SUPPORT

The contractor shall provide 5 years of technical support for the 5-axis CAM software by phone during regular business hours.

3.27.2 MACHINE WARRANTY

The contractor shall provide a minimum 24-month warranty from the date of commissioning at the customer facility.

3.28 TRAINING

3.28.1 MACHINE TRAINING

The contractor shall provide in-person training at the manufacturing facility and the installation facility. The training shall cover the necessary skills and knowledge to operate the machine safely to its fullest capacity and to maintain the machine via cleaning, basic maintenance, daily inspections. The training shall be available to a class size of at least 7.

For the training, the manufacturing facility must be within 500 miles of WPAFB.

3.28.2 SOFTWARE TRAINING

The contractor shall provide in-person training for machine software at the manufacturing facility and the installation facility. The training shall cover the necessary skills and knowledge to use all components of the CAM software package to its fullest capability including but not

Wright Patterson AFB, C. R. Onsrud X Series Equipment Specification – Page 5 limited to how to import & export part files, create the tool paths to machine parts, simulate those tool paths for accuracy and anti-collision, and prepare to send the completed program to the machine. The training shall be client-specific and able to be tailored to the specific needs of the trainees. The training shall be available to a class size of at least 7.

For this training, the manufacturing facility must be within 500 miles of WPAFB.

3.28.3 TRAINER

• The trainer shall be an expert in the operation of the software, the machine, and all associated peripherals for the machine required in this specification. Multiple trainers may be present to satisfy this breadth of technical expertise.

• The trainer shall be a native English speaker or shall be certified by the ACTFL (American Council on the Teaching of Foreign Languages) at the “Superior” or “Distinguished” level for speaking and listening or by CEFL (Common European Framework of Reference for Languages) with a C2 rating.

3.29 ACCEPTANCE

The contractor shall assemble the machine in a fully operational configuration at the manufacturing facility for inspection by the Government per the requirements in this PD.

For this inspection, the manufacturing facility must be within 500 miles of WPAFB. The inspection may be concurrent with the on-site training.

3.30 SHIPPING

The contractor is responsible for all shipping costs.

3.31 INSTALLATION

The contractor shall provide all equipment and technicians required to align the machine and all accessories after it has been placed in the approximate installation location. The contractor shall set up, align, and commission the machine at the installation facility. The contractor is not responsible for unloading goods from the truck(s).

3.32 DOCUMENTATION

The contractor shall provide a comprehensive owner’s manual, maintenance manual, and software manual for the machine and software.