Statement_of_Work_-_OMAX_Waterjet_Upgrade.pdf

OMAX Maxiem 1515 Waterjet Upgrade

1.0 Background:

The NIST Center for Automotive Lightweighting (NCAL) conducts mechanical testing of polymers, composites, and metals including advanced high strength steels though use of various testing instruments. Test specimens and fixturing are manufactured through use of an OMAX CNC Waterjet. NCAL has a need to expand the capabilities of its waterjet manufacturing. These expanded capabilities will allow for new and complex specimen and fixture geometries, tapper compensation, manufacture of composite specimens without delamination, and conservation of materials. These additional capabilities shall be achieved through the purchase of new waterjet accessories, equipment, and training.

2.0 Instrument Specifications:

Table Model Number: OMAX Maxiem 1515 Serial Number: M15155141

Pump Model Number: OMAX Maxiem M20 Serial Number: P122188

Software: Maxiem Intelli-MAX Standard Version: 21.0 (Patch: 4)

3.0 Scope of Work:

The Contractor shall perform the following tasks:

1. Remove existing cutting head and associated components. Install 5 axis cutting head to existing z-axis assembly, including required hardware/software to operate new cutting head.

2. Remove existing whip line plumbing and install Scissor High Pressure Tubing to supply pressurized water to the new cutting head.

3. Remove existing Terrain Follower accessory and install new Terrain Follower accessory compatible with new cutting head.

4. Install pneumatic drill accessory compatible with new cutting head.

5. Install protective splash guards.

6. Install MiniJet accessory compatible with new cutting head.

7. Provide all required parts and components from the original equipment manufacturer (OEM).

8. Provide On-site Training

4.0 Conditions of Work:

• Work performed on the OMAX waterjet instrument shall be performed in accordance with the manufacturer’s technical service, installation, and repair instructions. Work must be performed in accordance with the following industry standard practices: U. S. DEPARTMENT OF LABOR 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 1998 or most recent edition;

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA-79 – Electrical Standards for Industrial Machinery, 2014; ELECTRONIC INDUSTRIES ALLIANCE (EIA) STANDARD EIA TIA/EIA-232-F – Interface between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange, 1997 or most recent edition; AMERICAN NATIONAL STANDARD INSTITUTE

ANSI/NEMA MG-1 - National Standards for Motors and Generators, 1998 or most recent edition;

ANSI/NFPA/JIC T2.24.1 - Hydraulic Fluid Power-Systems Standard for Stationary Industrial Machinery, 1991 or most recent edition.

• Any component of the instrument assembly that is disassembled to install accessories shall be reassembled after the installs are completed, unless the disassembled components are no longer required due to the new accessories. All O-rings, gaskets and seals that are disassembled during the install must be discarded and replaced. All O-rings, gaskets, filters and seals used must be ordered from the original equipment manufacturer (OEM) or meet all technical specifications set forth by the OEM.

Any hardware that is specified as torque to yield or one time use by the OEM will be replaced with new hardware that is of the same class and meets or exceeds the technical specifications set by the OEM.

• After the instrument accessories are installed and the instrument is reassembled the instrument and accessories shall be recalibrated in accordance with OEM published specifications. All equipment required to perform work outlined for this installation shall be furnished by the contractor. All work shall be performed on site at NST in building 231/B133 at 100 Bureau drive Gaithersburg MD 21740.

• The instrument accessories shall be constructed of parts which are new, without defects, and free of repairs. Processes such as welding, plugging, or filling with solder or paste shall not be used for reclaiming any defective part(s). All screws, pins, bolts, and other fasteners shall be installed in a manner as to prevent change of tightness. The accessories shall all be designed and built in the USA.

• All replaceable parts shall be manufactured to definite standards, tolerances and clearances in order that any such parts of a particular type or model can be replaced or adjusted without modification of the equipment.

• The accessories shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, and repair of parts.

• The 5 axis cutting head shall be a complete software-controlled, multi-axis accessory that features the flexibility to automatically compensate for taper, as well as cut severe angles up to 60° off vertical. The 5-axis head shall cut countersunk holes and precision shapes with beveled edges at angles specified by the user. The accessory shall supply additional axes of motion, allowing the operator to fabricate and shape metal edges for weld preparation. This head shall match to the existing z- axis assembly and work with the existing installed software.

• The Terrain Follower shall allow the waterjet to automatically and accurately cut parts from materials with irregular or warped surfaces without the need for special programming. The device shall be a ring that fits around the nozzle body and shall automatically set the appropriate stand-off height to achieve accurate cutting. It must be compatible with the 5-axis head and work with the existing software.

• The pneumatic drill shall be designed with enclosed inside water-resistant cases and bellows to protect from a waterjet environment. The Drill shall operate up to 5,000 RPM with air motor designed to promote longer drill bit life and quality holes. Drill shall be equipped with a collet holder and collet to hold 1/16” drill bit. The drill shall have a fully adjustable pneumatic feed rate and depth of feed up to 3” of travel and 110 pounds of thrust with 85 psi air. The Drill shall be controlled automatically from waterjet software.

• Protective splash guards on the sides of the work tank shall be installed. Sections of the shield assembly shall not weigh more than 45 pounds each and shall be easily installed and removed to permit loading and unloading of material. The shields must prevent overspray and shall be made from transparent material.

• The MiniJet small nozzle assembly shall have a mixing tube diameter of no larger than 0.015 inches. The MiniJet small nozzle shall be compatible with the existing bypass valve to allow operation with existing pump and software. This must be a seamless operation with changes to software. If the existing bypass valve and hardware is non-compatible with the new accessory a new bypass valve and new hardware must be provided and installed. Minijet nozzle shall be for use to cut small features in parts.

• The contractor shall provide a comprehensive list of software hot-keys.

• On-site training must be provided during accessory installation. On-site training must consist of one (1) day and include operation, programming and routine maintenance of the accessories for up to three (3) NIST employees. Additional training at factory location must be offered to individuals for the first year of the machine at no additional cost other than all travel expenses.

5.0 Acceptance Criteria:

(1) Upon completion of the accessory installation the instrument and accessories will meet the minimum performance standards as determined by the OEM manufacturer.

(2) The contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The contractor may utilize his own or any other facility suitable for the performance of the inspection requirements specified herein. NIST technical point of contact reserves the right to perform any of the inspections set forth in the specification when such action is deemed necessary to assure supplies and services conform to prescribed requirements. The contractor shall provide all tooling, fixturing, measurement indicating devices, material and programs required of the compliance, accuracy alignment and machining acceptance tests.

(3) The accessories shall be visually examined to determine compliance with all requirements within section 2.0.

NIST technical point of contact may select parts for cutting to specification after installation. Technical point of contact will measure parts cut to specification to ensure manufactures published accuracy, and repeatability specifications are met.

6.0 Period of Performance

Delivery, installation and training shall be 30 days after award.

7.0 Place of Performance

National Institute of Standards and Technology 100 Bureau Drive Building 231, Room B133 Gaithersburg, MD 20899

8.0 General information

(1) Safety: The Contractor employee shall be responsible for knowing and complying with all installation safety prevention regulations. Such regulations include, but are not limited to, general safety, fire prevention, and waste disposal.

(2) Security: NIST is a restricted campus. An identification badge is required for access for entry into buildings and also is shown to the armed Security Police when entering the campus.

(3) Identification Badges: Contractor employees shall comply with NIST identification and access requirements. The Contractor employee is responsible for absences due to expired identification and access documents. Each Contractor employee shall wear a visible identification badge provided by the NIST Security Office. The badge must show the full name, title, and if required by NIST, the words “Contractor” in front. The Contractor employee shall turn in the NIST identification badge and vehicle pass to the TPOC, COR, or Contracting Officer (CO) upon termination of their services under this contract.

(4) Vehicle Registration: All Contractor employees must register their vehicles with the NIST Security Office to gain access to the campus. A valid driver’s license, Government-furnished civilian ID, proof of insurance and current registration must be presented to the NIST Security Office, at which time a NIST vehicle pass must be issued. The pass shall be displayed on the vehicle’s rear-view mirror in accordance with instructions. The Contractor employee shall follow NIST procedures for removal and turn-in of the vehicle pass upon termination of services under this contract.