26-20-1001 SAM Purchase Description.pdf

PURCHASE DESCRIPTION FOR THE ACQUISITION OF TWO

(2) HIGH PRECISION JIG-GRINDING MACHINES

SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for the acquisition of two (2) high precision Computer Numerically Controlled (CNC) Jig-Grinding machines. This specification also includes the minimum requirements for technical data, tooling, accessories, ancillary equipment, delivery, unloading, rigging, installation, testing, and training. Delivery, installation, and training will occur at Fleet Readiness Center Southeast (FRCSE) aboard Naval Air Station Jacksonville, Jacksonville, FL. Materials processed include but are not limited to various types and temperaments of aluminum and steel alloys.

APPLICABLE DOCUMENTS.

General. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

GOVERNMENT DOCUMENTS.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract. Not including electrical, safety, military, or environmental specifications such as NFPA, OSHA, MIL, and EPA, FRCSE will allow certain exceptions to these standards due to the machines originating country’s practices. Any standard taken exception to shall be explicitly mentioned in the contractor’s proposal. The contractor is to provide the originating country’s alternate standard that shall meet or exceed the US equivalent.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910 Vol. 5: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

Environmental Protection Agency (EPA)

40 CFR 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions

(Application for copies should be addressed to the EPA Ariel Rios Building 1200 Pennsylvania Avenue, N.W. Washington, DC 20460)

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

Other Government Documents, Drawings, and Publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

RESERVED

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

American National Standards Institute, Inc. (ANSI)

ANSI B5.1M: T-Slots, their Bolts, Nuts, and Tongues, Revision of ANSI B5.1-1975

B11/STD B11.0: General Safety Requirements Common to ANSI B11 Machines

B11/STD B11.23: Safety Requirements for Machining Centers and Automatic, Numerically Controlled Milling, Drilling, and Boring Machines

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME Y14.100: Engineering Drawing Practices https://quicksearch.dla.mil/qsSearch.aspx

ASME Y14.5-2018: Dimension and Tolerancing

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org)

International Organization for Standardization (ISO)

ISO 1328-1: 2013 Cylindrical Gears – ISO System of Flank Tolerance Classification

ISO 3408: Ball Screws

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA ICS 1: Industrial Control and Systems General Requirements

NEMA ICS 6: Industrial Control and Systems: Enclosures

NEMA ICS 16: Industrial Control and Systems: Motion/Position Control Motors, Controls, and Feedback Devices

NEMA MG 1: Motors and Generators

NEMA Z535.4: Product Safety Signs and Labels

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322) http://www.asme.org/

Society of Automotive Engineers (SAE)

SAE EIA-274-D: Interchangeable variable block data contouring, format for positioning and contouring/positioning numerically controlled machines

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale PA 15096)

Japanese International Standard (JIS)

JIS 6336: Test Code for Performance and Accuracy of Machining Centers

German National Organization of Standards (DIN)

VDI/DGQ 3441: Statistical Testing of the Operational and Positional Accuracy of Machine Tools

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

REQUIREMENTS. **ALL REQUIREMENTS IN SECTIONS 3 AND 4 SHALL

APPLY TO BOTH MACHINES AS THEY SHALL BE IDENTICAL MACHINES.

Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the US Customary Units.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910. Safety signs and labels on all equipment shall comply with NEMA Z535.4.

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI

B11 standards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment.

Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture with the exception of fluorescent lighting where required.

Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

Lead. Lead and materials containing lead shall not be used on or in the machine with the exception to radiation, cladding, and lead solder in circuits.

Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited. The machine shall be considered PCB free providing certification to be verified containing less than 5 parts per million (<5ppm) in accordance with 40 CFR part 761.

Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

Lubrication. The machine shall be equipped with a system that provides lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements.

Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible.

Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/DIN/JIS standards.

Gears. All gears of axis drive trains shall conform to or exceed all provisions of ISO 1328. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

Gears in drive trains shall be hardened and ground steel.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead and hexavalent chromium free type.

Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

Components. The machine shall consist of not less than the following components:

Base. The base shall be a stress relieved, heavy duty, ribbed quality casting having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

Table. The worktable shall be a casting of iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights and tool thrust loads. The worktable shall be precision fitted to the scraped ways integrated into the base. The top of the worktable shall be machine finished for a work-mounting surface. The worktable shall have a coolant trough or similar means for draining spent coolant into its reservoir. The worktable shall have at least seven (7) equally spaced T-slot rows, starting in the center of the table and extending outwards to the edges of the table. The T-slots shall be of the size and configuration of the manufacturer’s standard. Means shall be provided at each end of the table to prevent table overtravel.

Machine Ways. Machine ways shall be hardened. The ways shall be of a type suitable for high-grade precision numerically controlled machines covered by this purchase description. Movement of the slides on the way surfaces shall be through adjustable preloaded, re-circulating roller bearing cartridges or nonmetallic way liners having a low coefficient of friction, with excellent slip-stick and damping properties. Protection of the machine ways shall be either telescoping or curtain type way covers equipped with way wipers.

Machine Ways. Machine ways shall be hardened. The ways shall be of a type suitable for high-grade precision numerically controlled machines covered by this purchase description. Movement of the slides on the way surfaces shall be through adjustable preloaded, re-circulating roller bearing cartridges or nonmetallic way liners having a low coefficient of friction, with excellent slip-stick and damping properties. Protection of the machine ways shall be either telescoping or curtain type way covers equipped with way wipers.

Axes. All axes of the machine shall be actuated through a closed loop, high-gain electrical servomechanism driving re-circulating ball screws and nuts. Closed loop shall be dual feedback type linear scales with accuracy grade of 3 microns or better. Linear scales shall be fully sealed or mounted in a location with no exposure to the environment. All axes with backlash mechanisms shall support both internal (ID) and external (OD) grinding machining thrusts. Infinitely variable feed drives shall be provided for all axes. Axes shall be machined to accept way bearings of a precise fit to their respective ways. The way bearings shall be an antifriction type and shall be provided with adjustable gibs, guides, or bearings to maintain and adjust alignment of the table to the ways and prevent causing excessive loading of the feed drive motor. Antifriction, re-circulating ball type linear ways are acceptable. All motion/position control motors, controls, and feedback devices shall conform to NEMA ICS 16. Axes shall be as follows in terms of communicating requirements within this specification:

a) X axis – Table moving under the gantry from front to back of the machine.

b) Y axis – Spindle saddle traverse left and right on the cross rail or the table moving left and right in the case of a fixed spindle saddle design.

c) W axis – Cross rail/spindle saddle vertical motion.

d) Z axis – Vertical motion of the spindle quill.

e) C axis – Rotation axis of the sub-spindle driven by the main spindle.

f) U axis – Traverse axis of the sub-spindle.

g) Grinding Spindle Axis – Rotates the grinding arbor (tool holder)

U Axis. This U axis ways shall be manufactured to the same standard as all other machine ways and support full travel specified in Table I without the support of any modular components including, but not limited to extension plates. The U axis drive system shall offer manual and automatic feed based configurable at the controller.

Grinding Spindle. The grinding spindle shall be connected to the U axis. The grinding spindle shall be modular allowing for mounting and dismounting of different grinding spindles. Table II Spindle Section defines the types of spindles to be provided with machines. Tool changes on the grinding spindle shall be of manual type as tool changer is not a requirement of this specification.

In-Process Probe (Part Probe). The machine shall utilize a Renishaw or equivalent measuring device for automatic best fit of the setting position of a component.

Tool/Grinding Wheel Probe. The machine shall utilize a Renishaw or equivalent measuring device for verifying wheel and arbor characteristics to decrease air grinding time and verify characteristics of the grinding tools.

Cross-Rail. The cross rail shall be a casting of iron or iron alloy and proportioned to support and withstand the spindle assembly and tool thrust loads. The cross-rail shall be supported by a dual column design. The dual columns shall remain fixed in the X and Y axes. Cross-Rail shall be precisely fit to the ways of the columns. Cross-Rail shall be supported by a locking mechanism that maximizes rigidity. If required, cross-rail controls shall prevent any crashes with guarding.

Enclosure. An enclosure is not a requirement for this machine. Due to the nature of the set-up of parts on this machine, an enclosure is not required. Guarding that can be easily removed by an operator shall be provided. The guarding shall be easily removable during part set-up processes and shall be able to be easily installed again after the set-up process is complete. The provided guarding shall be transparent or shall have transparent viewing windows so that machining can be monitored during operation. There shall be means to have complete overhead access to the worktable for the use of crane loading of parts onto the worktable.

Coolant System. Coolant system including conduits, pumps, chillers, and any other components related to the coolant system shall be able to accept entirely oil based, entirely water based, or a hybrid mixture coolants. Coolant system shall be variable high volume type. A manually adjustable flex hosing shall be used to deliver coolant. A minimum of 2 coolant delivery hoses that maintain position near the sub-spindle throughout spindle and spindle saddle travel shall be provided. A minimum of one (1) flex hose shall be provided near the grinding truing station. A wash down hose shall be provided that is tied into the coolant system. Coolant shall have a return path that is integrated in the machine design so that coolant can be returned to a sump system and recycled. Coolant system shall be serviced by a band paper filter system with a minimum filter efficiency of 10 microns. The coolant system shall include a sump or reservoir, a power driven pump, and all necessary piping.

The system shall have means for draining and cleaning. The system shall incorporate a system to temperature control the coolant that is easily programmed at the controller. This temperature control shall be able to be turned off and allow the coolant system to run as intended with a temperature-controlled system.

Hydraulic System. The hydraulic system and all components shall conform to ISO 4413. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

Electrical System. The machine shall conform to NFPA 79 or current equivalent ISO/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing source power available at the facility is 480 volt, 3-phase, 60 Hertz (Hz), 60 amps. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/DIN/JIS standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent ISO/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Controller Features. The machine controller shall consist of a Fanuc 30i-B (or the manufacture’s newest model) or equivalent CNC Controller incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine.

Control features shall include Manual Data Input (MDI), simultaneous control of all axes, linear interpolation, circular interpolation, programmable interface, part program edit, buffer edit capability, part program storage, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits.

Grinding Method Controls. Jig grinding machine shall be able to perform both ID and OD grinding. Spindle shall be able to both grind in a planetary mode (C axis) and profile/interpolation (X and Y axes move around spindle) mode for all grinding operations.

The operator shall be able to control interpolation in the controller using sub routines or form of conversational programming.

Console. The operator control console shall have at a minimum the following:

a) Windows based operating system

b) Instruction and data input via keyboard and soft keys

c) 15 inch LCD (or largest manufacturer size available) color screen with touch input ability

d) Capability to store up to 200 machining programs and up to 200 different tools – 8 mB of capacity.

e) Hand pendant controller with a selection switch for the X,Y,U,C axis. Shall not include W axis control.

Grinding operator interface. The operator interface shall at a minimum include the following functionality:

a) Grinding cycles selectable by dedicated menus.

b) W axis automatically determined by set-up height settings.

c) Wheel files and past programs can be easily referred and assist in generating new programs.

d) Using macro based programs, rough and finish grinding; executed in a single push of a button and not require separate part programs.

e) Software that records the last manual infeed interruption and overrides values that can be reflected to the upcoming cycle.

f) Input fields, which requiring inputs and/or are out of range, are highlighted for ease of operator input.

g) Software shall have a code screen, which has quill up/down settings and automatic infeed settings.

h) C axis automatic conversion.

Required Controller Cycles. At minimum, the machine shall be equipped with the following cycles:

a) Circular interpolation programing

b) Helical interpolation

c) Wheel diameter compensation

d) Cutting federate clamp

e) Data protection key (memory protection key)

f) Dry run

g) Programmed dwell (0.001 ~ 99999.999 sec)

h) Emergency stop

i) External machine zero point shift

j) Extended part program editing

k) External data input

l) External tool offset

m) Feed hold

n) Handle feed: x, y, z, a and b axis, selectable

o) Resolution switch in x1, x10, x100

p) Initial point / r point return in canned cycle

q) Automatic recognition

r) Label skip

s) Machine lock

t) Macro executor

u) Manual feed select: rapid/high/medium/low

v) Handle/ ref z (zero return)

w) Max command value: +/- 99999.99 mm, +/- 99999.999º

x) MDI Function

y) Minimum input value: .00004” (.001 mm), .001º

z) Mirror image: any axis

aa) Multi axes simultaneous control

bb) Multi buffer register (5 blocks)

cc) Nano interpolation

dd) Operation history display

ee) Operation panel with 15” LCD color display with PC type key arrangement

ff) Part program editing

gg) Part program storage size 160m (64kB)

hh) Positioning

nn) Program directory by group: same group of programs will be listed on CRT program protect

oo) Programmable data input: (tool offsets, work offsets can be changed by program)

pp) Programmable parameter input

qq) Rapid traverse override; 0, 2, 15, 50, 100%

rr) Registerable programs: 60

ss) Self-diagnosis: servo system alarms, feedback

tt) System alarm, NC alarms, PC alarms, NC status i/o signal,

uu) Status ladder diagram are shown on CRT

vv) Sequence number search

xx) Sequence number: N1 - N99999 (5 digits)

yy) Single block single direction positioning

zz) Skip function aaa) Spindle speed override: 50 - 150% (10 steps in 10% incl) bbb) Stored pitch error compensation: up to 128 points on each axis, max +/- 7 pulses x 100 ccc) Subprogram: M98, M99 (up to 4 levels of nesting and 10000 times repeat) up to 9000 subprogram ddd) Tangential speed constant control eee) Chopping Cycle Function fff) Tool function (T code): 3 digits (tool no) ggg) Tool length offset: (+),(-),(off) hhh) Tool offset memory a: 99 sets (h, d 3 digits) offset value ±999.999

iii) Tool offset pairs 64 jjj) Work coordinate system change kkk) Z axis command neglect lll) Custom software size 4mb mmm) Addition of custom macro common variables 600 nnn) Customer macro variables #100 ~ #199, #500 ~ #999 ooo) Bi-directional pitch error compensation ppp) Custom macro function qqq) 100 sets common variables rrr) Data server function sss) Fast data server + fast Ethernet ATA flash card type ttt) High speed skip uuu) Inch / metric conversion

vvv) Part program storage 8mb www) Stored limit check before move

xxx) Tool offset memory (length / diameter / geometry / wear memory)

Universal Serial Bus (USB) Connection Port. A minimum of one (1) Standard USB connection port for the transfer of process information to the system control shall be provided. All protocol documentation shall be supplied.

Ethernet Connection Port. An RJ-45 connection port for Ethernet shall be readily available on the exterior of the machine. The CNC controls shall have the capability to upload and download part program results using standard Ethernet protocol.

CNC and Control Restoration Data. The contractor shall be responsible for the generation of all program logic and documentation necessary for machine operation. The Programmable Memory Controller (PMC) program, CNC parameters and all data required for configuring a new control and any other configured or programmed electronic device shall be provided in electronic format on read-only optical disc and delivered with the equipment. For safety and security reasons, the vendor shall not provide encrypted files containing proprietary cycles PMC, PLC programs/data.

Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate in accordance with paragraph 3.8 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

Remote Pendent. One (1) handheld pendent shall be connected to machine at the operator’s station to enable the operator to control machine functions. The control pendent functions shall include at least, but not limited to emergency stop, machine stop, axes jog, and axes positioning via manual electronic hand wheel. Remote pendent shall include an enabling switch that shuts down all machine functions when not in contact with operator.

The remote pendent shall have sufficient travel range to allow operator access to the worktable while holding the pendent.

Work light. A work light, whether built-in or added on, shall be provided. The light shall comply with NFPA 79 requirements, have a protective shield, and provide maximum light to the work area.

Electrical Outlet. One (1) 120V duplex standard Type B receptacle shall be supplied at the operator station and shall be accessible from the outside of the operator station.

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Hour Meter. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) run time shall be considered to meet this requirement. The CNC control shall allow up to 99,999.9 hours recorded with a minimum resolution of 1 second.

Size and Capacity. The size and capacity of the machine shall be not less than specified in Table I.

Table I Size and Capacity

Characteristic Size/Capacity Table Minimum Dimensions 50 X 33 inches Cross Rail (W axis) Minimum Column Spacing

38 inches

Table Capacity 2500 pounds X Axis Travel 40 inches Y Axis Travel 29 inches Z Axis Travel 5.5 inches W Axis Travel 25 inches X, Y Rapid Traverse Rate Maximum 150 inches per minute Z Rapid Traverse Rate Maximum 90 inches per minute Z and U Axis Minimum Grinding Feed Rate 0.004 inches per minute U Axis Radial Outfeed Travel Minimum 1.75 inches U Axis Radial Infeed Travel Minimum 0.10 inches U Axis Stroke 0.10 inches (infeed) to 1.75 inches (outfeed) Maximum Machine Footprint (Length x Width x Height)

16.5 feet x 14 feet x 12 feet

Grinding Spindles. Modular spindles shall be provided in order to meet the requirements specified in Table III.

Table II Grinding Spindles

Low RPM Spindle Tool Holding Interface Manufacturer’s Standard Spindle RPM Range 4,000 – 40,000 Quantity Provided 1 per machine plus 2 additional spares = 4 total High RPM Spindle Tool Holding Interface Manufacturer’s Standard Spindle RPM Range 9,000 – 70,000 Quantity Provided 1 per machine plus 2 additional spares = 4 total

Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the machine shall be as specified in Table V.

Table III

Axis Positioning Accuracy in X, Y, Z +/- 0.000059 inches Axis Repeatability Accuracy X, Y, Z +/- 0.000040 inches

Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the machine (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal.

Dressing and Truing Station. The machine shall incorporate a means to dress and true grinding wheels in the spindle through a sub-routine. This grinding truing station can exist as a standalone-mounted unit(s) that the spindle can always travel to or it can be attached to the worktable that the machine can find based on controller input. All components of grinding/truing station shall take up the minimal amount of table space possible. For all electrically driven dressing tools a cable management system shall be incorporated that allows the dressing tools to move with the table and handle the quick changing distances during grinding operations. The dressing tools and units shall be of modular type for ease of removal and maintenance.

The machine tool manufacture can choose to supply a profile dresser, single point diamond dresser, any other dresser tooling types, or a combination of different types. When entering a dressing cycle the machine shall retract the quill to its minimum Z axis position to prevent a crash and return to this retracted Z position at the conclusion of the dressing cycle. The dressing cycle sub-routine shall memorize the position.

Auditory Device. Grinding machine shall be equipped with one (1) audio listening device. The device shall be external and serve the purpose of operator monitoring during the grinding operations. All support equipment for this device shall be supplied including but not limited to headphones. This device shall include a visual cue to accompany the audio.

Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

a) Points of Lubricant Application

b) Servicing Interval

c) Type of Lubricant

d) Viscosity

e) Military or Federal Specification for Each Lubricant (If available)

f) Size and Type of Each Lubricant Filter

Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

a) Nomenclature

b) Manufacturer’s Name

c) Manufacturer’s Model Designation

d) Manufacturer’s Serial Number

e) Power Input (Volts, Total Amps, Phase, Frequency)

f) Contract Number

g) Date of Manufacture

Identification Marking of Military Property. An Item Unique Identification

Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.8.2 Nameplate.

Technical Data. Three (3) hard copies and two (2) electronic copy(s) of technical data shall be provided with the machine. Each electronic copy shall be provided on a read-only optical disc. All copies of technical data shall be legible and written in the English language.

Technical Data shall include the following:

a. All engineering drawings shall be in accordance with ASME Y14.100. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine, consumables and expendables information (such as oils, fluids, grease, filters…), and recommended spare parts list.

b. Factory service and operator manuals for the type and model of the machine being purchased.

c. Diagnostic procedures for isolating and correcting faults. Procedures shall be included in the service manuals for recalibrating and performing operational checks to ensure proper operation of any replaced parts, as required.

d. Preventative and predictive maintenance tasks, including oil and vibration analysis, and show recommended intervals of tasks.

e. Software manuals and registration keys/codes shall be provided, along with original software installation disks.

f. The Contractor shall provide the Government a copy of all test results completed in section 4.7 of this specification.

Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

Control of Hazardous Energy (Lockout/Tagout) Procedures. A written procedure for isolation of all energy sources on all equipment provided under this contract, in accordance with 29 CFR 1910.147, shall be provided by the contractor and included in the technical manuals. The draft procedures shall be submitted in Microsoft Word compatible format thirty (30) calendar days ACA for Government review and approval.

Instrument and Calibration Procedures. Calibration procedures and/or tooling requiring operator verification or recalibration as part of a production run or on a daily or periodic basis shall be provided to the Government. The contractor shall provide a list of these items at the time of proposal. All items shall have a certificate of calibration traceable to the National Institute of Standards and Technology (NIST). The contractor shall submit draft procedures thirty (30) calendar days ACA for Government review and approval.

Acceptance Test Plan (ATP). The Contractor shall adhere to the Acceptance Test Plan (ATP) outlined in section 4.7. The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. The Manufacture’s standard testing procedures shall be included in the ATP. The ATP shall include any procedures necessary for compliance with Sections 4.4 and 4.5 that are not covered by the Manufacturer’s standard testing procedures. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The approved ATP shall become part of the contract.

Equipment Drawings. The Contractors proposal shall be provided with dimensioned equipment drawings in both a .PDF file and CAD file compatible with AutoCAD 2015 or newer edition. The dimensioned CAD file shall be drawn to actual size and show footprint and any manufacturer’s special foundation requirements of new equipment to include ancillary pieces, utility connection points, access doors and required maintenance clearance dimensions. The CAD file shall show side and elevation views.

Removal of Existing Equipment. There are currently two S55 Hauser Jig Grinders (S/N 0572 & 0569) in the location where the new machines will be installed. These machines shall be removed prior to the installation of the new jig grinders. The order of removal of the current machines shall be done so in according with section 3.16 in this contract. The government will be responsible for disconnecting the machine from facility services (power and air) and also for completely draining the machine of all fluids. The contractor shall be entirely responsible for the disassembly, packaging, rigging and disposal of the current S55 Hauser Jig Grinders (S/N 0572 & 0569). The contractor shall be responsible for disconnecting and disassembling the machines and place them outside of the building in accordance with FRCSE’s specified location and instruction. The contractor shall be responsible for disposing of the machines off-site in accordance with FRCSE instructions and regulations. The contractor shall provide a receipt of disposal to FRCSE upon disposal.

The contractor shall coordinate with the government technical point of contact the schedule of removal for the machines in order to reduce equipment downtime. The contractor shall possess the ability to perform all of the requirements listed below:

• Disassemble and remove the existing machine along with its components and ancillary items including the chiller, hydraulic system, electrical cabinet, and all other ancillary systems.

• The machine may be removed from the facility either whole or in pieces.

• All machine parts, components, and ancillary items will be removed and disposed offsite.

• The contractor shall fully prepare the area for the turnkey installation of the new machines. This shall include removing any barriers, stanchions, or other obstructions that would impede the installation of the new machines. The contractor shall receive a confirmation from the Technical Point of Contact (POC) at FRCSE stating that the area is fully arranged and prepared for the installation of each of the new machines.

Installation. Contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel required for unloading, rigging, installation, anchoring, connecting machine to utilities, and leveling the machine in place. The Contractor shall provide the necessary anchor bolts, leveling screws and related hardware to secure machine components to a foundation. The contractor shall account for the storage of the second machine at their own facility if both machines are shipped together. FRCSE does not have the capacity to store the second machine during the time the first machine is being installed.

The order of the removal of the current machines and the installation of the new machines shall be as listed below:

The contractor shall remove, dispose of, and install the machines in the following order to reduce machine downtime:

1. Remove existing Hauser Jig Grinder (S/N 0572 ) and all of its components and ancillary items. Prepare location for the installation of the new jig grinder.

2. Install new jig grinder to a complete working condition. This installation must be approved by the technical POC at FRCSE before moving to step

3. below.

3. Conduct all training specified under 3.17 and tests specified in 4.0 of this document.

4. Remove existing Hause Jig Grinder (S/N 0569) and all of its components and ancillary items. Prepare location for the installation of the new machine.

5. Install new machine to a complete working condition and conduct all tests specified in 4.0 of this document.

Installation Plan. The Contractor shall be responsible for providing an Installation

Plan. The Installation Plan shall contain detailed information regarding all installation work.

The initial Installation Plan shall be delivered to the Government within 90 calendar days After Contract Award (ACA) for review and approval.

Compressed Air Connection. The Contractor shall be responsible for design and installation of new compressed air piping and associated components in accordance with the machine requirements. The existing compressed air pressure available at the Government facility fluctuates between 90 to 110 psi. The contractor shall assume that all compressed air qualities to be of the lowest quality that is useable as compressed air. The Contractor shall make provisions to filter, dry, humidify, lubricate, amplify, and regulate the Government supplied compressed air to meet the Original Equipment Manufacturer (OEM) compressed air requirements and recommendations.

Machine Foundation. The space where the new machines will be installed currently has the below foundation dimensions:

Length: 23 feet 10 inches Width: 31 feet 6 inches Depth: 26 inches

Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is an American citizen of good standing and repute and proficient in the English language, shall be provided for specialized training to familiarize Government personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The course shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and hands-on portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government.

Operator Training. Operator training shall be provided at FRCSE. Training shall be provided for up to 6 operators. Training shall not be less than 3 consecutive 8 hour workdays, between 6:30 am and 3:00 pm excluding weekends and federal holidays. Training shall include preparation of equipment for safe operation and proper isolation of equipment procedures. The operator shall be properly trained on the daily, weekly, and monthly upkeep and cleaning of the machine. The operator shall be provided instruction for the care, use and operation of all attachments and accessories.

Conversational Programming Training. Training for the use of conversational programming of the Fanuc control shall be provided for up to 6 operators. Training shall be performed at the Government facility by an OEM applications engineer proficient with supplied control. Training shall not be less than five (5) consecutive eight (8) hour workdays, between 6:30 am and 3:00 pm excluding weekends and federal holidays. All conversational programming features supplied with the controller shall be covered. The contractor shall provide all training supplies. Conversational programming training shall have a focus on the interpolation programming.

Maintenance Training. Mechanical and Electronic/Electrical maintenance training shall be provided for up to 4 maintenance personnel each. Training shall be performed at the Government facility and shall not be less than 3 consecutive 8-hour workdays each, between 6:30 am and 3:00 pm excluding weekends and federal holidays. Training manuals shall be provided for each student. The maintenance course shall cover at a minimum:

a) review of systems drawings and schematics

b) component location and function

c) troubleshooting procedures and techniques

d) repair procedures including disassembly and assembly

e) system maintenance and servicing

f) setup, adjustments, and calibration (how, when, and where)

g) preventative maintenance procedures

h) Procedures for proper isolation.

i) Basic start up, manual, auto, and MDI mode

j) SRAM, Ladder, PMC Memory, Parameters, Backup and Restoring

QUALITY ASSURANCE.

Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein and in accordance with the attached Quality Assurance Provision (QAP). Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

Classification of Inspections. The inspection requirements specified herein are classified as follows:

a) Contract quality assurance inspection (Origin) (see 4.4).

b) Final Inspection/Acceptance test (Destination) (see 4.5).

Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and 10% to 95% relative humidity.

Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. The machine and all peripheral equipment added to the machine shall be fully assembled and perform all functions in accordance with this specification. Quality conformance inspection shall consist of the examination in 4.6 and the tests in 4.7. The machine shall pass the examination, all tests, and contract quality assurance inspection to be acceptable for shipment.

Final…