26-30-1400 SAM PD.pdf

VIBB 26-30-1400

SAM DRAFT

PURCHASE DESCRIPTION FOR THE ACQUISITION OF ONE (1)

PUNCH/FIBER LASER COMBINATION MACHINE

SCOPE.

Scope. The content of this specification describes the minimum requirements for the acquisition of one (1) Computer Numerically Controlled (CNC) Punch/Fiber Laser Combination Machine. This specification also includes the minimum requirements for technical data, tooling, accessories, additional ancillary equipment, new foundations, delivery, unloading, rigging, installation, testing, and training. Delivery, installation, and training will be at Fleet Readiness Center East (FRCE) aboard Marine Corps Air Station (MCAS) Cherry Point, North Carolina. The machine will be used to process aircraft sheet metal engine components in Shop 93213, Building 137 for all air systems at FRCE. The machine will primarily be used for precision punching and laser cutting operations.

Materials processed include various types and tempers of aluminum, steel, inconel, titanium, copper, brass, nickel and stainless-steel alloys.

APPLICABLE DOCUMENTS. 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.

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)

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 Gear Manufacturers Association (AGMA)

AGMA ISO 1328-1-B14: Cylindrical Gears - ISO System of Flank Tolerance Classification - Part 1: Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA 22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

B11/STD B11.18: Safety Requirements for Machines Processing or Slitting Coiled or Non-Coiled Metal

B11/STD B11.21: Safety Requirements for Machine Tools Using Lasers for Processing Materials

ANSI Z136.1/Z136.7/Z136.9: Safe Use of Lasers

ANSI/ASHRAE 52.2-----------------------Method of Testing General Ventilation Air- Cleaning Devices for Removal Efficiency by Particle Size

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

American Society of Mechanical Engineers (ASME) https://quicksearch.dla.mil/qsSearch.aspx

ASME Y14.100: Engineering Drawing Practices

(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 9013: Test Conditions for Thermal cutting Geometrical products specification and quality tolerances

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/

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 regulations unless a specific exemption has been obtained.

Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

Proposal Format. Proposal shall be submitted using the following mathematical conventions:

a. Whole numbers will be expressed where one thousand is written as 1,000.

b. Decimals will be expressed where one-tenth is written as 0.1.

c. Submission of compliance statement and descriptive literature shall be in the same units as the units listed in this document.

d. In accordance with ASME Y14.5, all values listed in parenthesis will be treated as reference units and not the official proposed value in determining acceptability. For example, 300mm (11.8 inches), the 300mm will be used in determination of acceptability, and the measurement in parenthesis will not be considered in determining acceptability.

REQUIREMENTS.

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.

Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. 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 inch/pound system or both inch/pound and metric.

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

OSHA Compliance. The equipment installation, its component parts, and bulk gas installation shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79.

Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303, paragraph 1910.399 and General Industry Standards 1910.104.

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 the requirements of OSHA 29 CFR 1910. Safety signs and labels on all equipment shall comply with NEMA Z535.4 and ANSI Z136.1.

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.18, B11.21, ANSI Z136.1, ANSI Z136.9. 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. Light curtains and fence protection for the machine shall be provided.

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/EN/DIN/JIS standards.

Gears. All gears of axis drive trains shall conform to or exceed all provisions of ANSI/AGMA ISO 1328-1-B14. 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-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:

Punching Turret Station. The number of punching stations and indexable punching stations shall be in accordance with Table I. The punching station shall include a minimum of three (3) multi tools and the turret shall contain multi tool functionality. All turret stations shall be sleeved for ease of future repair.

Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment 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 combination of brushes and roller bearings around the punching station and shall be provided and ensure part material remains scratch free during processing.

3.3.3.1.1 Table Grid. The worktable grid for both laser cutting and punching shall encompass the entire Nominal Worksheet Size outlined in Table I. Roller and brush combination type auxiliary extension table supports shall be provided to support the entire sheet of material. sheet material extending past the table surface will be deemed unacceptable.

3.3.3.1.2 Table Part Chute. The worktable 3.3.3 shall include a part chute for ejecting completed parts. The part chute shall include a sensor and be activated and operated by the control and or programming software provided in 3.3.18.4 The rectangle shaped chute size opening shall meet the requirement outlined in Table I.

Work Holding Clamps. Three (3) automated clamps for work holding shall be provided. Work clamps shall include repositioning capability. A means of piece part/sheet pullout detection shall be provided.

Foot Switch. A foot switch shall be provided with equipment for the operation of the clamps during loading and unloading.

Laser Scrap Conveyor. A suitable scrap conveyor shall be supplied with the machine. All components to make the conveyor a complete and usable system shall be supplied.

3.3.6.1.1 Scrap Hopper for Laser Scrap Conveyor. A scrap hopper shall be provided and fit comfortably without modification under conveyor

Punch Slug Conveyor. A suitable scrap punching conveyor shall be supplied. All components to make the conveyor a complete and usable system shall be supplied.

3.3.7.1.1 Scrap Hopper for Punch Slug Conveyor. A scrap hopper shall be provided and fit comfortably without modification under conveyor.

Parts Conveyor. A parts conveyor belt with collection pan shall be provided with machine. A bin for collecting parts from part chute and conveyor shall be provided.

Nozzle Cleaner. An integrated nozzle cleaner to automatically remove debris, dust, and spatter from the nozzle shall be provided.

Drive System. The drive system provided on the machine shall be a rack and pinion style and AC servo motor driven, utilizing ball screws and links. A combination of rack and pinion or ball screw drives are acceptable.

High Speed Capacitive Cutting Head. The High-Speed Capacitive Cutting

Head shall be a non-contact cutting head suitable for a variety of cutting applications, including piercing of all materials and thicknesses listed in Table I, and equipped for following distorted material. The High-Speed Cutting Head shall include the following features, as a minimum:

a. Collision Detection System

b. Protection Window

c. Spare Protection Window Holder

d. Spare Protection Window

Dust Collector. The dust collector shall be integrated into the Fiber Laser

Cutting System such that it will remove all smoke and dust generated by the cutting operation, filter the air, and return the filtered air to the inside shop atmosphere. Filter efficiency shall meet the requirements of ANSI/ASHRAE 52.2. Filter efficiency test results shall be provided with the dust collector. The dust collector shall be located inside the building and contain no less than the following features:

a) Particulate emissions of no more than .05 grams per dry, standard cubic foot

b) Continuous duty, pulse jet cleaned, cartridge style High Efficiency

Particle Air (HEPA) filters

c) Filter efficiency of 99.99% at 1.0 micron

d) Solenoid operated diaphragm valves shall pulse sequentially

e) Inlet of pneumatic system capable of accepting 85 psig compressed air

f) Compressed air inlet shall be at a single connection point.

g) Differential pressure gauge for monitoring condition of filters

h) Spark Arrestor

Chiller Unit. When a chiller unit is required by the manufacturer to keep the laser resonator and optics at a constant temperature, the chiller unit shall be provided and installed inside the building and include all materials needed to connect the chiller to the laser cutting machine. British Thermal Unit (BTU) capacity shall be determined by the vendor for the machine provided.

Gas and Assist Gas Systems for Laser Cutting. The following gas supply system shall be provided. The working systems shall include installation, anchoring, safety fencing, regulation stand, bollards, stainless steel piping, supply lines, regulators, hoses, fasteners, wall mounts, fittings, testing, and all associated parts and connections.

Complete systems provided shall be in accordance with OSHA Compliance. Gas and assist gas shall be provided for 99% or greater purity and provide clean and dry compressed air as an assist gas for cutting. Refer to designated locations of gas supply tanks on drawing PE-22170.

Nitrogen Gas. One (1) 5500 Liter 500 PSI Micro Bulk Nitrogen tank shall be provided to include a new foundation located on the exterior of the building. The designated location is shown on drawing PE-22170. The foundation and installation requirements shall meet the tanks Original Equipment Manufacturer (OEM) requirements and recommendations.

Oxygen Assist Gas. One (6) pack of bottled Oxygen supply tanks shall be provided. The Oxygen tanks shall be wall mounted inside building 137 near the equipment installed.

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. The existing source power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). 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 conform to

NEMA ICS 6 standards. The enclosure shall be a NEMA type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall include the ventilation and heat exchange of components. The enclosure shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 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.

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” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

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 shall be provided with a CNC controller, incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other program directed functions for the machine. Movement in all axes shall be independent and shall be capable of independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, programmable interface, part program and buffer edit capability, part program storage, fixed cycles, and control diagnostics to at least board level. The CNC shall direct machine functions from command data stored in memory. 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. MAC addresses for laser/punch shall be provided at least 30 days prior to delivery. The controller shall also contain the following minimum features:

a) 19-inch touch screen

b) Ability to limit control functions to match user level

c) Parts and Nest Thumbnail views

d) Graphic Layout for tool installation

e) Display of material type, tooling, and clamp setup

f) Machine setup information

g) Engraving Function

h) Adaptive Stroke Calibration

i) Smart Punch Monitoring

j) Multi Tool Function

k) Cutting Packages for Material Types outlined in Table I

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 programming 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.

Cam Software. A licensed Computer Aided Manufacturing (Cam) Software solution shall be provided on the required Laptop 3.3.18.5 with the capability to generate laser cut and punching toolpaths for all available functionality, material types, and material thicknesses of the machine’s capability and outlined in Table I. The post processor of the machine shall be provided by the same OEM as the software. The software provided shall be used for the punching/laser cut performance acceptance test in section 4.7.3. The software solution shall contain standard computer aided design (CAD) functions and custom functionality including but not limited to the following:

a) Nesting

b) Punching

c) Laser Cutting

d) Nibbling

e) Forming

f) Countersinking

g) Wheeling

h) Scribing

i) Marking

j) Deburring

k) Engraving

l) Tapping

m) Cutting tables for all available material types and tempers including but not limited to Aluminum, Steel, Inconel, Titanium, Copper, Brass, Nickel, and Stainless-Steel alloys

n) DXF import and export capability

Laptop for Offline Programming. A laptop shall be provided with the following characteristics:

a. Dell Mobile Precision 7780 CTOG BASE

b. Windows 11 Pro English 23H2

c. Processor: 32-Core 2.2 GHz 13th Gen Intel Core i9-13950HX Intel64 Family 6 Model 183 Stepping 1 Processor speed 2200 (Min)

d. Memory: 64GB, 1x32GB NECC 4800MHz DDR5 CAMM Module (min)

e. Video Graphics Card: NVIDIA RTX 5000 Ada Generation Laptop GPU (min)

f. Hard Drive: M.2 2280 1TB, Gen 4 PCIe x4 NVMe, Solid State Drive

g. Optical Readers shall be external

h. Intel Wi-Fi 6E AX210 Wireless Card with Bluetooth 5.2

i. Wireless Driver: Intel Wi-Fi 6E AX211 160MHz

j. Intel Ethernet Connection (22) I219-LM

k. TPM Module (Trusted Platform Module 2.0)

l. 110 Volt Power Cord

m. 1 Year onsite service with 1 Year NBD Limited Onsite Service After Remote Diagnosis

n. Palm Rest, with Smart card only (Microsoft Usbccid Smartcard Reader (WUDF))

o. 17.3" Anti-Glare Laptop Screen with Camera and Mic

p. CAT 6 cable connection to equipment, computer, and facility local area network, all 4 connections simultaneously active.

q. Shall be TAA compliant.

r. MAC address for laptop shall be provided to customer at least 30 days prior to delivery.

Accessories for Laptop. The following laptop accessories shall be provided:

a. Two (2) Dell Ultra Sharp 24” Infinity Edge Monitors - U2422H

b. Dell MDS19 Dual Monitor Stand

c. 240W AC Adapter

d. Dell Smartcard Keyboard KB813/ with corded mouse.

e. Dell Performance Dock - WD19DC 240W PD

Maintenance Laptop with Siemens Step 7 Software. An engineering maintenance laptop with a permanently licensed Siemens Step 7 software seat loaded onto the laptop shall be provided with the machine. The laptop shall demonstrate troubleshooting of the PLC, Controls, and Drives. The computer provided shall be sufficient to run the software without error.

Auxiliary Oil Cooler Unit. An auxiliary oil cooling unit shall be provided with the machine

Punch Spray Lubrication. Punch spray lubrication shall be provided to increase tool life and shall be programmable using different intensity levels.

Warped Sheet Detection. An automatic stop of processing shall be supplied for when warping of sheet is detected.

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 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance with the requirements. Each motor shall have an identification plate in accordance with paragraph 3.7 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).

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

Hour Meter. The machine shall be equipped with a non-resetting type, analog hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine. 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 meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

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

TABLE I

Maximum Allowable Footprint (LxW) 44 Ft 0 inches X 36 Ft 0 inches Maximum Allowable Height 16 Ft

PUNCHING

Nominal Worksheet Size

120 inch X 60 inch (without workpiece move)

144-inch X 60 inch (with workpiece move)

Material Thickness .016 - .250 Thick Material Types Aluminum, Mild Steel, Inconel, Titanium, Copper, Brass, Nickel, and Stainless-Steel Alloys.

Max Work-piece Weight 300 lbs Punching Capacity 30 Tons Punch Turret Configuration 48 Stations with minimum of (3) 3.50-inch

Auto Indexing Stations Hit Rate 350 Hits Per Minute Table Brush and Roller Bearing combination Part Chute Size 15 inch by 56 inch Max Punching Diameter 3.0 inch Programmable Work Holder Clamps 3 Traverse Positioning Speed X,Y = 120 m/minute

LASER CUTTING

Fiber Laser Power 4000 Watts Cutting Gas O2, N2 Power Stability +/- 2% or Less Laser Wavelength 1.08 µm

Material Types Aluminum, Mild Steel, Inconel, Titanium, Copper, Brass, Nickel, and Stainless-Steel

Alloys.

Nominal Worksheet Size 120-inch X 60 inch

(without workpiece move)

144-inch X 60 inch (with workpiece move)

Material Thickness .016 - .250

Work Holder Clamps 3

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

Table II

Positioning Repeatability ±0.002 inches Positioning Accuracy ±0.004 inches Finished Workpiece Accuracy ±1/64 inches Finished Workpiece Repeatability ±1/32 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. The following shall also be included as a minimum:

a) Consumables for the initial operation of machine

b) The contractor shall provide consumable parts for machine and cutting head, including a detailed list for approximately one year of running one shift per day four days per week for materials listed herein at time of solicitation

Camera System. A camera system for providing visual aid while obstructed laser cutting is being performed shall be provided. The camera system must include a monitor attached conveniently to the control panel of the machine.

Stand Alone Tool Sharpening Unit. A stand-alone sharpening solution shall be provided for sharpening tool punches and dies of all shapes and diameters. The connection of facility, air and power for the sharpening unit shall be the contractor’s responsibility.

Sharpening Unit Requirements.

a) Tool sharpening up to 3.0-inch Diameter

b) Grinding Motor Power 3 Horsepower

c) Wheel Rotation Speed 2750 RPMs

d) Table Motor Power of .2 Horsepower

e) Minimum Table Rotation Speed of 35 RPMs

f) Closed coolant system

g) Tool loading Chuck with chuck key

h) Intuitive touch screen

i) Auto Interlocking Safety Guard

j) Sharpening adapters (2)

k) Grinding Wheels (2)

l) Dressing Stone

m) Coolant for sharpening unit

Tooling and/or Required Accessories.

Table III Tooling. For the first quantity of all tools outlined in Table III the vendor shall provide the full tool and holder to include the punch, die, and strippers. For any additional quantities called out the vendor is to provide the punch, die, and strippers only. All punch diameters identified shall include a quantity of one each die clearances of .006, .012, and .018 for each tool identified in Table III.

Computer Workstation. One (1) Vidmar Type A-1 Straight workstation with one

(1) 1-SEP1023AL cabinet, one (1) BL1751 bench leg, and one (1) HT60 hardwood top.

Punch and Die Tooling Storage Cabinets. A quantity of four (4) stationary tooling cabinets constructed to hold the punches and dies outlined in Table III shall be provided. The cabinets shall have eight (8) drawers and an overall dimension of 30-inch wide by 27-inch deep by 42-inches high shall be provided. The cabinets shall be constructed to withstand the weight of the tooling and be anchored to the floor. The location for floor mounting is to be determined by FRCE.

TABLE III

Type Size Quantity

Multi Punch Tool Holders for Indexing Stations

Three (3)

Turret Adapters for turret B to D Two (2)

Top Center Punch Set One (1) Bottom Center Punch Set One (1)

Round Dia. (inch) 0.06 Three (3) .062 Three (3) .072 Three (3) .076 Three (3) .078 Three (3) .091 Three (3)

3/32 Three (3) .100 Three (3) .101 Three (3) .104 Three (3) .112 Three (3) .113 Three (3) .114 Three (3) .116 Three (3) .124 Three (3) .125 Three (3) .128 Three (3) .131 Three (3) 9/64 Three (3) .149 Three (3) .150 Three (3) .165 Three (3) .170 Three (3) .172 Three (3) .173 Three (3) .174 Three (3) .175 Three (3) .176 Three (3) .177 Three (3) .178 Three (3) 3/16 Three (3) .193 Three (3) .196 Three (3) .198 Three (3) .199 Three (3) .201 Three (3) .206 Three (3) .225 Three (3) .234 Three (3) .250 Three (3) .279 Three (3) .310 Three (3) .285 Three (3) 11/32 Three (3) .355 Three (3) .375 Three (3) .388 Three (3) .404 Three (3) .500 Three (3) .687 Three (3) .750 Three (3) .980 Three (3)

1.250 Two (2)

1.311 Two (2)

1.316 Two (2)

2.500 Two (2)

3.000 Two (2)

Square (Inch) 1/8 Two (2) 3/16 Two (2) ¼ Two (2) 5/16 Two (2) 3/8 Two (2) 7/16 Two (2) 1/2 Two (2) 5/8 Two (2) ¾ Two (2) 7/8 Two (2) 1 inch Two (2) 2 inch Two (2)

Rectangle (Inch) 1.000 X .250 Three (3)

3.000 X .250 Three (3)

Coining Style Countersink Punch/Die Set for .032 thick Aluminum sheet

Top Hole CSK Size .147 One (1) Through Hole Size for CSK .098 Full Angle Between Sizes 90 degrees

Top Hole CSK Size .187 One (1) Through Hole Size for CSK .125 Full Angle Between Sizes 90 degrees

Forming Tap Heads Three (3)

Tapping Pitch Inserts 4-40 UNC 0.1in Two (2) 5-40 UNC 0.113in Two (2) 6-32 UNC 0.122in Two (2) 8-32 UNC 0.149in Two (2) 10-24 UNC 0.17in Two (2) 10-32 UNF 0.175in Two (2) 12-24 UNC 0.196in Two (2) 2-56 UNC 0.079in Two (2) 3-48 UNC 0.091in Two (2) 1/4-20 UNC 0.225in Two (2) 1/4-28 UNF 0.225in Two (2)

3/8-16 UNC 11/32in Two (2) 3/8-24 UNF 0.355in Two (2) 5/16-18 UNC 0.234in Two (2)

Multi Tool 1 (Round) Three (3) each 1,8 .092 2,8 .098 3,8 .119 4,8 .124 5,8 .126 6,8 .185 7,8 .216 8,8 .249

Multi Tool 2 (Round) Three (3) each 1,8 .093 2,8 .104 3,8 .109 4,8 .140 5,8 .156 6,8 .171 7,8 .177 8,8 .191

Multi Tool 3 (Round) Three (3) each 1,8 .200 2,8 .219 3,8 .256 4,8 .264 5,8 .293 6,8 .326 7,8 .341 8,8 .372

Roller Deburring .125 One (1)

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:

Points of Lubricant Application

Servicing Interval Type of Lubricant Viscosity Military or Federal Specification for Each Lubricant (If available) 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.

• Nomenclature

• CAGE Code

• Manufacturer’s Name

• Manufacturer’s Model Designation

• Manufacturer’s Serial Number

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

• Contract Number

• Date of Manufacture

• Full-load current for each supply

• Ampere rating of the largest motor or load

• Short-circuit current rating of the industrial control panel

• Max ampere rating of short-circuit and ground fault protective device, where provided

• Electrical diagram number(s) or number of the index to the electrical drawings

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 3.7.2 Nameplate.

Warranty Data Plate. The Contractor shall securely attach a warranty data plate to the machine enclosure in accordance with MIL-STD-130N, the data plate shall include the statement “WARRANTIED ITEM” and the warranty expiration date.

Technical Data. Two (2) hard copies and Three (3) 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. All electrical, hydraulic, pneumatic schematics shall be included.

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 prepare an Acceptance

Test Plan (ATP). 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 Contractor shall provide dimensioned drawings of the proposed test part specified in Paragraph 4.7.3.

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.

Part Model and Drawings. The Contractor shall develop a test part model (DXF) for the performance testing outlined in section 4.7.3 The Contractor shall submit the test part model and drawing along with the POA&M. The test part shall utilize all laser, punching functions, and features of the machine. The Government will review the test part model within fifteen (15) business days of submission. The Contractor shall re-submit any required changes to the test part model within five (5) business days for review and approval by the Government. The Contractor shall provide the Government dimensioned drawings of the approved test part thirty (30) calendar days prior to Origin testing.

Equipment Drawings. The Contractors proposal shall be provided with dimensioned equipment drawings in both a .PDF file and CAD file compatible with AutoCAD 2015 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.

Installation. Contractor shall be responsible for the attached Installation

Responsibilities Sheet. The contractor shall be responsible for all necessary certifications and permits required, for shipping, EPA, or other, by any government agency, local, state, or federal. The contractor shall follow the customers’ hours of operation; 6:30am to 3:00pm, Monday through Friday excluding all federal holidays, unless informed otherwise. Contractor shall be responsible for reading, understanding, and complying with Government facility requirements

Rigging. The contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel for unloading, rigging, installation, anchoring, connecting machine to utilities, and leveling the machines in place. The contractor shall provide the necessary anchor bolts, leveling screws, and related hardware to secure the machines’ components to a foundation.

Field Supervisor. The Contractor shall provide a full-time field supervisor to direct installation and testing of the supplies from start of installation to final acceptance. The field supervisor shall be capable of reading, writing, and conversing fluently in the English language. The field supervisor shall have full authority to implement field decisions expeditiously. No work shall be accomplished when the field supervisor is not in the immediate work area. The field supervisor shall be identified to the receiving activity prior to the start of installation. The field supervisor shall be responsible for coordinating with the receiving activity for any security clearances for all contractor personnel expected to perform on-site work. The receiving activity

Government Point of Contact shall be notified of any change in personnel performing this duty.

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 thirty (30) 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. The existing compressed air pressure available at the Government facility fluctuates between 83 to 93 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 Contractor shall be responsible for providing a machine foundation conforming to Original Equipment Manufacturer (OEM) requirements. For unforeseen issues that are found during installation of the foundation, the contractor shall notify the facility point of contact (POC) and the Contracting Officer immediately to determine further course of action.

Telecommunications Connection. The Contractor shall be responsible for coordinating with the FRCE Project Manager and IT group via the DLA contracting officer regarding communication signal connection of equipment to the manufacturing network along with any required stand-alone computer systems.

Geotechnical Survey. The Government does not provide the underground utility locations of the installation area, the contractor shall perform a geotechnical survey to determine if and where there are any hidden utilities in the location of the current foundation. The contractor shall provide a copy of the completed survey to

DLA.

Lead and Asbestos Testing. The Contractor shall be responsible for conducting an onsite survey for Lead Based Paint (LBP) and Asbestos Containing Material (ACM).

The onsite survey shall be completed within sixty (60) calendar days ACA, coordinate with the Contracting Officer. The facility has a known presence of LBP and ACM. A North Carolina, accredited Asbestos Inspector shall perform the onsite survey for Lead and Asbestos to identify any suspected material that appears to be involved in the project.

Assume the presence of asbestos and lead paint is a possibility and be prepared to do some sampling and analysis. Provide a signed report certifying the inspection. State the findings of the inspection and state if the area appears to be asbestos free or present the results of the sampling and analysis. The report shall be certified by the Asbestos Inspector and include the Inspector's certification number. If either of these two substances are found in areas that will be disturbed by the Installation, and will pose a health and safety threat, the contractor must notify the contracting officer. The contractor is not required to remove or abate the lead and asbestos under this contract.

Work Stoppage. For unforeseen issues that are found during installation of the foundation, the contractor shall notify the facility point of contact (POC) and DLA immediately to determine further course of action.

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 FRC East.

Training shall be provided for a minimum of three (3) operators. Training shall not be less than three (3) consecutive eight (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 provided instruction for the care, use and operation of all attachments and accessories. Training manuals shall be provided for each student.

Laser/Punch Software Training. Following the completion of Operator

Training, additional training shall be provided at FRC East or at an offsite training center for the cam software solution provided and called out on 3.3.18.4 The training shall be for a minimum of three (3) artisans.