5 Axis IDIQ Statement of Work Rev.4.pdf

STATEMENT OF WORK

FOR

5-Axis Computer Numerical Control (CNC) Machining Center Indefinite Delivery/Indefinite Quantity (IDIQ)

Prepared By

Jeremy Roof and Richard Weaver

76 CMXG/MXDEK

15 June 2021 – Rev. 4

5-Axis Statement of Work (SOW) Rev 4

June 15, 2021

Contents

1.0 OVERVIEW

1.1 Scope

1.2 Background

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 Specifications, Standards, and Handbooks

2.1.2 Other Government Documents, Drawings, and Publications

2.2 Non-Government Publications, Specifications, Standards, and Handbooks

2.3 Order of Precedence

3.0 GENERAL REQUIREMENTS

3.1 Design

3.1.1 Measuring and Indicating Device Graduations

3.1.2 Machine Controls

3.1.3 Safety and Health Requirements

3.1.4 Audible Noise Level

3.1.5 Mercury Restriction

3.1.6 Asbestos Restriction

3.1.7 Lead

3.1.8 Use of Polychlorinated Biphenyl (PCB)

3.1.9 Environmental Protection

3.1.10 Lubrication

3.1.11 Replacement Parts

3.1.12 Special Tooling and Equipment

3.1.13 Marking on Instruments, Control Panels, and Plates

3.2 Construction

3.2.1 Castings and Forgings

3.2.2 Fastening Devices

3.2.3 Threads

3.2.4 Gears

3.2.5 Surfaces

3.2.6 Welding, Brazing, or Soldering

3.2.7 Painting

3.2.8 Workmanship

3.2.9 Bearing Information

3.2.10 Fans and Blowers

3.3 Machine Components

3.3.1 Machine Bases

3.3.2 Machine Tables

3.3.3 Machine Ways

3.3.4 Measuring Systems

3.3.5 Machine Enclosures

3.3.6 Mist Collectors

3.3.7 Work light

3.3.8 Hydraulic System

3.3.9 Pneumatic System

3.3.10 Electrical System

3.4 Shutdown Program

3.5 Machine Warm Up Program

3.6 Cooling System

3.7 Status Signal Light

3.8 Starrag Packages

4.0 STC MODEL REQUIREMENTS

4.1 STC Machine Configuration

4.1.1 Axes

4.1.2 Tilting Spindle Head Housing and Saddle

4.1.3 Spindle Head

4.1.4 Machine Spindle

4.1.5 Color Scheme

4.2 Automatic Pallet Changer

4.3 Automatic Tool Changers (ATC)

4.3.1 ATC Guards and Enclosures

4.3.2 ATC Tool Loading Work Light

4.4 Coolant System

4.4.1 Coolant System Exception (STC 1250X ONLY)

4.4.2 Flood Coolant

4.4.3 Through Spindle Coolant

4.4.4 Through Spindle Air Supply

4.4.5 Flexible Nozzle Air Supply

4.4.6 Coolant Wash Down Hose

4.5 Chip Conveyor

4.5.1 STC 1000 & 1250 Chip Conveyor

4.5.2 STC 1250X Chip Conveyor

4.6 STC Model Size and Capacity

4.7 STC Model Alignment and Accuracy Tolerances

5.0 ECOSPEED F1540 REQUIREMENTS

5.1 Ecospeed F1540 Machine Configuration

5.1.1 Axes

5.1.2 Spindle Head

5.1.3 Color Scheme

5.2 Automatic Pallet Changer

5.3 Automatic Tool Changers (ATC)

5.3.1 ATC Guards and Enclosures

5.3.2 ATC Tool Loading Work Light

5.3.3 Automatic Right Angle Head Changer

5.4 Coolant System

5.4.1 Flood Coolant

5.4.2 Through Spindle Coolant

5.4.3 Through Spindle Process Cooling Air

5.4.4 Coolant Wash-Down Hose

5.5 Chip Conveyor

5.6 Ecospeed F1540 Size and Capacity

5.7 Ecospeed F1540 Alignment and Accuracy Tolerances

6.0 OPERATING SYSTEM AND SOFTWARE REQUIREMENTS

6.1 Controller

6.1.1 Data Access

6.1.2 Controller/PLC Operating Systems and Interfaces

6.1.3 Account Privileges

6.1.4 Anti-Virus Software

6.1.5 Universal Serial Bus (USB) Communications

6.1.6 Data Access Protocols

6.1.7 Discrete Input/Discrete Output (Di/Do) Information

6.1.8 Minimum Sensing Requirements

6.1.9 Crash Prevention

6.1.10 Machining Time Display and Part Count

6.1.11 Patches and Software Updates. The

6.1.12 Security Vulnerabilities

6.1.13 Tool Management

6.2 RFID System

6.3 Machine/Control Simulation Model

6.4 Digital Twin

6.5 Post Processor

6.6 Part Probe System

6.7 Tool Length Offset/Breakage Detection System

6.8 Hour Meters

6.9 Uninterruptible Power Supply (UPS)

6.10 Remote Diagnostics

6.11 Handheld Operator Pendant

7.0 TRANSPORTATION, RIGGING, FOUNDATIONS, AND INSTALLATION

7.1 Transportation

7.2 Rigging

7.3 Installation

7.3.1 Leveling

7.3.2 Utility Hook-Up

7.3.3 System Charging

7.3.4 Installation Drawings

7.3.5 Foundation

8.0 TRAINING REQUIREMENTS

8.1 Training Overview

8.2 Initial Training

8.2.1 Initial Operator Training

8.2.2 Initial Programmer Training

8.2.3 Initial Maintenance Training

8.2.4 RFID System Training

8.3 Follow Up Training

8.3.1 Follow Up Operator Training

8.3.2 Follow Up Programmer Training

8.3.3 Follow Up Maintenance Training

8.4 Advanced Training

8.4.1 Advanced Operator Training

8.4.2 Advanced Programmer Training

8.4.3 Advanced Maintenance Training

9.0 TOOLING, ACCESSORIES, & TECHNICAL DATA

9.1 Tooling

9.2 Accessories

9.3 Technical Data

10.0 QUALITY ASSURANCE

10.1 Responsibility for Inspection

10.1.1 Responsibility for Compliance

10.2 Classification of Inspections

10.3 Inspection Conditions

10.4 Origin Inspection

10.5 Final Inspection/Acceptance Test (Destination)

10.6 Examination

10.7 Tests

10.7.1 Alignment and Accuracy Tests

10.7.2 Operational Tests

10.7.3 Performance Tests

10.7.4 Post Processor Test

10.7.5 Audible Noise Level Test

10.7.6 Software Tests

10.8 Post Order Delivery Award (PODA) meeting

10.9 Plan of Action and Milestones (POA&M)

11.0 OTHER REQUIREMENTS

11.1 Safety and Quality Control

11.2 FOD and DOP

11.3 Housekeeping

11.3.1 General Work Area

11.3.2 Packing Material Disposal

11.4 Standard Operating Procedures

11.4.1 Environmental Protection & Safety

11.4.2 Safety Data Sheet (SDS) and Labeling

11.4.3 Hours of Operation

11.4.4 Spills

11.4.5 Forms, Technical Orders (T.O.), AFI, Air Force Material Command Instructions (AFMCI), and Publications

11.4.6 Tool Control and Accountability

11.4.7 Privately Owned Motor Vehicles (POV)

11.4.8 Visitors Pass

11.4.9 Foreign Nationals

11.4.10 Safety and Health on Government Installations

11.4.11 Emergency Procedures

11.4.12 Shipping

12.0 GOVERNMENT FURNISHED PROPERTY AND SERVICES

12.1 Shared Storage Areas

12.2 Government Furnished Services

12.2.1 Security Forces

12.2.2 Fire Emergency and Routine Services

12.2.3 Utilities

12.2.4 Refuse Collection

12.3 Intangible Government Property

12.4 Government Furnished Drawings

INSTALLATION RESPONSIBILITIES

1.0 OVERVIEW.

1.1 Scope. The content of this specification describes the minimum requirements for the name brand procurement of multiple Starrag 5-axis machining centers including models STC 1250/130, STC 1250X, STC 1000, and Ecospeed F1540. Equipment will be ordered on an indefinite delivery and indefinite quantity (IDIQ) schedule over multiple years. Equipment shall be provided as a turn-key solution and shall be completed in accordance with the specification(s) defined in this document to include all materials and labor necessary to deliver and install the machine(s) at Tinker Air Force Base.

1.2 Background. The Numerically Controlled (NC) Shop, 553 CMMXS/MXDPA manufactures and repairs weapon system component parts on Computer-Numerically-Controlled (CNC) machines in support of B-1, B-2, B-52, E-3, E-6, and KC-135 platforms maintained at Tinker AFB, as well as provides manufacturing support to PMXG, SCMS, and DLA, as required. The end item part geometry, size, and material type dictate which machine is utilized to manufacture or repair the component parts and contributes to the desired machines’ minimum capabilities.

Typically, manufactured aircraft component parts require a CNC machine with multi-axis contouring capabilities. Diminishing replacement parts for the existing 5-Axis Machining Centers will soon negatively impact manufacturing support requirements. Equipment procured under this effort will be utilized to maintain supportability of the NC shop to meet the needs of its customers and provide capacity for a growing workload. The installation of the equipment will be within Building 9001 located on Tinker Air Force Base, OK.

2.0 APPLICABLE DOCUMENTS.

The Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation and safety as applicable. The term “most recent edition” shall be understood to mean, “most recently released edition as of date of issuance of contract.” While every effort has been made to ensure the completeness of this section, document users are cautioned that they must meet all specified requirements of documents cited throughout this SOW whether they are listed.

2.1 Government Documents. The following Government documents form a part of this document to the extent specified herein.

2.1.1 Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein.

U.S. Department of Labor

29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/)

(Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

Environmental Protection Agency

40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

(Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

Federal Standards

FED-STD-H28A – Screw Thread Standards for Federal Services, 1994 (R2001) or most recent edition

FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

(Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, D.C. 20402-001).

Military Standards

MIL-STD-130N w/Change 1: Identification Markings of U.S. Military Property (2012 Ed.) Item Unique Identification Marking (IUID) or most recent edition

(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)

2.1.2 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.

Local Facility Documents

2.2 Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein.

National Fire Protection Association (NFPA)

NFPA 1 – Fire Code, 2010 edition or most recent edition

NFPA 70 – National Electrical Code, 2014 edition or most recent edition

NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition

NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

(Application for copies should be addressed to National Fire Protection Association, Battermarch Park, Quincy, MA 02269)

Telecommunications Industry Association (TIA) Standard

EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data Circuit- Terminating Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition

(Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

National Electrical Manufacturers Association (NEMA)

NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

NEMA ICS 1 – Industrial Control and Systems General Requirements (2015 Ed.) or most recent edition

NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

(Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

American National Standards Institute

ASTM SI 10 – American National Standard for use of the International System of Units (SI): The Modern Metric System, 2010 or most recent edition

ANSI B11.23 – Safety Requirements for Machining Centers and Automatic, Numerically Controlled Milling, Drilling, and Boring Machines (2012 Rev.) or most recent edition

(Application for copies should be addressed to American National Standards Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-3363)

American Welding Society INC (AWS)

AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most recent edition

(Applications for copies should be addressed to the American Welding Society Inc., 550 North LeJeune Road, Miami, FL 33126)

International Organization for Standardization (ISO)

ISO 4413 – Hydraulic fluid power-General rules and safety requirements for systems and their components (2010 Ed.) or most recent edition

ISO 4414 – Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.) or most recent edition

ISO 10791-7 – Test conditions for machining centres: Accuracy of finished test pieces (3rd edition, January 2020) or most recent edition

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostalea56, CH211Geneva 20, Switzerland)

Society of Automotive Engineers (SAE)

SAE EIA-267-C – Axis and Motion Nomenclature for Numerically Controlled Machines (2015 Ed.) or most recent edition

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

2.3 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.

3.0 GENERAL REQUIREMENTS.

IDIQ Totals

Minimum order – 2 Machines (any type)

Maximum Contract Total – 9 Machines

3.1 Design. The items offered shall be new and current commercially available models. 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 machines shall include all components, parts, and features necessary to meet the performance requirements specified herein. Parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Measuring and Indicating Device Graduations. Measuring and indicating devices on the machines shall be graduated in both US customary units and International System of Units (SI).

3.1.2 Machine Controls. Electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator’s workstation.

3.1.3 Safety and Health Requirements. Machine parts, components, mechanisms, and assemblies furnished on the machine, whether specifically required herein, shall comply with requirements of OSHA 29 CFR 1910.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.23. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.4 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 three (3) feet away from the equipment. Noise generated by the work piece and ambient workplace shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.5 Mercury Restriction. The machines shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

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

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

3.1.8 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

3.1.9 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.

3.1.10 Lubrication. Means shall be provided to ensure adequate lubrication (oil, grease, coolant, etc.) for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Each machine shall be provisioned via electronic means to indicate that a low-level lubrication condition exists.

The lubrication status shall be available for data collection IAW Paragraph 6.1.6. 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.

3.1.10.1 Lubrication Data. The Contractor shall provide the following information on all liquid or grease lubricants contained within equipment/system or in bulk (5 gallons or more) supplied under this procurement.

a. Liquid Lubricants

• Viscosity grade in ISO units

• Viscosity Index

• AGMA and/or SAE classification as applicable

• Mil Spec and/or NATO Code as applicable

• Cincinnati Milacron Specification Number as applicable

• Viscosity in Centistokes (cst) @ 40° C and 100° C

• Type Additive package. Example: ZDDP, Rust inhibitors, Foam inhibitors.

• Neutralization, the TBN (alkalinity) and/or TAN (acidity).

• Flash point

• Pour point

b. Grease Lubricants

• National Lubrication and Grease Institute (NLGI) Number

• Type and percent of thickener

• Dropping point

• Maximum Service Temperature

• Base oil viscosity range in SUS or centipoise

3.1.11 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.

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

3.1.13 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.

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

• Points of Lubrication Application

• Servicing Interval

• Type of Lubricant

• Viscosity

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

• Size and Type of Each Lubricant Filter

3.1.13.2 Machine Nameplate. A nameplate shall be securely attached to each machine. The nameplate data shall meet the requirements of NFPA 79 and contain, at a minimum, the following 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.

• Manufacturer’s Name

• Manufacturer’s Model Designation

• Manufacturer’s Serial Number

• Rated voltage, number of phases, and frequency

• Full-load current for each supply

• Ampere rating of the largest motor or load

• Short-circuit current rating of the industrial control panel

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

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

3.1.13.3 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) and 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.

• Nomenclature

• Cage Code

• Manufacturer

• Model Number

• Serial Number

• Date of Manufacture

• Contract Number

3.1.13.4 Warranty Data Plate. At machine acceptance, 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 “WARRANTED ITEM” and the warranty expiration date.

3.2 Construction. The machines 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.

3.2.1 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 filling with paste shall be used for reclaiming any defective part.

3.2.2 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.

3.2.3 Threads. All threaded parts used on the machines and their related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein.

3.2.4 Gears. All gears shall be of proper width and size to transmit full-rated torque and power throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.2.5 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.

3.2.6 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.

3.2.7 Painting. The machines shall be painted in accordance with the manufacturer’s commercial practice. Paint shall not contain lead.

3.2.8 Workmanship. Workmanship of the machines 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.

3.2.9 Bearing Information. The Contractor shall provide bearing manufacturer and part number for all bearings used in all rotating equipment supplied under this contract. The information shall be included on the sectional drawings for each bearing location. The Contractor shall provide the operating speed for constant speed units and the normal operating speed range for variable speed equipment.

3.2.10 Fans and Blowers. The Contractor shall provide the following information on fans and blowers supplied with the proposed equipment:

• Fan and blower type(s)

• Number of rotating fan blades/vanes

• Number of stationary fan blades/vanes

• Rotating speed(s)

The Contractor shall provide the following information for belt driven fans:

• Number of belts

• Belt lengths

• Belt Part Number

• Diameter of the drive sheave at the drive pitch line

• Diameter of the driven sheave at the drive pitch line

The Contractor shall ensure sufficient access to all fans is present in order to allow for cleaning and in-place balancing of the fan.

3.3 Machine Components. The machines shall consist of not less than the following components:

3.3.1 Machine Bases. The machine bases shall be a stress relieved and heavy-duty ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects.

The bases shall be of strength and size to provide support for all loads within the machines rated capacity without distortion to the bases, machine, or other machine components.

3.3.2 Machine Tables. The worktables 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 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. When equipped with T-slots the number and size of T-slots shall meet requirement in Tables I and III. The worktable shall be precision fitted to the ways of the machine saddle.

3.3.3 Machine Ways. Machine ways shall be constructed of hardened and precision ground steel. The ways shall be of a type suitable for high grade precision numerically controlled machines covered by this document. 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 slip-stick and damping properties. Protection of the machine ways shall be either telescoping or curtain type way covers equipped with way wipers.

3.3.4 Measuring Systems. Each machine shall be provisioned with linear glass scales for axes traversing distance calculations. Measurement systems shall be fully encapsulated by housings or sealed machine structure to prevent coolant, debris, and swarf from interfering with the system or causing damage.

3.3.5 Machine Enclosures. Each machine shall be housed within a self-contained enclosure. The enclosure shall provide containment for coolant/chips and for operator safety in the event of a broken tool. The enclosure shall be equipped with interlocking sliding doors. Interlocking doors shall provide unhindered access to the work envelop for unloading/loading of tools, raw material, and parts. The enclosure shall be constructed with safety windows for operator visibility of the workpiece and machine spindle. Each enclosure door shall contain a safety window.

3.3.6 Mist Collectors. Each machine shall be equipped with a mist collector system. The mist collector shall remove mist generated during cutting operations and return it to the coolant unit.

The mist collector shall operate concurrently during machining operations without operator input.

3.3.7 Work light. A built-in LED work light shall be provided. The light shall comply with NFPA 79 requirements, have a protective shield, and supply a minimum of 500 lux to the workpiece fixture.

3.3.8 Hydraulic System. Each machine’s hydraulic system shall conform to ISO 4413. The system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. A means shall be provided for controlling fluid temperature, so that it does not exceed 120℉ during normal operation. Machine shall alarm and report IAW Paragraph 6.1.6 when temperature thresholds are reached or exceeded.

3.3.9 Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The existing source pneumatic air available at the facility ranges from 80 to 120 psi. Each machine shall integrate with the facility source pneumatic air. Source air integration shall maintain air quality class IAW ISO 8573-1 per Paragraph 4.6 Table I or Paragraph 5.6 Table III as applicable for machine model being procured. Each machine’s pneumatic system shall be complete including all pumps, valves, plumbing, cylinders, and pressure controls. Each machine shall alarm and report IAW Paragraph 6.1.6 when insufficient pressure thresholds are reached.

Each machine shall include a compressed air quick connect that supplies a minimum of 70 psi within 10ft of the operator workstation.

3.3.10 Electrical System. Each machine shall conform to NFPA 79. The existing source power available at the facility is 480 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 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. Wiring inside electrical enclosures shall be individually labeled.

3.3.10.1 Electrical Enclosures. Construction of electrical enclosure(s) shall conform to NEMA ICS 6 standards. The electrical enclosure(s) shall be a NEMA type 12 intended for indoor, non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. Machine electrical cabinet shall meet requirements of NFPA 79. Electrical enclosure(s) shall provide means for ventilation. Each machine shall be equipped with a maintenance mode for electrical troubleshooting and repair. A lighting device shall be incorporated inside each enclosure. Each lighting device shall provide adequate lighting for troubleshooting and maintenance purposes.

3.3.10.2 Enclosure Outlets. All internal and external enclosure electrical outlets shall conform to the requirements of NFPA 79. Each machine shall be equipped with a single, easily accessible 120V (15A) quad outlet located externally on the enclosure within 10 feet of the machine controls.

3.3.10.3 Arc Flash Protection. Each machine’s electrical enclosure and enclosures of disconnecting devices shall be marked for arc flash hazard warning in accordance with NFPA 79 Paragraph 16.2.3.

3.3.10.4 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.

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

3.3.10.6 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 with the following information below. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer’s design and construction drawing(s).

• Manufacturer

• Model number

• Voltage

• Amperage

• Horsepower

• Phase

• Frequency

• Frame number

3.4 Shutdown Program. Each machine shall come equipped with a shutdown program. The program shall be capable of a controlled, automatic shutdown of the NC-control without fault upon completion of a NC part program. The program shall maintain warm condition for spindle, controls, and circulating coolant system.

3.5 Machine Warm Up Program. Each machine shall come equipped with a warmup program.

The program shall be capable of cycling automatically when electrical power is applied to the machine control. The program shall include spindle warm up with incremental RPM increases with a programmed dwell at each level. The program shall warm up axes drives through full traverse of each axis.

3.6 Cooling System. Each machine shall include a 12kW compressor cooling system. The cooling system shall cool the spindle unit, rotary table, and control cabinet.

3.7 Status Signal Light. Each machine shall include a status signal light consisting of the following:

a. Blue: Action by operator required

b. Red: Dangerous situation

c. Yellow: Abnormal situation, imminent critical situation

d. Green: Normal situation, machine producing in automatic mode

3.8 Starrag Packages. Each machine shall include the Starrag Uptime Package.

4.0 STC MODEL REQUIREMENTS.

4.1 STC Machine Configuration. In addition to the requirements detailed in Section 3, all STC model machines shall at a minimum meet the requirements detailed in this section and maintain the configuration as shown in Figure 1.

Figure 1: STC Model Machine Configuration

4.1.1 Axes. All axes of the machines shall be actuated through a closed loop, high-gain electrical servo mechanism. Infinitely variable feed drives shall be provided for all axes. Machine shall incorporate antifriction re-circulating ball type linear ways. The X, Y, Z, A, and B axes shall meet minimum requirements in Paragraph 4.6 Table I.

4.1.1.1 Longitudinal Bed and Rotary Axis. The machine’s structure shall consist of a longitudinal bed that provides X-axis movement of the machine. The longitudinal bed shall securely mount the machine table to the rotary B-axis. The rotary B-axis shall be driven by worm gear.

4.1.1.2 Transverse Bed. The machines shall be constructed to have a transverse bed that provides for Z-Axis movement of the machine’s longitudinal bed and table.

4.1.1.3 Column. The machines shall have a vertical column that provides means for Y-Axis movement and means to securely and precisely house the machine head and spindle. The machine column shall have a means of weight compensation for the Y-axis based on location of the head assembly.

4.1.2 Tilting Spindle Head Housing and Saddle. The tilting spindle head housing and saddle shall be stress relieved, heavy duty, ribbed castings or steel weldments of boxlike construction internally ribbed and braced to minimize distortion and deflection under normal cutting loads.

The tilting spindle head saddle shall be fitted to the guide-way system of the column to support and withstand maximum weights and cutting forces. The tilting housing shall incorporate drive motor(s), precision bearings, worm gears, feedback devices, and related components necessary to maintain the range of axis travel and alignment/accuracy tolerance requirements of Section 4.6 Table I and Section 4.7 Table II.

4.1.3 Spindle Head. The machines shall be constructed with a fork-type spindle head. The spindle head shall allow for tilting to account for the A-axis motion. The spindle head shall house the machine spindle, see Paragraph 4.1.4. The spindle head shall be cooled to minimize thermal effects. The spindle head shall be counterbalanced for smooth vertical motion.

4.1.4 Machine Spindle. Each machine shall be equipped with a rotating spindle that meets the requirements listed in Section 4.6 Table I per applicable machine. The spindle shall orient the tools to maintain the same radial position they occupied in the tool changer arm. Each machine shall come provisioned with electronic means of spindle overload protection. The spindle overload protection shall function independent of operator input to immediately halt all spindle axes movement. Each machine shall alarm and report, IAW Paragraph 6.1.6, when a spindle overload condition is reached.

4.1.5 Color Scheme. The color scheme for STC model machine components shall meet below specifications.

• Machining area enclosure: RAL 7016 Anthracite Grey

• Columns, tool magazine, and setup station enclosure: RAL 7035 Light Grey

• Roof, pallet changer, coolant unit, chip conveyor: RAL 7005 Mouse Grey

• Other components: RAL 7035 Light Grey

4.2 Automatic Pallet Changer. Each machine shall be provided with an automatic pallet changer (APC) system to accommodate two (2) pallets. The pallets shall be uniquely numbered.

The APC shall be a linear rail, transport cart type system that is interfaced to the machine controls and shall include at a minimum, the following characteristics:

a. Handheld HT2 terminal with a membrane keyboard, e-stop, and cabling to enable remote system operation.

b. Workpiece/pallet management system providing control of pallet location, destination, transport, and data storage. Workpiece/pallet management system software shall have provisions for fixture data and multiple clamping on individual pallets.

c. Sequence control including activation of pallet exchange operations, automatic NC program activation, auto sequence generation, operation modes of manual, automatic manned and unmanned, editable sequencing and assignment of NC programs to pallets.

d. Preparation for vacuum clamping

e. Two (2) interchangeable T-slotted pallets IAW ANSI B5.1M meeting the requirements outlined in Paragraph 4.6 Table I.

f. Safety fencing/guarding surrounding APC area.

g. Access gates to enable loading/operation of machining center when APC system is off-line.

h. Pallet clamp

i. Coolant wash to automatically clean the pallet and work piece during pallet change.

j. Mechanism to clean pallet mating system during pallet change

k. Three (3) side pallet accessibility while pallet is in the load/unload station. Pallet unload cycle to unload pallet at 180°.

l. Pallet loading work platform(s) for ergonomic pallet loading/unloading. Work platform(s) shall allow access to a minimum of three sides of each pallet simultaneously.

Work platform(s) shall adhere to OSHA 29 CFR 1910 standards, including railing and non-slip surfaces. Work platform(s) shall not be permanently attached to the machine.

Work platform(s) shall be movable by a maximum of two individuals without need of mechanical assistance.

4.3 Automatic Tool Changers (ATC). Each machine shall each be equipped with an automatic tool changer magazine for storing not less than the minimum number of tools specified in Paragraph 4.6 Table I. The automatic tool changer shall select from, return to, and store tools from fixed tool addresses within the tool magazine. The tool magazine shall be of a design that permits manual tool loading/unloading during set-up. Each machine shall come provisioned with a manual tool magazine operation panel located at the carousel load station. Each machine shall be provisioned for automatically cleaning tool holder mating surfaces with compressed air during tool change.

4.3.1 ATC Guards and Enclosures. Each machine shall be equipped with tool magazine guard(s) and enclosure(s). Tool magazine guards and enclosures shall be of a design that safeguards personnel from stored tools and magazine movements during tool change. Tool magazine enclosures shall be provisioned with a door or guarded opening that allows unhindered access for manual loading and unloading the tool carousel. Each machine shall incorporate electronic safeguards to prevent the traversing of tools within the boundaries of the tool carousel with lengths that exceed enclosure dimensions.

4.3.2 ATC Tool Loading Work Light. The magazine tool loading area shall be equipped with a lighting device(s). Lighting device(s) shall provide a minimum of 250 lux to the surface area encompassing the tool magazine door or guarded opening. Lighting device(s) shall automatically illuminate when the tool loading door is open. Lighting device(s) installation shall meet the requirements in NFPA 79.

4.4 Coolant System. Each machine shall be provided with an ambient temperature coolant system used for part/tool cooling and chip removal during cutting operations. The coolant system shall include a sump or reservoir, a power-driven pump and necessary plumbing to meet the minimum requirements outlined in Paragraph 4.6 Table I. The coolant reservoir shall include a site glass, a paper band filtration system, and an oil skimmer for removal of residual oil in the coolant tank. The system shall have means for draining. Means of foreign object removal shall be provided via baffles and removable strainers in the coolant flow loop.

4.4.1 Coolant System Exception (STC 1250X ONLY). A shared coolant filtration system, ARS Model CL 1600 or equivalent, shall be provided for the STC 1250X machining centers. The system shall be capable of delivering coolant to a cell of up to three (3) machining centers. Each machine shall be capable of independent control of the coolant for on/off, pressure, and coolant method (flood, flush, or through spindle). The coolant filtration system shall provide a two reservoir tank with an overall capacity of 1,600 gallons (800 gallons clean and 800 gallons dirty) and an auto mixing coolant proportioner. The system shall be able to collect dirty coolant from the chip management system, filter and remove solids and suspended oils from the dirty coolant and return cleaned coolant back to the clean reservoir side of the tank.

4.4.2 Flood Coolant. Each machine shall be equipped with a programmable flood type coolant system to deliver coolant to the cutting tool. Means shall be provided to permit the operator the ability to direct and control the amount of coolant delivered to the tool.

4.4.2.1 Additional Flood Coolant (STC 1250X ONLY). In addition to requirements in Paragraph 4.4.2, flood coolant system shall provide increased flow for high-speed machining operations (PF1-5164). Each machine shall include swiveling shower heads mounted in machine’s roofs. Swiveling heads shall be directed towards spindle head and axes way covers.

4.4.3 Through Spindle Coolant. Each machine shall be equipped with a through spindle coolant system. The through spindle coolant shall be a high-pressure system capable of meeting the minimum pressure and flow requirements as stated in Paragraph 4.6 Table I as applicable for the machine model being procured. High pressure coolant pump shall incorporate Starrag Energy Efficiency Plus feature.

4.4.4 Through Spindle Air Supply. Each machine shall be provided with through spindle cooling air. Through spindle air shall include programmable air plumbed through the spindle and cutting tool holder. The through spindle cooling air shall be capable of delivering a minimum of 70 psi to the workpiece and cutter location.

4.4.5 Flexible Nozzle Air Supply. Each machine shall be provided with programmable process cooling air. The process cooling air shall be delivered to the workpiece and cutting tool through flexible nozzles. Flexible nozzles shall permit the operator to direct air pressure. The flexible nozzle air shall be capable of delivering a minimum of 70 psi to the workpiece and cutter location.

4.4.6 Coolant Wash Down Hose. Each machine shall be equipped with a coolant wash-down hose. The coolant wash-down hose shall be located within 10 feet of the operator control station.

Wash down hose length shall be sufficient to reach all areas of the enclosed work envelope. Hose storage via retractable reel mechanism shall be provided.

4.5 Chip Conveyor. Each machine shall be equipped with a chip conveying system capable of evacuating chips to the outside of the enclosure.

4.5.1 STC 1000 & 1250 Chip Conveyor. The STC 1000 & 1250 machining centers shall each consist of a two (2) scraper chain, vacuum slot screen chip conveyor system. The chip conveyor systems shall have a minimum discharge height of 40 inches to accommodate swarf storage containers/bins.

4.5.2 STC 1250X Chip Conveyor. The STC 1250X chip conveyor system shall be arranged in a format compatible with STC1250X Rough Machine Layout in Appendix P. Swarf shall feed into a centralized chip handling system capable of accommodating up to three (3) STC1250X machines. The centralized chip handling system shall include a below floor level horizontal auger system. The auger system shall traverse swarf in a liquid tight trough to a centralized chip briquetting system, see location Appendix P. The Contractor shall provide an ARS RST 1000 or equivalent briquetting press. The briquetting press shall include a discharge conveyor with minimum discharge height of 40” above floor level. The chip briquetting system shall have a means to directly return recovered coolant back into the dirty coolant tank of the coolant filtration system detailed in Paragraph 4.4.1. The auger systems shall include safeguards to prevent leakage into foundation.

4.6 STC Model Size and Capacity. The size and capacity of each STC model machine shall be not less than specified in Table I.

TABLE I: STC Model Minimum Requirements

STC1250 STC1250X STC1000

X Axis 86.6 inches 86.6 inches 66.9 inches Y Axis 74 inches 74 inches 62.9 inches Z Axis 82.6 inches 82.6 inches 76.8 inches A Axis 160 degrees (+60/-

100) 160 degrees (+60/- 100)

160 degrees (+60/- 100)

B Axis 360 degrees continuous

360 degrees continuous

360 degrees continuous

Horizontal Spindle Nose to Pallet Surface

3.94 inches – 78.7 inches

3.94 inches – 78.7 inches

3.94 inches – 78.7 inches

Vertical Spindle Nose to Pallet Surface

66 inches Max 66 inches Max 66 inches Max

Linear Resolution 0.000004 inches 0.000004 inches 0.000004 inches Rotary B-Axis

Drive Torque 4,000 ft/lbs. 4,000 ft/lbs. 2,900 ft/lbs.

Clamped Holding Torque 18,000 ft/lbs. 18,000 ft/lbs. 11,000 ft/lbs.

Permissible Tilting Moment 44,250 ft/lbs. 44,250 ft/lbs. 29,000 ft/lbs.

Measurement Resolution 0.0001 degrees 0.0001 degrees 0.0001 degrees

Tilting Head A-Axis Max Drive Torque 3,750 ft/lbs. 1475 ft/lbs 3,750 ft/lbs.

Clamped Holding Torque 4,000 ft/lbs. 4000 ft/lbs 4,000 ft/lbs.

Measurement Resolution 0.0001 degrees 0.0001 degrees 0.0001 degrees

Automatic Tool Changer (ATC) Capacity 80 80 80 Type Chain Chain Chain Max Tool Diameter (without/with adjacent tools)

12.8 inches/4.9 inches

9.9 inches/4.9 inches

12.8 inches/4.9 inches

Max Tool Weight 77 lbs. 33 lbs. 77 lbs.

Max Tool Length 25.5 inches 15.7 inches 25.5 inches Tool Change Time (chip to chip)

12 seconds 12 seconds 12 seconds

Automatic Pallet Changer (APC) Number of Pallets 2 2 2 Pallet Size 49.21 inches x

49.21 inches

49.21 inches x

49.21 inches

39.4 inches x 39.4 inches

Pallet Load Capacity 11,000 lbs. 11,000 lbs. 6,600 lbs.

T-Slots (Width x No.) ¾ inches x 10 ¾ inches x 10 ¾ inches x 10 Storage Location Fixed Fixed Fixed

Drive Chain Chain Chain Spindle

Max Spindle Speed 8,000 rpm 30,000 rpm 8,000 rpm Max Power 49.6 HP 160 HP 49.6 HP Max Torque 693 ft/lbs. 61 ft/lbs. 693 ft/lbs.

Spindle Orientation Horizontal Horizontal Horizontal Taper HSK-A100 HSK-A63 HSK-A100

Rapid Traverse Rates X-Y-Z Axis 1,700 ipm 1,700 ipm 1,700 ipm A-Axis 6 rpm 12 rpm 6 rpm B-Axis 20 rpm 20 rpm 20 rpm

Feed Rates X-Y-Z Axis 1,575 ipm 1,575 ipm 1,575 ipm Max Feed Force, X and Z 6,700 lbf 6,700 lbf 6,700 lbf Max Feed Force, Y 5,600 lbf 5,600 lbf 5,600 lbf A-Axis 6 rpm 12 rpm 6 rpm B-Axis 20 rpm 20 rpm 20 rpm

Coolant System Reservoir Capacity 844 Gallons 844 Gallons 844 Gallons Flood Coolant Flow Rate 15.8 Gallons/min 15.8 Gallons/min 15.8 Gallons/min Flush and Rinse Flow Rate 92 Gallons/min 92 Gallons/min 92 Gallons/min Through Spindle Flow Rate 7.9 Gallons/min 7.9 Gallons/min 7.9 Gallons/min Through Spindle Pressure 1,015 psi 725 psi 1,015 psi

Pneumatic System Through Spindle Air Pressure 87 psi 87 psi 87 psi Air Quality Class 7.4.2 7.4.2 7.4.2

4.7 STC Model Alignment and Accuracy Tolerances. Each STC model machine shall meet or exceed the alignment and accuracy tolerances specified in Table II in accordance with VDI/DGQ 3441.

TABLE II: All STC Model Accuracy and Repeatability Positioning

[P] Linear Axes (X/Y/Z) 0.00024 inches Rotational Axes (A/B) 6 sec

Repeatability [Ps]

Linear Axes (X/Y/Z) 0.00011 inches Rotational Axes (A/B) 4 sec

Reversal [U]

Linear Axes (X/Y/Z) 0.00008 inches Rotational Axes (A/B) 3 sec

5.0 ECOSPEED F1540 REQUIREMENTS.

5.1 Ecospeed F1540 Machine Configuration. In addition to the requirements detailed in Section 3, Ecospeed F1540 machining centers shall at a minimum meet the requirements detailed in this section and maintain the configuration as shown in Figure 2.

Figure 2: Ecospeed Model Machine Configuration

5.1.1 Axes. Each machine’s axes shall be actuated through a closed loop, high-gain electrical servo mechanism. Infinitely variable feed drives shall be provided for all axes. Machine shall incorporate antifriction re-circulating ball type linear ways.

5.1.1.1 Longitudinal Bed. The machine’s structure shall consist of a longitudinal bed that provides X-axis movement of the machine utilizing two (2) friction free linear guiding systems.

The longitudinal bed shall securely mount the machine pallets. X-Axis drives shall utilize a master-slave principle utilizing twin pinion and rack.

5.1.1.2 Column. Each machine shall have a rigid vertical column constructed of steel weldment that provides means for vertical Y-Axis movement and means to secure and accurately house the machine head and spindle. The vertical head movement shall be driven along the column by use of dual ball-screws and servomotors attached securely to the column.

5.1.2 Spindle Head. Each machine shall be constructed with a parallel kinematic machining Sprint Z3 NC head. The head shall provide A, B, and Z axis movements and meet the minimum requirements of Paragraph 5.6 Table III. The head shall be cooled to minimize thermal effects.

The spindle shall be equipped to orient the automatically inserted tools to maintain the same radial position they occupied in the tool changer. The machine shall have overload protection which automatically stops the movement of all axes and the rotation of the spindle should it stall from overload.

5.1.2.1 C-Axis. Each machine shall be provisioned for a C-axis in the form of interchangeable right-angle drilling or milling heads. Each machine shall include a right-angle milling head that meets the minimum requirements established in Paragraph 5.6 Table III.

5.1.3 Color Scheme. The color scheme for Ecospeed model machine components shall meet below specifications.

• Machine base color: RAL 7035 Light Grey

• Contrasting color: RAL 7016 Anthracite Grey

• Electrical cabinet: RAL 7035 Light Grey

• Peripheral components: RAL 7005 Mouse Grey

5.2 Automatic Pallet Changer. Each machine shall be provided with an automatic pallet changer (APC) system utilizing a double-sided pallet saddle to accommodate two separate machine pallets. The saddle shall have means to securely attach both pallets simultaneously.

Pallets shall be transferred in a vertical orientation between the saddle and machine by use of a worm shaft connected to a drive between the two.