4200681268_SOW_for_Turning_center_with_Live_tooling.doc

Scope of Work Purchase of CNC TURNING maching center with Live tooling

1. Description of Requirement: We have a requirement to purchase a CNC Turning Center with Y axis and Live Milling capabilities. The center should operate on 220 volts 3 phase, have 5 axis of motion with a minimum of 4 axis of simultaneous motion controlled by an onboard computer system capable of reading ISO G-code programming, have an automatic tool changing system, main and sub spindles with independent live tool cutting capability. The center shall be fully enclosed with a flood coolant system capacity of providing through the spindle coolant up to 1,000 psi. The system should provide adequate safety features to insure operator safety when operating.

2. System Requirements Overview: The system shall include, but is not limited to the following:

Cast iron base, minimum of a 4,000 RPM main spindle, minimum of 6,000 rpm sub spindle with a minimum swing over the bed of 30 inches, minimum Y axis travel of 4 inches, minimum Z axis travel of 29 inches, minimum X axis turning capacity of 14.8 inches and full B or C axis contouring capability on both the main and sub spindles. The system should include an integrated cast iron box way base, with all feed axis traveling on box ways, a programmable automatic tool changer incorporating an indexing turret with live tooling capacity driven by an independent inline direct drive motor with a minimum of 12 tool positions, integrated CNC control with programmable X, Y, Z, B and C axis control capability. Ethernet connectivity via installed wired and upgradeable WiFi should be integrated to facilitate machine monitoring and connectivity for data transfer.

3. Specification requirements for the CNC control:

3.1.0 Core CNC control must meet or exceed the following identified capabilities:

3.1.1 ISO G code and M code compatible with user definable macros 3.1.2 minimum 20 inch color LCD monitor with dedicated keypad for system operation on the control box 3.1.3 digital documentation of machine manuals 3.1.4 The control should include conversational control functions.

3.1.5 Provide an interface to control 6 axis of motion with up to 4 axis of simultaneous motion via manual, data input and programmable methods. (X/Y/Z/C1/C2/B)

3.1.6 Minimum of 80 pairs of tool Geometry/Wear offsets.

3.1.7 Minimum of 800 registrable programs.

3.1.8 Helical milling capability. Rigid tapping capability.

3.1.9 tool life management and tool life monitoring

3.1.10 Cylindrical interpolation capability.

3.1.11 Polygon turning capability via software control.

3.1.12 machine based maintenance tracking as a function of the control.

3.1.13 Gear and spline cutting via skiving, hob cutting and broaching software control capability. Capable of producing spur and helical gearing of class 8 AGMA gears.

3.1.14 6 Gigabyte on board solid state program storage and direct control access. With USB port minimum of one

3.1.15 minimum programmable input of .0001

3.1.16 tool load monitoring capability with alerts

3.1.17 synchronization of main, sub spindle and/or milling spindles for simultaneous cutting capability in lathe or milling mode.

3.1.18 power failure detection for controlled system stop in the event of power outage

3.1.19 Network capable job management, file access, tool life management, maintenance history and machine status

4.0 . Specification requirements for the Hardware

4.1 The CNC Machining Center should meet or exceed the following requirements.

4.1.0 Working range in the X axis of a minimum diameter of 14.8 inches.

4.1.1 Working range in the Y axis of a minimum of 4 inches linear travel.

4.1.2 Working range in the Z axis of a minimum of 29 inches linear travel.

4.1.3 Main spindle should be minimum of a 25 HP 4,000 RPM high torque, inline, direct drive spindle with a 10 inch 3 jaw chuck with a minimum of 3.1 inch diameter through the spindle.

4.1.4 Sub Spindle should be minimum of a 15 HP 6,000 RPM inline, direct drive spindle with an 6 inch 3 jaw chuck and sub spindle assembly location controlled using ball screw and servo motor via programming.

4.1.5 Main and sub spindles should be temperature controlled by refrigeration and able to be synchronized during programed operation.

4.1.6 Rotary spindle should be a minimum of 7.5 HP capable of 0-10,000 RPM

4.1.7 Positional linear accuracy requirements of +/- .0002 per axis minimum.

4.1.8 Repeatability linear accuracy requirements of +/- .00012 per axis minimum.

4.1.9 Rotational accuracy of C1 and C2 axis of +/- 10 arc sec minimum 4.1.10 Rotational repeatability C1 and C2 axis of +/- 8.5 arc sec minimum 4.1.11 Rotary axis should be capable of rotary speeds up to 150 degrees/sec.

4.1.12 Rotary axis OD tool overhang capable of 3.9 inches.

4.1.13 Capability for through the spindle coolant up to 1000 psi in addition to external coolant system.

4.1.14 The system should include a refrigerated thermal mitigation system as a part of the machine basic design that includes main and sub-spindle plus rotary axis on the turret.

4.1.15 The live tooling turret should accept live tooling capable of 0-10,000 rpm at a minimum. Live tooling should be able to be mounted in all tool positions on the turret.

4.1.16 Direct scale feedback for a full closed loop on the X axis should be included 4.1.17 Turret should have a minimum capacity of 12 stations capable of using dual holders, a programmable Y axis with a range of 4 inches.

4.1.18 Programmable Part unloader 4.1.19 Helical interpolation for thread milling capability 4.1.17 Step down transformer for the machine from 440 to 220 volt 3 phase.

4.1.18 High output LED lighting for power and heat reduction.

4.1.19 Structural components should be made of stabilized cast iron with box ways on all feed axis.

4.1.20 Main 10 inch and 6 inch sub spindle chucks should be Kitagawa 3 jaw hydraulic chucks.

4.1.21 Programmable coolant nozzle controllable from both the program and pendant.

4.1.22 The CNC machining center should be setup for 220 volt operation 3 phase and include transformers to reduce from 440 volt 3 phase.

5.0 Additional requirements

5.1.1 Two (2) year full system warranty including parts and labor.

5.1.2 Trade in of MAZAK CNC is required” Mazak Quick Turn 250-II Turning Center S/N: 215121 includes chip conveyor system.

5.1.3 Rotary tool package consisting of a minimum of 3 OD holders and 2 End holders with collets.

5.1.4 Turning tool package consisting of a minimum of 9 turning holders including but not limited to OD, Cutoff and boring bar holders. Plus sleeves for boring bars.

5.1.5 The system should include a hinge type chip conveyor that discharges swarf material into a standard 30/50 gallon drum.

5.1.6 The system should include an integrated flood coolant tank and pump system with a minimum capacity of 96 gallons.

5.1.7 The system should include tool presetter with automatic cycles for main and sub spindles.

5.1.8 Installation of the machine, setup and validation of the install with digital report of installed specs.

5.1.9 Operator training on machine and control.

5.1.10 Job management capacity for structured storage of job data via the control.

6.0 . Safety requirements for the system:

6.1.1 Safety switches to insure operation only when doors are closed.

6.1.2 Power failure detection for controlled system stop in the event of power outage.

6.1.3 Onboard error report capture and storage.

7.0 Shipping Requirements:

7.1.1 Delivery and rigging of new machine to shop floor location in Building 5 to be included. Removal of all crating materials.

7.1.2 Removal of trade in machine to be included. Note: we will load the machine on riggers truck.

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