Attach 1 Statement of Work (Waterjet Cutter) MacDill 2.pdf

STATEMENT OF WORK (SOW):

ABRASIVE WATERJET CUTTING CENTER

Date: 25 Sep 2020

PREPARED BY: MSgt Ryan Vaught, 6 MXS/MXMFM

STATEMENT OF WORK (SOW)

ABRASIVE WATERJET CUTTING CENTER

1.0 SCOPE

1.1 Scope: The following establishes the minimum requirements for the purchase of an abrasive waterjet machine with equipment and accessories specified herein.

2.0 APPLICABLE DOCUMENTS

U. S. DEPARTMENT OF LABOR

29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 1998 or most recent edition.

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA-79 – Electrical Standards for Industrial Machinery, 1997 or most recent edition.

ELECTRONIC INDUSTRIES ALLIANCE (EIA) STANDARD

EIA TIA/EIA-232-F – Interface between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange, 1997 or most recent edition.

AMERICAN NATIONAL STANDARD INSTITUTE

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

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

2.2 Order of Precedence: In the event of a conflict between the text of this specification and the reference cited herein, the text of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

3.0 REQUIREMENTS

3.1 General: The waterjet abrasive cutting machine shall be new (not a prototype) and one of the manufacturer’s standard current production models capable of operations in accordance with the requirements herein. The machine shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. The design must be a bridge style design with cutting head integrated with the cutting table. Cantilever design with separate catcher tank (independent of cutting unit) will not be allowed.

3.1.1 Measuring/Indicating Devices: All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine shall be graduated in dual, inch-pound units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located so as to allow reading from the operator’s normal workstation.

3.1.2 Safety and Health: Covers, guards, and other safety devices shall be provided for all parts of the machine that present safety hazards. 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 removable to facilitate inspection, maintenance, and repair of the parts. All machine parts, components, mechanisms, and assemblies furnished on the machine shall comply with all of the requirements of 29 CFR 1910.

3.1.3 Caution-Warning Plates: Corrosion resistant “Caution” or “Warning” plates shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

3.1.4 Audible Noise: Audible noise emitted by the equipment under load shall be ≤80 dBA at the operator’s workstation or at any other point at a distance of three (3) feet from the equipment as measured on the “A” weighted scale of a standard Type II sound level meter. Noise level obtained by cutting submerged.

3.1.5 Prohibited Materials: Asbestos, mercury, lithium or polychlorinated biphenyl (PCB) shall not be used in any part or component of the system. Lithium batteries used in the computer system are exempt from this requirement.

3.1.6 Environmental Protection: The machine shall be so designed and constructed that under the operating, service, transportation and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prescribed by federal, state, or local statutes in effect at location of installation.

3.1.7 Nameplate: A corrosion resistant metal nameplate identifying the machine shall be securely attached to the machine. The nameplate shall contain the following information:

Nomenclature Contractor’s Name Contractor’s Model Designation Contractor’s Serial Number Power Input (volts, total amps, phase) Date of Manufacture

3.2 Construction: The abrasive waterjet cutting machine shall be constructed of parts which are new, without defects, and free of repairs. The cutting axes and tank shall be one unit to guarantee the cutting accuracy listed herein. The machine structure shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion. Processes such as welding, plugging, or filling with solder or paste shall not be used for reclaiming any defective part(s). All screws, pins, bolts, and other fasteners shall be installed in a manner as to prevent change of tightness. The machine shall be manufactured, tested and shipped as a complete unit from the manufacturers’ location within the USA.

3.2.1 Castings/Forgings: All castings/forgings shall be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solders or paste shall not be used on casting or forgings for reclaiming any parts of the machine.

3.2.2 Welding, Brazing or Soldering: Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

3.2.3 Surfaces: All surfaces of castings, forgings, molded parts, stampings and welded parts shall be clean and free from sand, dirt, fins, sprues, flux, and other harmful or extraneous materials. External surfaces shall be smooth, and all edges shall be either rounded or beveled unless sharpness is required to perform a function.

3.2.4 Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with 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.

3.2.5 Painting: The machine shall be painted in accordance with the manufacturer’s commercial practice.

Yellow or orange safety color-coding shall be used for designating physical hazards.

3.2.6 Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28.

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

3.2.8 Maintainability: The machine shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, and repair of parts. One piece, bellows shall cover the axis drive components.

3.3 Components: The abrasive waterjet cutting machine shall consist of, but not limited to, the following described principle components, attachments, and accessories necessary to meet the operational and performance requirements specified herein.

3.3.1 Table: The machine’s total footprint (including all accessories and support equipment) shall be less than 25’ x 12’ 9” and provide a working envelope capable of housing a 8’ x 4’ 6” piece of material. The bed height shall be 36” and form a foundation for the entire machine providing sufficient rigidity and mutual component alignment to assure the accuracy required herein. The bed shall have galvanized steel support slats. The bed shall have means for leveling the machine on a flat mounting surface. The system must be of unitized design to eliminate misalignment due to an operator bumping either the cutting head or table during material loading. The base shall have access doors or removable plates as necessary for servicing components housed within. The table must be capable of supporting 400 pounds per square foot of load. The contractor shall provide the necessary anchor bolts, leveling screws and related hardware to secure machine components to the floor, if design requires.

3.3.2 Bridge: The bridge shall be controlled by closed loop, digital drives with brushless servo motors that requires no periodic tuning. The resolution shall be 1 micron with linear scale. The bridge shall have full Y-axis travel and a motor controlled, programmable, precision Z-axis. The X-axis motion shall be controlled by a maintenance free drive system that is fully enclosed. Rack and pinion style drive systems are not acceptable due to their lack of accuracy and repeatability as well as maintenance concerns. Bridge shall be able to move entirely off of the cutting table for safety while loading material. A cantilever style cutting head is not allowed.

3.3.3 Computer Control System (CCS): The waterjet abrasive cutting system shall be provided with a fully automatic, solid-state, integrated circuit, 32-bit, multiple microprocessor based-type personal computer integrated with CAD/CAM software and LCD flat panel display. The unit shall provide for 3-axis simultaneous contouring capabilities and automatic control for all machine functions.

3.3.3.1 CCS Features: The Computer Control System (CCS) shall consist of, but not limited to, the following functions and features:

a. Ergonomic swivel pendant mount

b. Inch/Metric switchable

c. 160GB part program storage

d. 17 inch color LCD flat panel display (min)

e. Built-in DVD ROM/CD-RW & USB mass storage device ports

f. On-screen help including operation, programming and alarm help

g. Hour meter

h. Real time 3D graphics

i. Sequence stop

j. 99 programmable homes

k. Unidirectional positioning

l. Helical interpolation

m. Feedrate programming

n. Cycle time reduction function

o. Graphical data input of fixed cycles and 2D graphics display

p. Coordinate calculation

q. Coordinate shift-rotation-copy

r. User defined logical operators, variables, math and trig functions

s. Linear & circular interpolation

t. Decimal point programming

u. Automatic zero referencing

v. Manual Data Input (MDI) capabilities

w. Positioning display - all axis

x. Linear feed display – ipm

y. Automatic acceleration and deceleration all axis

z. Software travel limits

aa. Array nesting

bb. Interactive, menu driven screen(s) w/inputs

cc. Graphical display of input values and online help

dd. Programmable mirror image

ee. Geometry enlargement/reduction

ff. Controlled depth etch capabilities

gg. Nozzle Taper control of up to ±59° (If A-Jet Option Selected)

hh. Controlled high/low pierce pressure

ii. Scribe capabilities

jj. Part Preview

kk. Collision detection/prevention

ll. Corner compensation and automatic corner passing

mm. Saw cut operation

nn. Percent utilization

3.3.4 Software: Software shall run on Windows® 10 and be specifically designed for all abrasive jet and waterjet machining functions. Contractor shall provide unlimited free upgrades and unlimited seats for as long as the receiving activity has possession of the machine. Upgrades to software must be provided when available for no charge for all seats.

3.3.5 Pump System: The pump shall be a direct drive crankshaft type pump with variable frequency drive controller, capable of obtaining and maintaining the designed operating pressure without the use of hydraulic assistance. Pressure attenuators are not allowed to maintain operating pressure.

SAFETY ITEM: When unit is shut down, must release high pressure water from the entire system including all waterlines and head unit.

3.3.6 Electrical System: The machine shall be designed to operate from a single 460 volt (±3%), 3 phase, 60-hertz (Hz) (±1 hertz) power source. The machine shall consist of independent electric servo drives. All electrical equipment shall comply with NFPA-79 standards.

3.4 Related Components: The following features must be included at no additional cost to the government.

3.4.1 High Pressure Tubing: The high pressure tubing that supplies pressurized water to the cutting head via the X and Y axis must be made of 3/8” O.D X .125 I.D stainless steel tubing.

3.4.2 Adjustable Dump Orifice: The adjustable dump orifice is required to allow the machine operator to conveniently switch cutting nozzle assemblies without the need to switch dump valve orifices. The adjustable dump orifice will incorporate an easy-to-turn pressure adjustment knob.

3.4.3 Cutting Head Assembly: The cutting nozzle assembly shall be fully integrated with long-life diamond orifice and all internal components considered as a one piece design. This nozzle assembly must be warranted to last ≥ 500 hours and the only additional part required is the mixing tube and final filter.

3.4.4 Bulk Abrasive Feed System: Automatic pressurized bulk garnet feed system that eliminates the need for manually filing the smaller garnet feed hopper mounted above the cutting head. Bulk hopper must provide over 12 hours of operating time using a standard cutting head. Must hold a minimum of 600 lbs capacity of garnet.

3.5 Capacities: The sizes and capacities of the machining center shall meet the minimum requirements of Table I below:

TABLE 1

TRAVELS

X-Y Travel 8’4” x 4’7”

TABLE

Table Size (W x L) 10’6” x 5’5” Footprint 12’11” x 7’10” Operating Weight 22,000 lbs.

Maximum Material Load 400 lbs/sq. ft.

NOZZLE

Z-axis travel, min (H) 8.00”

SPEED

Traverse rate 180 ipm

3.6 Accuracy/Repeatability: The machining center shall conform to the following accuracies/alignments of Table 2:

TABLE 2

AXIS POSITIONING REQUIREMENT

X, Y, & Z Linear axes +/-0.0010”

AXIS REPEATABILITY

X, Y, & Z Linear axes +/-0.0010”

3.7 Optional Equipment: The following optional equipment shall be separately priced items:

3.7.1 Tilting Head for Taper Elimination: Method for eliminating taper must be provided. A nozzle that automatically rotates up to 9 degrees controlled by the software is required. The software can easily enable this mode with a single click. The software calculates the taper requirements continuously, not by average.

3.7.2 Pump and Nozzle Spares: Spares for the nozzle and pump are required. Include any special tooling for maintenance. Include first set of filter changes, nozzle muffs, and abrasive tubing along with minor pump rebuild kit and nozzle spares. A compartmented box for storage of spares must be included.

3.7.3 Water Recycling System : The system must include a 60,000 BTU chiller and settling weir. The weir tank shall be a 135 gallon functional capacity tank constructed of non-rusting components. The intent of the design is to prevent dissolved solids or water from entering the drain. All overflow water must be filtered and reused. The system must be designed for an industrial metalworking application.

3.7.4 Variable Speed Solids Removal System: The solids removal system shall be a ¾ yd hopper and of steel construction. The system shall be operated by a ½ hp motor with a garnet removal rate up to 5.6 lbs/min.

The solids removal system shall have a steel shielding over the suction line and have gravity return to main water tank. The solids removal system shall use 230 VAC 10 A and have a variable frequency drive/motor combination that allows for automated back flushing of the cutting tank.

3.7.5 Precision Optical Locator (or Adequate Device): The device allows for accurate location of parts on the machining table or feature on exiting parts. USB camera with microscope lens is provided to zoom in on features, locate, and select with software integrated into the cutting program. Device must have reverse engineering capabilities.

3.7.6 Fine Nozzle: Nozzle capable of utilizing 120 grit abrasive with the capability of utilizing a .007 orifice and a .015 mixing tube combination.

3.7.7 Collision Sensor/Terrain Follower: The Collision Sensing Terrain Follower allows the waterjet to automatically and accurately cut parts from materials with irregular or warped surfaces without the need for special programming. The device is a ring that fits around the nozzle body and automatically sets the appropriate stand-off height to achieve accurate cutting.

3.7.8 Reverse Osmosis System: Reverse Osmosis System w/ water softener to control water quality.

3.7.9 Water Level Control: Contains in tank pneumatic system allowing for water level adjust of up to 3”.

Operation must be easily controlled at operation station by joystick

4.0 QUALITY ASSURANCE PROVISIONS

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

4.2 Responsibility for Compliance: The machine shall meet all requirements of Section 3. The inspections set forth in this specification shall become a part of the contractors overall inspection system or quality program.

4.3 Quality Conformance Inspection: Quality conformance inspection shall be conducted on machine prior to being offered for acceptance under the contract. Quality conformance inspection shall be conducted at origin and could be monitored by purchasing personnel. Testing of the complete machine (Table, controller, and pump) must be completed at the factory prior to shipment. The inspection shall be in accordance with par.

4.5, 4.6, 4.7.1, 4.7.2, 4.7.3 and 4.7.4.

4.4.1 Origin Acceptance : All components (pump, table, controller) must be tested together as a complete system prior to shipment. Cut a sample part using the complete system to ensure adherence to specifications before shipment. A ball bar test report must be provided for the same machine prior to shipment, at the request of the government.

4.5 FRC Machine Accuracy Inspection: A FRC machine accuracy inspection ensuring the machine’s accuracy must be complied with by the serial number of that machine to accompany the machine prior to final acceptance.

4.6 Examination: The machine shall be visually examined to determine compliance with all requirements within Section 3. Buyer may select part for cutting to specification during installation.

4.7 Training: On-site training must be provided during machine installation. Additional free training at factory location must be offered to unlimited individuals for the life of the machine.

4.8 Warranty: The machine shall have a two year parts and labor limited warranty.

5.0 TECHNICAL DATA

5.1 Manuals/Drawings: The contractor shall furnish one (1) hard copies of all technical manuals/drawings containing all information necessary for the programming, operation and maintenance (parts lists, electrical schematics, ladder logic and I/O diagrams) of the waterjet abrasive cutting system. One (1) complete set of manuals/drawings shall be sent to the receiving activity concurrent with machine delivery.

5.2 Installation Drawings: The contractor shall provide to the receiving facility, engineering installation drawings showing the necessary compressed air, water, and electrical utilities of the waterjet abrasive cutting system.

5.3 Documentation: All documentation, i.e. operation manuals, maintenance manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and grammatically correct.

6.0 GOVERNMENT PURCHASE CARD

6.1 The Government Reserves the right to pay for this contract with a Government Purchase Card at no additional expense.

7.0 RESPONSIBILITIES

Contractor Responsibility

a. Remove and discard of the current machine immediately or prior to delivery.

b. Remove the machine and components immediately upon the delivery trucks arrival.

c. Provide estimated time of arrival of machine to the facility.

d. Connect components of the system and perform start up. To be done after the utilities are connected by the government.

e. Level and align machine.

f. Provide training immediately upon start up.

Purchaser Responsibility

a. Provide unobstructed utilities hook-up to machine location and make the connections.

b. Fill the catcher tank with water

c. Provide between 1 and 3 personnel for training.

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