Attachment 0001- Equipment Engineering Specification 12-20-3416.docx

Attachment 0001: Equipment Engineering Spec #12-20-3416

Two New CNC Turning, Boring, and Milling Center Millturns

Table of Contents

1. Scope

1.1 Abbreviated Description 2

2. Applicable Standards and Publications 2

3. Requirements

4. Quality Assurance Provisions

5. Preservation, Packaging and Delivery Instructions 29

1.

Scope:

1.1 Abbreviated Description. The machine tool covered by this specification shall be Two New CNC Turning, Boring, and Milling Center, Millturns heavy duty type. Fitted with two independent spindles, slant bed with one piece base. With CNC controlled 5-axis (X, Z, Y, C, and B) Millturn, complete with 2 self-centering c-rest, coolant system, automatic chip removal system, automatic tool changer and other features and characteristics as specified herein including new boring bar. The slant bed shall be of heavy duty full box construction four rail design. The preferred machine is a WFL model M100-G/8000 or equal.

2. Applicable Standards and Publications. All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal, OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

2.1 The Following Publication Apply

· NAS 966

· ISO 1708 AND 230-2

· NFPA 79

· IEC 60204-1

· ANSI/ASME B5

3. Requirements. All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

3.1 General Requirements.

3.1.1 Design and Engineering. The machine shall be designed and engineered in accordance with latest standards recognized or adopted by the following, Association for Manufacturing Technology (formerly the National Machine Tool Builders Association), NAS 966 and ISO 1708. The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use.

3.1.2 Materials. Materials incorporated in the construction of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability.

3.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.3.1 Alignment Retention. Nonintegral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of accidental dislocation.

3.1.4 Slideway Design and Construction. All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown as acceptable way system. The only acceptable way system shall be of type, integral cast iron ground ways which shall be hardened to RC 50 to RC 54 to a depth of .200 inch or more. Also shall be stress-relieved by a gradual annealing process to eliminate possible tensions and any consequent risks of deformation.

3.1.5 Bed. Machine bed shall be made from gray cast iron and shall be a one piece casting. Machine bed shall be a slant bed design for better operator ergonomics and easy chip flow to the chip conveyor. Z-axis guide way plane shall have at least a 50 degree angle of slant. The machine bed shall have at least 4 guide ways. At least two guide ways for the Z-axis machining slide and two guide ways for supporting counter spindle and steady rests. Guide ways for the weight supporting tailstock and steady rest shall be of box way construction.

3.1.5.1 Way Wipers. All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall also be easily removable and replaceable.

3.1.6 Workmanship. Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology.

3.1.6.1 Shimming. Shims that do not appear on the engineering drawings shall not be incorporated in the machine.

3.1.6.2 Spacing. Spacers that do appear on the engineering drawings are permissible.

3.1.7 Maintainability. All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement or adjustment as applicable. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

3.1.8 Interchangeability. All parts bearing the same part number shall be functionally interchangeable.

3.1.9 Applicable Power Source. The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 HZ AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. If a transformer is required, it shall be supplied with the machine.

3.1.9.1 Electrical Safety Devices. The machine and its equipment shall be protected with circuit breakers which comply with NEMA and NFPA 79 standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plugin circuit breakers or currentlimiting fuses are not acceptable.

3.1.9.2 Motors. All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. All motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service. Each motor shall bear an identification plate containing, as a minimum, the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency and frame or mounting. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 hp or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 Hp or greater shall be of the high efficiency type.

Note: All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

3.1.9.3 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.1.9.4 Utility Outlet. The machine shall be provided with an operational 120volt singlephase, 20-ampere dualreceptacle 3wire utility outlet. This outlet shall be protected by a groundfault interrupter and shall be externally mounted and easily accessible. A “noise" suppression device shall be provided.

3.1.10 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment D and comply as applicable.

3.1.10.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent state, federal, local laws and regulations.

3.1.10.2 Protection of the Machine. The machine shall be fully equipped with the devices necessary to prevent selfdamage in the event of malfunction and/or ordinary operator negligence insofar as practical.

3.1.10.3 Noise Levels. Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a properly calibrated sound level meter set for “A” weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the proper operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.1.10.4 Ozone Depleting Substances. Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozonedepleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: OzoneDepletionPotential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC11, CFC12 and CFC 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

3.1.10.5 Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

3.1.10.6 LeadFree and ChromiumFree Paint Certification. All paints and primers applied to the system shall be certified as lead free and chromiumfree. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery.

3.1.10.7 PCBFree Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection (see section 3.4), these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and its equipment shall be certified as PCBfree prior to being shipped.

3.1.10.8 Lockout/Tagout Procedures. The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.11 Identification Plate. A corrosionresistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and total amps) Government Contract Number Date of Manufacture

3.1.12 Lubrication. The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon Inc. Gearboxes or transmission cases shall be lubricated by the wetsump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Systems of the foregoing types are considered automatic systems and they shall be equipped to be fail safe to the maximum extent possible. Any sensors or other devices used to detect the presence (or absence) of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods (e.g. Grease fittings, oil cups etc.) are permissible for lubrication points not practically served by automatic systems. For nonrecirculating automatic systems (such as slideway lubrication), the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems (such as pressure spray), easily cleanable or replaceable filtration devices shall be provided. Wetsump type systems shall be equipped with means to confirm proper oil level. Sight gages, if used, shall be of the external standing tube type rather than the flushmounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.1.12.1 Lubrication Plate. A lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

3.1.12.2 Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor is requested to choose the required lubricants, hydraulic fluids, oils and coolants from Attachment “A”, enclosed or where designated (*see note) approved industry/commercial equivalents. If a substitute is required, the contractor shall provide, at time of machine delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.13 Hydraulic System. Hydraulic systems provided shall be sized and powered for the intended application and shall conform industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. An appropriately sized refrigeration system shall be provided to ensure the hydraulic fluid does not exceed 120 degrees f in temperature. The hydraulic system shall be protected against overpressure as well as underpressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, antisurge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

3.1.14 Painting. All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromiumfree and leadfree. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semigloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.1.15 Machine Hold Down and Leveling. The machine base shall be provided with sufficient and properly located holes for positive holddown when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended holddown and leveling hardware.

Note: All holddown and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

3.1.16 Gears. All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.1.17 Handwheels. Where power feed and/or rapid traverse of a machine component is provided or specified, associated handwheels or cranks, if any, shall not rotate when power feed or rapid traverse is engaged.

3.1.18 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

a. Foundation Drawings, Standard or Special (see note): Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award or within 30 days of award. All drawings shall be dimensioned in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. All layers separated out from machine and foundation. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

If a special foundation (see note) is required and the vendor/contractor refuses to provide the detailed drawings required then this shall be grounds for disqualification from further consideration in the machine tool procurement. Vendor proposals submitted shall be clear in their response to this requirement.

Note: Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specificallyshaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc.

The soil (sub-straight) for a foundation is assumed to be medium dense gravel or medium dense gravel and sand with a minimum bearing capacity of 4,000 PSF. Should the contractor disturb the soil below the yet to be constructed concrete foundation then the contractor shall compact the disturbed soil to achieve at least 2,000 pounds per square foot (PSF) bearing capacity.

Important: See instruction par. 6.5

Foundation Drawings details shall include at least:

1) At least one drawing shall depict an over-lay top view of the machine foundation outline, machine general arrangement drawing (including all ancillary equipment) and the anchor bolt hole pattern.

2) The foundation drawings shall include 100% complete foundation details necessary for Watervliet Arsenal to directly hand over to a General Contractor for construction. This detail shall include, but not be limited to, complete foundation dimensions, rebar locations, rebar size, rebar pattern, concrete PSI requirements, and load bearing specs.

3) Machine to be mounted in pit to maintain floor level.

b. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in AutoCAD shall be provided on a CD. This plan shall contain the dimensioned bolt-hole pattern of the holddown bolts for the machines. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power, air, water, etc.) required to operate the machine. This data shall be furnished as soon as possible after contract award or at least within 60 days WITH ATTACHMENT C. One reproducible hardcopy and one electronic copy on CD in AutoCAD.

c. Catalog of Standard Tooling and Accessories shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (two copies)

d. NonStandard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2007 or later.

e. Installation Instructions and Drawings containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/hold down holes. This data shall be furnished as soon as possible after contract award or at least within 60 days. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2007 or later.

f. Lubrication Diagram or Instruction. To be delivered at time of machine delivery. Two reproducible hardcopy and 2 electronic copies on CD in AutoCAD Release 2007 or later.

g. Operator, Machine Operating Instructions. These instructions shall be in provided in separate manuals from other technical data provided. To be delivered upon machine delivery. Four hard copies minimum and 2 electronic copies.

h. Maintenance and Troubleshooting Instructions for all machine systems. This material shall also include the machines mechanical assembly drawings. To be delivered at time of machine delivery. Two reproducible hardcopies and 2 electronic copy on CD in AutoCAD Release 2007 or later of the machines mechanical assembly drawings.

i. Electrical and hydraulic schematics to be furnished. To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. Two reproducible hardcopies and two electronic copies on CD in AutoCAD Release 2007 or later. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

Note: If, during installation and testing, the actual electrical and/or hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "AsBuilt" schematics shall be a condition of final acceptance.

j. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be furnished not later than 30 days prior to delivery of the machine. Two reproducible hardcopies and two electronic copies on CD in AutoCAD Release 2007 or later.

k. Programming Manuals. Where a CNC machine is offered or specified, programming manuals shall be supplied. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented and usable on the system offered or specified. These manuals shall be delivered at machine delivery. One Fanuc CD-ROM Manual and one Operation and Fanuc Handbook.

l. Software Documentation. The offeror shall provide copies of all system software and/or ladder logic developed to control and interfaces the new control/drives with the existing machine tool. Two copies shall be on CD and two copies shall be paper (hard) copies. To be delivered to the technical POC 30 days after final acceptance of the machine.

m. Test Part Drawing. Dimensioned and tolerance drawing of the finished configuration of any contractor-designed and/or contractor furnished workpiece used for machine acceptance testing (see par. 3.4) shall be furnished to the arsenal 60 days prior to preliminary acceptance testing.

NOTE: All electronic information provided above shall be provide on two CD’s.

3.1.19 Training Required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal” and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". If specialized formal off-site or on-site training is available specify on offer availability and price as an option. The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Hydraulic maintenance (if applicable)

Spindle/Axes Drives (if applicable)

Note: For all types of training, the associated technical data (see 3.1.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training.

3.1.20 Repair/Replacement Parts and Service. The offeror shall also agree to provide parts and/or service for the contracted equipment within 72 hrs. of notification of a problem. Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major machine components. The offeror further agrees, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and be sufficient in detail to permit successful acquisition of the parts and associated repair service. In the event of a national emergency the U.S. Government reserves the right to obtain the data and use it to support operation of the machine tool(s) purchased under this contract.

Note: The offeror shall supply a list of recommended spare machine parts as an option with the offer.

3.1.21 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 80 psi and if higher or lower pressure is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 80 psi supply pressure. The machine shall also be equipped with devices to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 80 psig. An external compressor is not acceptable.

3.1.22 Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.1.23 Control of Cutting Fluids. Machine shall be equipped with a coolant system, the contractor shall insure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine or leaking to the floor when producing workpieces of a size within the machine's normal working range. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leakproof metallic or nonmetallic liner.

3.1.24 Site Conditions. The machine covered by this specification will be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65 degrees f. To 95 degrees f. and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4 degrees f. per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying whatever is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.1.25 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine wherever it is needed to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable.

3.1.26 Chip Removal. It is desired that the machine design provide chip removal system. An automatic, totally enclosed, reversible, chip removal unit shall be provided, capable of conveying various types of ferrous chips from entire work area of machine to a suitable container outside of machine without manual aid. The unit shall be of watertight construction, and be provided with gasket and sealed access panels. Positive lubrication shall be provided for all bearings and moving parts. The conveyor shall allow for the draining of excess coolant back into the sump before the chips are discharged. The width of the conveyor chute at discharge end shall not be less than 23. Height of discharge chute from floor shall not be less than 46" nor more than 60". Speed of chip conveyor shall be a minimum of 6 feet per minute and not more than 20 feet per minute. The chip removal unit shall be the full length of the work area at rear of machine or full length of work area within the confines of the machine bed. The system shall be of a type which efficiently handles ferrous chips of all types, including small broken chips and elongated unbroken long string of chips and chips that ball up in nature. Throat depth of the discharge chute shall not be less than 12 perpendicular inches from the belt to the top of the opening so the conveyor can operate without undue jamming or tangling. The system shall minimize the need for operator intervention to clear jams or free tangles. Conveyor controls shall include Manual/Auto, Fwd/Rev and Stop. There shall be controls located at the conveyor output as well as at the operator’s station. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The unit shall operate successfully in a variety of machining environments including drycutting, machining with cutting oils and machining with waterextendable oils. The unit shall be reversible to facilitate clearing of blockages. The chip removal unit shall be engineered for the machine so that when fully installed in accord with instructions all points subject to periodic maintenance and lubrication shall be externally accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself.

Note: Adjustment of chip conveyor discharge height (1250mm/49”) to floor level when machine is mounted in a pit.

3.1.27 Machine Installation, Startup and Testing.

3.1.27.1 Work to be performed by the Arsenal. Upon receipt of the required installation and foundation drawings (see 3.1.18); Watervliet Arsenal will prepare the intended installation site if a special foundation is required prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities (power and air) to first points of connection. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon his arrival and continue under his guidance.

Note: If installation instructions, foundation drawings and electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.18), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

3.1.27.2 Work to be performed by the Contractor. This project will be turn-key with the contractor being responsible for all aspects of the project except as mentioned in par 3.1.27.1 above. If a special foundation is not required the Contractor is responsible for the removal of wood block flooring and existing concrete preparation. Grouting for machine hold downs shall be the contractor’s responsibility regardless of foundation type.

The contractor shall provide competent Englishspeaking service personnel to install the machine, rough and finish level the machine place the machine in operation and conduct the acceptance tests specified in section 4. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, and the service personnel shall remain until the machine activation and testing have been successfully completed.

Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenalfurnished equipment.

Contractor personnel shall also adhere to the WVA requirements to wear OSHA approved safety glasses and safety shoes while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine(s). Watervliet does not have the resources to provide such material. Crane capacity within each building is limited (2, 5, 10 or 15 tons) and therefore if not adequate then the contractor will need to provide alternate means necessary for the installation.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

3.2 MachineSpecific Requirements.

3.2.1 Machine Tool Description. The machine tool covered by this specification shall be Two New CNC Turning, Boring, and Milling Center, Millturns heavy duty type. Fitted with two independent spindles, slant bed with one piece base. With CNC controlled 5-axis (X, Z, Y, C, and B) Millturn, complete with 2 self-centering c-rest, coolant system, automatic chip removal system, automatic tool changer and other features and characteristics as specified herein including new boring bar. The slant bed shall be of heavy duty full box construction four rail design. The preferred machine is a WFL model M100-G/8000 or equal.

The Millturn will be used for, turning, boring, milling, contouring and internal tapper boring to a depth of 48” or more of such materials as 4340 alloy steel with a hardness of RC 38-42. The components to be machined will be 4340 Gun barrel forgings are up to 18” inches in outside diameter, 15 to 26 feet in length, weighing up to 10,000 lbs. and will be hollow with full length bore diameters up to 6 inches. The machine shall be designed and sufficiently powered for machining these materials.

3.2.1.1 Required Characteristics. The following listed characteristics are the essential features of the machine required:

Size and Performance Characteristics

3.2.1.2 Alignment And Accuracy Characteristics.

Spindle Runout Left and Right .0003” TIR

Workhead tool Spindle Runout 1”/.0004”, 4”/.0008”

Workhead tool Spindle axial runout at face .0002”

Workhead Straightness of Z1 axis motion X, Y Plane .0008”/40” max .002”

Parallelism toll spindle axis and Z1 & X 1”/.0006”, 4”/.0006”

Perpendicularity left spindle C1-axis and X, Y 12”/.0008”

Perpendicularity Right spindle C2-axis and X, Y 12”/.0008”

Flatness and Parallelism of Bedways .0005” Per Foot NTE .002”

Finish on All Ways 16 Microinches

3.2.1.3 Positioning Accuracy and Repeatability. The machine shall be operated under CNC control and laser tested with three bi-directional positioning accuracy and repeatability runs. Positioning accuracy and repeatability runs shall be tested at intervals specified by Watervliet machine inspectors. Before correction bi-directional readings will be supplied along with the corrected. The following tolerances shall apply:

Boring bar indexing repeatability Z, X&Y plane 12”/.0004”

Workhead B-axis accuracy 4”/.0004”

Workhead B- axis repeatability with and without indexing 12”/.0004”

Workhead Position accuracy linear Z1 .0003”

Workhead Position Repeatability Z1 .00015”

Workhead Position accuracy linear X, .0003”

Workhead Position Repeatability X, .00015”

Workhead Position accuracy linear Y .0003”

Position Repeatability workhead Y .00015”

Spindle Indexing Precision C1, C2 ±5 ARC seconds

Spindle Repeatability C1, C2 ±3 ARC Seconds

Spindle Indexing Resolution C1, C2 .001 Deg. / 3.6 ARC Seconds

HEIDENHAIN scales shall be used for positioning accuracy along the bed for all axes.

3.2.2 Other Required Characteristics.

3.2.2.1 Main Headstock Spindle: Machines shall have main turning spindle. Fixed main turning spindle, left side. Spindle shall be capable of moving the work piece between the spindles from left to right for secondary operations. Main turning spindle on left shall have at least 2 gear ranges. Gear box shall be separate from turning spindle housing to reduce the influence of vibration and heat. Main turning spindle shall incorporate a separate C-axis with an independent NC drive without using the turning spindle motor. The C-axis shall incorporate a mechanical braking system to clamp the C-axis at any position. 19” 3-jaw power chuck with quick jaw change, SMW Autoblok, including 1 set of base jaws and soft top jaws. A 23’ 4-Jaw manual chuck including 1 set of base jaws and hard top jaws shall be supplied.

3.2.2.2 Counter Headstock Spindle: Counter spindle located on the right shall be capable of moving the work piece between the spindles from left to right for secondary operations. Counter Headstock spindle shall incorporate a separate C-axis with an independent NC drive without using the turning spindle motor. The C-axis shall incorporate a mechanical braking system to clamp the C-axis at any position. Maximum distance between counter spindle face and Main spindle face shall be no less than 345 inches. 19” 3-jaw power chuck with quick jaw change, SMW Autoblok, including 1 set of base jaws and soft top jaws. A 23’ 4-Jaw manual chuck including 1 set of base jaws and hard top jaws shall be supplied.

3.2.2.3 TBM UNIT Spindle (workhead): The machine shall have the capability of turning, milling, drilling, boring and part measurement from one single unit. The machines must be capable of loading turning tools, milling tools, boring tools, drilling tools and probes into a single tool post to minimize interference. TBM UNIT head shall incorporate milling capability. When turning and not milling the bearings shall be completely protected from impact when turning. When turning, the milling spindle shall incorporate no less than one clamping system at the front of the spindle and no less than one clamping system at the rear of the spindle to isolate bearings when turning. The milling spindle shall be gear driven isolating the motor from the spindle. The machining head shall incorporate the ability to move in Z-axis, X-axis, Y-axis and a B-axis for rotation. All axis shall be capable of simultaneous motion. Machining head shall have no less than 40HP at 100% continuous duty cycle. Temperature stabilization of the TBM-unit by a closed loop cooling system with a compressor cooling unit shall be supplied. Distance from tool spindle face to main turning spindle face when tool spindle is facing main turning spindle shall be no less than 327”.

3.2.2.4 B-Axis TBM Unit: The Milling spindle shall incorporate a B-axis for machining at angles and for the capability of 5-axis machining. The B-axis shall have the capability of continuous movement when in the turning mode. When not rotating the B-axis shall have a clamping system to hold the spindle at any B-axis angle. For heavy duty milling the B-axis shall incorporate and additional clamping system to lock it in place at no more than 2.5 degree increments. There shall be outboard support for B-axis ensures maximum rigidity and using geared spindle drive versus a motor spindle ensures maximum torque available.

3.2.2.5 Tool Changer: The tool changer shall have the capability of changing standard tools at any position along the Z-axis without the need to return to a single tool changing position. Capacity shall be no less than 90 tools. Maximum tool length shall be no less than 35”. Maximum tool weight shall be no less than 77lbs. Operator access to the tool magazine shall be in the front of the machine without the need to go to the back of the machine. Software shall allow access to the tool magazine while the machine is cutting.

3.2.2.6 Steady Rest: The machine shall incorporate no less than two hydraulic Self centering steady rests. Each steady rest shall be independently programmable in the Z-axis direction. Each steady rest shall be capable of moving in unison with the second right hand spindle when moving the work piece for secondary operations. Steady rests shall have the capability of simple adjustment to centerline in X & Y direction without unclamping the work piece and without the need for special tools. Steady rest shall have workpiece capacity of no less than 3”-18”. Complete with pressure clamping and adjustment, via proportional valve being varied in program by M-codes.

3.2.2.7 Deep Hole Drilling and Boring: The machine shall have the capability of performing deep whole boring operations. Machine shall have the capability to use boring bars from a separate magazine up to 70” long and up to no less than 500lbs. For stability, the deep whole boring tools shall be supported by a prismatic tool clamp system which is in addition to the standard tool coupling. Boring bar stacker shall hold a minimum of 2 boring bars with holder.

3.2.2.8 Enclosure: The machine shall incorporate a total machine enclosure for work area with powered doors for operator access. Operator access shall be free of obstructions and allow easy access to the work at floor level. Operator access shall include step on grates to allow operator to reach centerline without standing in chips and/or coolant if necessary. Doors shall incorporate laminated safety glass for operator viewing. Windows shall incorporate 2 Visiport spinning windows. Enclosure shall include an oil mist extraction and filter.

3.2.2.9 Coolant system. The machine shall incorporate a cutting tool coolant system. System shall allow coolant delivery either through the tool or through standard coolant nozzles. System shall offer no less than 100psi for normal operation and no less than 1,100 psi for high pressure operation. System shall include an oil skimmer. System shall include a retractable coolant gun with a separate pump. Coolant unit with band filter, 400 l/min (105gpm), Filter mesh, 40 μm, tank capacity approximately 2000 l (526gallon), including waste water pump. Coolant system shall be supplied with an oil Skimmer mounted on coolant tank.

3.2.2.10 Probe: Machine shall incorporate a Renishaw RMP600 workpiece probe with software for probing diameters and length. Machine shall incorporate a touch probe and a laser tool probe to automatically measure both turning and milling tools before operation.

3.2.2.11 Required Toolholders for TBM Unit

· 4, holders for 1.5” X 1.5” tool

· 3, Boring bar holders 2.5”, 3”, 4”

· Milling Spindle Interface as HSKA100

3.2.2.12 Bar Holder. WVA uses a boring bar that is 70” long by 5.25” diameter at clamping end with through bar coolant. The TBM unit shall adapt to our boring bars and have the clamping capability to accommodate 4”, 5.25”, 5.5” and 6” bars this can be done by adaptive sleeves if necessary. The boring bar hangs out past the carriage boring bar holder 47.5”, currently at the present time at WVA. The machine shall be provided with all holders to accommodate automatic clamping and manual tool changes. Also the machine shall be supplied with Damping capability for the boring bars.

3.2.2.13 New Boring Bar. A new boring bar shall be provided to accommodate the new machine complete with axial tooling to be used at preliminary and finial testing and remain on machine.