Attachment 0001 - RIPD.pdf

ROCK ISLAND ARSENAL RIPD: E4000-24-1-06

PURCHASE DESCRIPTION DATE: 29-Sept-22

24-1-06 SEVEN AXIS MACHINE

1. GENERAL SYSTEM DESCRIPTION

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

2.2 National Standards and Specifications

3. DESIGN

3.1 Ownership

3.2 General Design Standards

3.3 Safety, Security and Environmental

3.4 Responsibilities

4. Information technology systems and support

4.1 Installation IT Support:

4.2 Inspection/Final Acceptance:

4.3 Media/ Devices

4.4 Information Assurance and Accreditation:

5. CLIN 0001- Seven Axis Machine and TILT ROTARY TABLE

5.1 Dimensions:

5.2 Machine Base

5.3 Axis Definition Drawings

5.4 X-Axis

5.5 Y-Axis

5.6 Z1-Axis

5.7 Z2-Axis

5.8 W-Axis

5.9 A-Axis

5.10 B-Axis

5.11 C-Axis

5.12 Trunnion Table/ Pallet Surface

5.13 Spindle

5.14 Tool Changer

5.15 Controls

5.16 Additional Features or Accessories

5.17 Ranges and Capacities

5.18 Accuracies

6. TEST STANDARDS AND SPECIFICATIONS

6.1 Responsibility for Inspections

6.2 Operational Test

6.3 Performance Test Requirements at RIA

6.4 Ball-Bar Standard

7. APPROVAL/SHIPPING

7.1 Shipping

7.2 Installation

7.3 Completion

8. TRAINING

8.1 Schedule

8.2 Location

8.3 Type

9. SERVICE

9.1 Service/Support Requirements

1. GENERAL SYSTEM DESCRIPTION

• This project is for the provision and installation of all materials, labor, and auxiliary components necessary for a Multi-Axis Machine. The machine and the trunnion table sitting in front of it shall account for a minimum of 7 Axis of machining capability. The machine is to be installed at the Rock Island Arsenal Joint Manufacturing and Technology Center.

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal.

Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.2 National Standards and Specifications

The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.2.1 Occupational Safety and Health Act of 1970 (OSHA).

2.2.2 American Society of Testing and Materials (ASTM).

2.2.3 American Society of Mechanical Engineers (ASME).

2.2.4 American National Standards Institute (ANSI).

2.2.5 National Electrical Manufacturers Association Standards (NEMA).

2.2.6 Electronic Industries Association (EIA).

2.2.7 Institute of Electrical and Electronics Engineers (IEEE).

2.2.8 American Code for Information Exchange (ASCII).

2.2.9 American Welding Society (AWS).

2.2.10 American Gear Manufacturers Association (AGMA).

2.2.11 National Fire Protection Association (NFPA).

2.2.11.1 NFPA-70 National Electrical Code

2.2.11.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.12 International Standards Organization (ISO).

3. DESIGN

3.1 Ownership

3.1.1 This equipment is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

3.2 General Design Standards

3.2.1 DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve require

3.2.2 Cements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a

10-hp motor would not be acceptable.

3.2.3 UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English-

US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.2.4 ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable): Manufacturer

Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine Weight. This information is necessary for compliance with the governments Unique Identification Program

(UID).

3.2.5 DATA PLATES: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering.

Lettering shall be permanent and have a contrasting background.

3.2.6 ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government

Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID 2-

D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

3.2.7 UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the http://dodprocurementtoolbox.com/site/uidregistry/ https://wawftraining.eb.mil/ documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.2.8 UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2.9 UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

3.2.9.1 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

3.2.9.2 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

3.2.9.3 Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. This is necessary to maintain IEPA compliance.

3.2.9.4 Connection of 1.5-in diameter natural gas pipe to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional.

3.2.9.5 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

3.2.10 ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.2.11 CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.2.12 SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

3.2.13 DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

3.2.14 NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

3.2.15 COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.2.16 REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.2.17 CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.2.18 SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.2.19 FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.2.20 CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.2.21 PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.2.22 LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

3.2.22.1 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be

English and the units shall be English standard (i.e. pints, quarts, and gallons)

3.2.22.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.2.22.2.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.2.22.2.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.2.22.2.3 All filters shall be either cleanable or replaceable.

3.2.22.2.4 All pumps shall be self-priming.

3.2.23 FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

3.2.23.1 Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

3.2.23.2 Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load.

3.2.24 HYDRAULICS: The machine will be equipped with a hydraulic system and the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir. All components necessary to make the system completely functional shall be provided.

3.2.24.1 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

3.2.24.2 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions.

3.2.24.3 Protection shall be provided to prevent damage to components.

3.2.24.4 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

3.2.24.5 Anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads.

3.2.24.6 The hydraulic reservoir shall be provided with means for draining and cleaning.

3.2.24.7 Means shall be provided to enable the operator to determine fluid level.

3.2.24.8 Each hydraulic system shall include a filter, which shall be either cleanable or replaceable.

3.2.24.9 All pumps shall be self-priming.

3.2.25 COOLANT: The machine will be equipped with a coolant system and it shall be equipped with external flood coolant capabilities, as a minimum. Machines using cutting tools shall be equipped with both through the tool and external flood coolant capabilities. Coolant on/off shall be a machine control function.

3.2.25.1 The coolant systems shall include all necessary components necessary to provide completely functional systems, with sufficient capacity to give satisfactory service and provide adequate pressure and flow under normal operating conditions.

3.2.25.2 Coolant troughs and chip screens shall be provided around the machine table base to trap, direct, and return the coolant to the reservoir. An easily removable strainer shall be provided in the return line to the reservoir. "Easily removable" is defined as being removable after no more than 5-min of work by experienced personnel.

3.2.25.3 All machine coolant systems and their components shall provide drip-proof coolant delivery to the coolant point of discharge. In addition, the machine shall be designed and constructed to prevent coolant from escaping the confines of the machine or leaking to the floor when producing work-pieces of a size within the dimensions of the machine table.

3.2.26 CHIP REMOVAL: A chip conveyor is required and it shall be an automatic, reversible chip removal unit shall be provided, by the contractor, capable of conveying various types of ferrous and nonferrous chips from the entire work area of the machine to a suitable container outside of the machine without manual aid.

3.2.26.1 The unit shall be of watertight construction.

3.2.26.2 The conveyor belt shall be equipped with a master link, easily disconnected, allowing the belt to be removed for maintenance purposes. All pillow block bearings shall be mounted for ease of replacement. Pillow block bearings shall be fitted with external lubrication fittings. The system shall allow manual movement of the conveyor belt for maintenance.

3.2.26.3 The conveyor shall facilitate draining of excess coolant back to the sump before chips are discharged.

3.2.26.4 The height of the discharge chute from the floor shall be not less than 49.5-in.

3.2.26.5 The chip removal unit shall be installed in a manner facilitating collection of chips from the entire work area without interfering with normal operation of the machine.

3.2.26.6 As a minimum, the chip removal unit shall be provided with an on/off switch or buttons, stop button, and reversing switch.

3.2.27 MOTORS:

3.2.27.1 All motors shall be rated for continuous duty.

3.2.27.2 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

3.2.27.3 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.2.27.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.2.27.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.2.28 DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.2.29 HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.2.30 CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

3.2.31 FOUNDATION: A separate foundation is required to meet alignment tolerances and/or to provide isolation of the system. Also see Documentation – Installation and Preparation.

3.3 Safety, Security and Environmental

3.3.1 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description;

Additional requirements will be placed on contractors requiring access to the Army Network, or

Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide

Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

3.3.1.1 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by

Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

3.3.1.1.1 Access to RIA: Contractor and all subcontractor employees performing work at

RIA shall comply with adjudication standards and procedures using the National Crime

Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening

Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The JMTC POC shall provide guidance to complete the

Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

3.3.1.1.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock

Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti-

Terrorism Training.

3.3.1.1.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

3.3.1.1.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the JMTC POC, or paced in a drop box at an RIA-

JMTC access point.

3.3.1.2 Security Training: The contractor shall complete the following training:

3.3.1.2.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The JMTC POC will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center

(RIA-JMTC) AT Level I Awareness Training and assure that the training is complete.

The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.1.2.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

3.3.1.3 For Contractors requiring Common Access Card (CAC): Before CAC issuance, the contractor employee requires a favorably adjudicated National Agency Check with Inquiries

(NACI) or an equivalent or higher investigation in accordance with Army Directive 2014-05.

The contractor employee will be issued a CAC only if duties involve one of the following:

(1) Both physical access to a DoD facility and access, via logon, to DoD networks onsite, or remotely or (2) Remote access via logon, to a DoD network using DoD-approved remote access procedures, or (3) Physical access to multiple DoD facilities or multiple Non-DoD

Federally controlled facilities on behalf of the DoD on a recurring basis for a period of 6-months, or more. At the discretion of the sponsoring activity, an initial CAC may be issued based on a favorable review of the FBI fingerprint check and a successfully scheduled NACI at the Office of Personnel Management. Contractors needing a NACI or equivalent investigation or higher investigation will coordinate this investigation through their JMTC

POC. Contractor personnel shall turn in CAC cards upon completion of their contractual obligations, or at the request by the JMTC POC, or at the request of the Contracting Officer.

3.3.2 FEDERAL MARIJUANA LAWS REMAIN UNCHANGED: Note: Rock Island Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering

Rock Island Arsenal.

3.3.3 FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation

Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

3.3.4 INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

3.3.5 MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl

(PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.6 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard

OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.3.7 SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.8 LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.9 TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.10 WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.11 ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

3.3.12 BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.13 EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

3.3.14 CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.3.15 OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.3.16 AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed

85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.4 Responsibilities

3.4.1 SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for this process.

3.4.2 SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system.

Examples would include, but are not limited to, buried sewer lines, standing water, and so forth.

The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

4. INFORMATION TECHNOLOGY SYSTEMS AND SUPPORT

4.1 Installation IT Support:

4.1.1 PERSONNEL: RIA-JMTC will not provide the technician credentials to access the workstation. Access to the workstation will be provided by the RIA-JMTC IT Support Staff escort. Removable Media e.g., CD/DVD/USB/SD/External hard drive will be scanned prior to use. Programs and software must be ran from RIA-JMTC approved/provided media or

CD/DVD(s). Contractor Devices will not be allowed to connect to the RIA-JMTC network nor will they be allowed to connect to RIA-JMTC equipment other than to scan and transfer media.

4.2 Inspection/Final Acceptance:

4.2.1 LICENSING: The software/ hardware license shall not have an internet connection. A license dongle or license file must be provided for offline use.

4.3 Media/ Devices

4.3.1 REMOVABLE MEDIA: Removable media consists of the following: CD, DVD, USB, SD, and External Hard Drives. Removable media shall be scanned prior to use. Programs and software must be ran from RIA-JMTC approved/ provided media or CD/ DVD(s).

4.3.2 CONTRACTOR DEVICES: Contractor Devices will not be allowed to connect to the

RIA-JMTC network and they will not be allowed to connect to RIA-JMTC equipment other than to scan and transfer media.

4.3.3 NON-GOVERNMENT OWNED SYSTEMS OR DEVICES: The contractor shall comply with AR 25-1 and AR 25-2. The contractor shall not install or connect non-Government-owned computing systems or devices to Government networks without the government representative’s coordination and obtaining the proper authorization from the appropriate

Information System Security Manager (ISSM), ensuring that all software has a Government

Assess Only Authorization. The non-Government-owned computing systems or devices include, but are not limited to, personal or Contractor-owned thumb drives e.g., memory sticks, flash drives, Universal Serial Bus (USB) drives, jump drives, pen drives, removable or external hard drives, Personal Digital Assistants (PDA), PC Cards/Express Cards, MP3 players, cell phones, digital media, floppy disks, compact disc (CD)/digital video disk (DVD) burners, optical recordings, photo flash cards, laptops, or any devices that can store data.

4.4 Information Assurance and Accreditation:

4.4.1 Non-Government-Owned computing systems or devices: The Contractor shall comply with AR 25-1 and AR 25-2. The Contractor shall not install or connect non-Government-owned computing systems or devices to Government networks without the JMTC POC’s coordinating and obtaining proper authorization from the appropriate Information System Security Manager

(ISSM), ensuring that all software has a Government Assess Only Authorization. The non-

Government-owned computing systems or devices include, but are not limited to, personal or

Contractor-owned thumb drives e.g., memory sticks, flash drives, Universal Serial Bus (USB) drives, jump drives, pen drives, removable or external hard drives, Personal Digital Assistants

(PDA), PC Cards/Express Cards, MP3 players, cell phones, digital media, floppy disks, compact disc (CD)/digital video disk (DVD) burners, optical recordings, photo flash cards, laptops, or any devices that can store data.

4.4.2 System Accreditation and Re-Accreditation: The Contractor shall assist in providing system accreditation documentation such as required artifacts and shall answer technical questions required for registration for accreditation. All documents shall be IAW Chapter 5, and

Appendices D and E, AR 25-2, Information Systems Security (dated 3 August 2007) and DOD

Instruction 8510.01, Risk Management Framework (RMF) Program or future DOD regulation that supersedes these regulations. The Contractor shall assist in performing yearly reviews of the accreditation, or whenever changes/additions are made to the system. The Contractor will assist in preparing risk assessments, as required.

5. CLIN 0001- SEVEN AXIS MACHINE AND TILT ROTARY TABLE

Equipment: The supplier shall furnish all equipment normally considered by him to be standard for his machine unless identified in this requirement to be of specific manufacture. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication.

The machine shall be a numerically controlled, multifunction, 7 axis machine, complete with automatic tool changer, control pendant, machine trunnion table, and chip conveyor. The machine shall be capable of automatically performing in any sequence, milling, drilling, tapping, boring, and counter-boring operations. It shall be capable of controlling the axis motions independently, and in any combination of simultaneous controlled motions. The machine and its numerical control unit shall constitute a completely functional system with operations programmable by means of USB port, Ethernet connection, downloading from a host computer through RS232 serial port, and manual data input (MDI). The system shall be used to machine large weldments, mild steel, stainless steel, bronze, aluminum, titanium, and possibly carbon-fiber composite material. It shall be an open system without an enclosure that could restrict loading of parts and fixtures.

5.1 Dimensions:

5.1.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 16-ft wide by 16-ft high, and shall not exceed 25-ft in length.

5.1.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed

25,000-lbs.

5.1.3 INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 55-ft wide and 45-ft long, excluding the operator’s area. Width is defined as front to back from the aisleway position.

5.2 Machine Base

5.2.1 CONSTRUCTION: The base shall be a heavily ribbed, close grained iron casting. The base shall provide access to components housed within for adjustment and servicing.

5.2.2 HARDWARE: All necessary leveling wedges, bolts, nuts, and foundation hardware required for the installation shall be furnished by the manufacturer.

5.3 Axis Definition Drawings

The following drawings (Figure 1 and Figure 2) are rough representations of the axis definitions used in this statement of work.

Figure 1: Column Axis

Figure 2: Trunnion Axis

5.4 X-Axis

5.4.1 AXIS DEFINITION: The X-Axis represents the horizontal travel of the column parallel with the face of the spindle.

5.4.2 FEED RATE: The system shall provide a maximum rapid traverse feed rate of not less than 1100-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

5.4.3 FABRICATION: The frame shall be stress-relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower cuts. This shall be a box style construction only, to maintain rigidity of the system over the life of the equipment.

The height of any bearing supporting surfaces shall be such that the moving load is fully supported and shall not overhang the frame in any position within the machine's rated travel.

5.4.4 DRIVE: The drive system shall be a rack and pinion system for X-Axis travel of the column on the guide rails. The system shall provide no less than 6,7000-lbs of axial force.

5.4.5 CONTAMINATION: Wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement. Also, each axis shall be provided with a cover system that will prevent large contamination reaching the guide blocks, rails, and drive systems.

5.5 Y-Axis

5.5.1 AXIS DEFINITION: The Y-Axis represents the travel of the spindle in the vertical direction on the column.

5.5.2 FEED RATE: The system shall provide a maximum traverse rate of not less than 472-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

5.5.3 FABRICATION: The frame shall be stress-relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower cuts. This shall be a box style construction only, to maintain rigidity of the system over the life of the equipment.

The height of any bearing supporting surfaces shall be such that the moving load is fully supported and shall not overhang the frame in any position within the machine's rated travel.

5.5.4 BEARINGS: The frame shall be supported on no less than (2) hardened, preloaded linear guides. These shall be replaceable, maintenance-free, lubed-for-life bearings and rails or lubricated from a centralized, automated system as described in section three of this purchase description. An alternative to linear guides is scraped ways. All slide surfaces shall be steel, hardened to a minimum of 60 Rockwell C and ground. Way linear axis shall be provided with adjustable, preloaded, recirculating roller bearings to support and guide the sliding elements or scraped box ways. Gibs shall not be deemed acceptable.

5.5.5 DRIVE: Motion shall be powered by an AC or DC brushless motor(s) driving a precision, dual ball screw system with a minimum diameter not less than 3.9 inches. The end of each screw opposite the motors, or in the case of gear driven screws both ends, shall be anchored in preloaded, antifriction, ball and/ or roller bearings, providing stiffness for servo response.

Position feedback shall be accomplished through the use of glass scales with positive air pressure system to prevent contamination. The system shall provide no less than 6,700-lb of axial force.

5.5.6 CONTAMINATION: Wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement. Also, each axis shall be provided with a cover system that will prevent large contamination reaching the guide blocks, rails, and ballscrews.

5.6 Z1-Axis

5.6.1 AXIS DEFINITION: The Z1-axis shall be defined as the extension and retraction of the ram out of the machine column.

5.6.2 COLUMN/SPINDLE: The column on our current machines moves in and out on a Z axis which allows the spindle to move towards and away from the part that is being machined. The new machine shall have this capability by either the column moving or by means of the spindle traversing out of the column via a rigid style ram system. The ram shall be designed in such a manner that the machining operation does not lose rigid function at full extension of the spindle.

5.6.3 FEED RATES: The system shall provide a maximum traverse rate of not less than 750-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

5.6.4 BEARINGS: The frame shall be supported on no less than (2) hardened, preloaded linear guides. These shall be replaceable, maintenance-free, lubed-for-life bearings and rails or lubricated from a centralized, automated system as described in section three of this purchase description. An alternative to linear guides is scraped ways. All slide surfaces shall be steel, hardened to a minimum of 60 Rockwell C and ground. Way linear axis shall be provided with adjustable, preloaded, recirculating roller bearings to support and guide the sliding elements or scraped box ways. Gibs shall not be deemed acceptable.

5.6.5 DRIVE: Motion shall be powered by an AC or DC brushless motor(s) driving a precision, preloaded ball screw(s) with a minimum diameter of 3.1-in. The system shall provide no less than 12,600 lbs of axial force.

5.6.6 CONTAMINATION: Wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement. Also, each axis shall be provided with a cover system that will prevent large contamination reaching the guide blocks, rails, and ballscrews.

5.7 Z2-Axis

5.7.1 AXIS DEFINITION: The Z2-Axis shall be defined as the extension and retraction of the spindle out of the ram extension.

5.7.2 COLUMN/SPINDLE: The column on our current machines moves in and out on a Z axis which allows the spindle to move towards and away from the part that is being machined. The new machine shall have this capability by either the column moving or by means of the spindle traversing out of the column via a rigid style ram system. The ram shall be designed in such a manner that the machining operation does not lose rigid function at full extension of the spindle.

5.7.3 FEED RATES: The system shall provide a maximum traverse rate of not less than 750-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

5.7.4 BEARINGS: The frame shall be supported on no less than (2) hardened, preloaded linear guides. These shall be replaceable, maintenance-free, lubed-for-life bearings and rails or lubricated from a centralized, automated system as described in section three of this purchase description. An alternative to linear guides is scraped ways. All slide surfaces shall be steel, hardened to a minimum of 60 Rockwell C and ground. Way linear axis shall be provided with adjustable, preloaded, recirculating roller bearings to support and guide the sliding elements or scraped box ways. Gibs shall not be deemed acceptable.

5.7.5 DRIVE: Motion shall be powered by an AC or DC brushless motor(s) driving a precision, preloaded ball screw(s) with a minimum diameter of 3.1-in. The system shall provide no less than 12,600 lbs of axial force.

5.7.6 CONTAMINATION: Wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement. Also, each axis shall be provided with a cover system that will prevent large contamination reaching the guide blocks, rails, and ballscrews.

5.8 W-Axis

5.8.1 AXIS DEFINITION: The W-Axis shall be defined as the movement of the trunnion table on its auxiliary slide parallel to the extension axis of the spindle.

5.9 A-Axis

5.9.1 AXIS DEFINITION: The A-Axis shall be defined as the horizontal rotational movement of the rotary trunnion table utilized to hold the work pallet. The rotation of the trunnion table shall be controlled clockwise and counter-clockwise by programmed numerical control and by

MDI.

5.10 B-Axis

5.10.1 AXIS DEFINITION: The B-Axis shall be defined as the tilting axis of the trunnion table towards the face of the spindle.

5.11 C-Axis

5.11.1 AXIS DEFINITION: The C-Axis shall be defined as the rotational axis of the spindle.

5.12 Trunnion Table/ Pallet Surface

5.12.1 FIXTURE MOUNTING SIZE: The mounting surface of the trunnion table shall be able to accept a work pallet of at least 60-in x 120-in dimension.

5.12.2 WORK SURFACE T-SLOTS: The pallet surface shall have t-slots that are 0.875-in in width.

5.12.3 CROSS-SLOTS: The work table shall be an English dim T-slot table. The cross slots shall run perpendicular from the t slots and shall include one sine key slot in the middle of the table or 3 dividing the 1/3 in.

5.12.4 LOCATING HOLE: there shall be a center counter bore on the tables to allow for quick fixture locating on the rotational centerline of the pallets. It shall be at least 2”

5.12.5 FLATNESS: The interface of the pallet work surface and the trunnion table shall be flat and true so that, when a pallet is secured on the trunnion table, the pallet surface shall have a flatness of no more than 0.0005-in-per-ft concave, not to exceed 0.0022-in total across the entire table top.

5.13 Spindle

5.13.1 DRIVE: The spindle shall be equipped with an infinitely variable speed, Ac spindle motor. Full horsepower (torque) shall be achieved at or below 114-rpm. All spindle drive shafts and gearing shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground. The spindle shall be capable of infinitely variable speeds. Spindle head shafts shall be mounted in precision ball and/or roller bearings.

5.13.2 MATERIAL: The spindle shall be machined from alloy steel, precision ground and fitted in the spindle head assembly. It shall be a minimum of 6.1-in in diameter, and shall be mounted in a minimum of three, duplex mounted, Class 7 or better, angular contact bearings. Bearing preload shall be adjustable.

5.13.3 SPINDLE LUBRICATION: The spindle head shall be provided with a separate, positive means of lubricating the components housed within it. This shall be an air/oil system.

5.13.4 COOLING: The spindle shall have a thermal controlling cooling jacket system. This will extend the life of the spindle and minimize distortion during heavy machining operations. The cooling may be combined with the spindle lubrication system.

5.13.5 FLOOD COOLANT: The system shall include a flood coolant system or air blast system around the spindle nose for removal of chip nests prior to tool exchange.

5.13.6 THROUGH SPINDLE COOLANT: The system shall include a flood coolant system through the spindle nose for removal of chip nests prior to tool exchange.

5.13.7 SPINDLE NOSE: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground.

5.13.8 TOOL HOLDER: The Main Spindle shall be 50 Big Plus and the speed up attachment shall be Capto C6. If Capto C6 is unavailable then 40 Taper shall be acceptable.

5.13.9 OREINTATION: Spindle orientation shall be provided, with the ability to stop within 1-deg of any given radial position.

5.13.10 SPEED: The spindle shall have an infinitely variable speed of up to at least 10,000 RPM.

This can be by means of a speed up attachment. If a speed increaser is necessary, the base spindle speed shall have a max speed of at least 3500 RPM. Any speed increaser used shall maintain capability for through-spindle air/ coolant. If a separate spindle/ attachment is used, all necessary means/ components needed to mount and attach the increaser to the main spindle shall be provided.