Attachment 0001 RIPD E4000-23-9-06 - SOW.docx

VERTICAL MACHINING CENTER

GENERAL SYSTEM DESCRIPTION

The purpose of this project is to provide precision machining capacity to support the Inner Office Business units. The average age of four mills in these business units is over 43 years where the expected life for these machines is 15 to 30 years. The systems provided shall be High Speed CNC vertical machining centers with CT-40 tool holders, chip conveyors, through spindle coolant, necessary components for future addition of a 4th axis table, and all the accessories necessary for safe and efficient operation. Request four Haas VF-3SSYT mills or equivalent.

STANDARDS AND PUBLICATIONS

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.

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.

Occupational Safety and Health Act of 1970 (OSHA).

American Society of Testing and Materials (ASTM).

American Society of Mechanical Engineers (ASME).

American National Standards Institute (ANSI).

National Electrical Manufacturers Association Standards (NEMA).

Electronic Industries Association (EIA).

Institute of Electrical and Electronics Engineers (IEEE).

American Code for Information Exchange (ASCII).

American Welding Society (AWS).

American Gear Manufacturers Association (AGMA).

National Fire Protection Association (NFPA).

1.1.1.1 NFPA-70 National Electrical Code

1.1.1.2 NFPA-79 Electrical Standard for Industrial Machinery.

International Standards Organization (ISO).

DESIGN

Ownership 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.

General Design Standards DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements 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.

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.

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).

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.

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.

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 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.

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.

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

1.1.1.3 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.

1.1.1.4 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.

1.1.1.5 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.

1.1.1.6 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.

1.1.1.7 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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

1.1.1.8 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)

1.1.1.9 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.

1.1.1.9.1 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.

1.1.1.9.2 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.

1.1.1.9.3 All filters shall be either cleanable or replaceable.

1.1.1.9.4 All pumps shall be self-priming.

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.

1.1.1.10 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.

1.1.1.11 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.

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.

1.1.1.12 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.

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

1.1.1.14 Protection shall be provided to prevent damage to components.

1.1.1.15 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.

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

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

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

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

1.1.1.20 All pumps shall be self-priming.

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.

1.1.1.21 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.

1.1.1.22 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.

1.1.1.23 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.

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.

1.1.1.24 The unit shall be of watertight construction.

1.1.1.25 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.

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

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

1.1.1.28 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.

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

MOTORS:

1.1.1.30 All motors shall be rated for continuous duty.

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

1.1.1.32 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.

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

1.1.1.34 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.

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.

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.

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

FOUNDATION: The requirement for a separate foundation is permissible, if necessary to meet the specified alignment tolerances, to provide isolation, or to conform to a standard system configuration. The contractor shall describe the foundation requirements at the time of bid. RIA-JMTC shall be responsible for installation of the foundation based upon the drawings provided by the vendor Safety, Security and Environmental 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.

1.1.1.35 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.

1.1.1.35.1 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 COR shall provide guidance to complete the Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

1.1.1.35.2 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.

1.1.1.35.3 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.

1.1.1.35.4 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 COR, or paced in a drop box at a RIA-JMTC access point.

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

1.1.1.36.1 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 COR 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.

1.1.1.36.2 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.

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

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.

REAL ID: Starting 03-May-2023 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

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.

MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

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.

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.

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.

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

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

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.

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.

CONTROL GUARDS: Controls shall be guarded against accidental operation.

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.

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.

COMPONENT SPECIFICATION

This is to be a Vertical Machining Center appropriately sized to manufacture small parts, accommodate the ball-lock fixture plates, allow addition of a fully functional 4th axis, and perform high speed machining. This shall include all equipment which would normally be provided by the manufacturer, even if not described herein.

Dimensions:

DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high, and shall not exceed 25-ft in length.

COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 15,000-lbs.

INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 15-ft long and 30-ft long, excluding the operator’s area. Maximum height shall not exceed 10-ft. Width is defined as front to back from the operator’s normal operating position.

Machine Base:

CONSTRUCTION: The base shall be a heavily ribbed, close grained casting and shall form a rigid structure supporting the table and column. This shall be a box style construction only, to maintain rigidity of the system over the life of the equipment.

ACCESS: The base shall provide access to components housed within for adjustment and servicing.

SUPPORT: The length of the base and bed-ways shall be such that the work table saddle and column are fully supported and shall not overhang the bed in any position within the machine's rated travel. The bed shall be integrally made with the column base or shall be separately made and machined to be rigidly attached to the column base.

HARDWARE/ANCHORING KIT: Means shall be provided for leveling and securing the base to the floor. All necessary leveling wedges, bolts, nuts, and other hardware required for the installation shall be furnished by the manufacturer.

Machine Table:

POSITION DRIVE: The table shall provide X and Y-axes motion powered by motors driving precision, preloaded ball screws with a minimum diameter of 1.25 inches.

1.1.1.38 Power shall be transmitted to the screws through hardened and ground gearing or by direct coupling to DC servo motors.

1.1.1.39 The end of the screw opposite the motor, 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.

1.1.1.40 Position feedback shall have a linear resolution of 0.0001-in or less.

WORK AREA: The table work area shall be no less than 48-in side-to-side and no less than 18-in front-to-back.

TRAVEL: The table shall be capable of simultaneous motion in both the X-Axis and the Y-Axis directions. The X-Axis shall be capable of a minimum of 40-in of travel. The Y-Axis shall be capable of a minimum of 26-in of travel.

PAYLOAD: The table shall be capable of supporting, during full-load cutting, a payload of 1750-lbs minimum. Payload is defined as the weight of the material to be machined combined with the weight of any fixtures used to hold/support the material.

WAY COVERS: Both X and Y-axes shall be equipped with telescoping, steel way covers.

FIXTURE MOUNTING: The table top shall be provided with (7), longitudinal, T-slots running the full length of the table, machined to accept .625-in T-nuts, and shall be spaced parallel to each other on 3.15-in centers held within .005 inch true position throughout the entire length. The center T-slot shall be located on the table centerline within .001 inch of true position throughout its length.

TABLE SUPPORT: Table and way configuration shall be such that the table cannot be lifted from its ways by machining forces. Table saddle configuration shall completely support the table, with no table overhang, throughout X-axis travel.

ENCLOSURE: The work area perimeter shall be enclosed by chip and coolant shields. A door shall be provided, allowing the operator access to the work area. This shall be interlocked to the machine controls to prevent operation with the doors open.

Column:

FABRICATION: The column shall be a close grained casting forming a rigid structure supporting the spindle head. The column 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.

VERTICAL WAYS: The column shall be provided with vertical ways supporting and guiding the spindle head.

VERTICAL DRIVES: Spindle head motion shall be provided by means in accordance with paragraph 4.3.1.

VERTICAL COVERS: The ball screw(s) providing Z axis travel shall be covered both above and below the spindle head, in a manner affording protection from extraneous material.

Spindle Head:

TRAVEL: The column shall allow Z-Axis travel of no less than 25-in of travel. This motion shall be capable of being performed simultaneously with X-Axis and Y-Axis travel.

FABRICATION: The spindle head shall be a close grained casting or steel fabrication, forming a rigid structure. The spindle head shall be stress-relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower cuts.

MOTION: The spindle head shall move vertically on the column ways for positioning and machining operations, providing the Z-axis motion. The spindle head shall be counterbalanced, relieving the ball screw of the spindle head weight. All spindle head and spindle functions shall be numerically controlled by the CNC control.

LOCATION: Position feedback shall have a linear resolution of 0.0001-in or less.

DRIVE: The spindle head shall be equipped with a variable speed motor rated for 30-hp continuous duty.

1.1.1.41 The spindle shall be direct driven for increased torque in low range and enhanced performance in the high range. This will also reduce the number of parts and improve maintainability of the equipment. Belt drives will not be deemed acceptable.

1.1.1.42 All spindle drive shafts shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground. Spindle head shafts shall be mounted in precision ball and/or roller bearings.

SPEED RANGE: The spindle shall be capable of variable speeds of at least as slow as 50-rpm to at least as fast as 12,000-rpm. This shall be programmable in increments of 1-rpm or finer.

BEARINGS: The spindle shall be mounted in a minimum of three, duplex mounted, Class 7 or better, angular contact bearings. Bearing preload shall be adjustable.

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

TAPER: The spindle nose shall provide positive tool-holder location for #40 taper, Cat Std tooling. Positive, pullback and retention of the tool-holder shall be provided. Provision shall be made to allow manual loading of tool holders into the spindle nose, as well as automatic loading, using the tool changer.

DEAD ZONE: The end of the spindle nose shall reach within 6.38" of the machine table face.

Tool Changer:

TYPE: Side mount style, high speed tool changer. Tool-to-Tool time of 4.2-sec average.

NUMBER OF TOOLS: This system shall be capable of simultaneously holding (30+1) or more tools of a maximum 2.5-in diameter.

VIBRATION: The tool changer shall be solidly mounted with vibrations sufficiently dampened to ensure proper alignment with the spindle, and ability to change tools during cutting cycles without transferring vibrations into the machine tool or work-piece.

FLOOR MOUNTING: If the tool changer is floor mounted, means shall be provided for securing the unit to the foundation. All necessary leveling devices and hold down bolts required for the installation shall be provided by the manufacturer. Apparatus for precision locating and holding the unit in place shall be provided by the manufacturer.

MACHINE MOUNTING: If the tool changer is mounted on the machine, the manufacturer shall provide means to allow safe access to the magazine and changing of tools INTERFACE: The tool changer system shall be capable of tool selection automatically by MDI and by command in the parts program.

WEIGHT CAPACITY: The system shall be capable of changing tools weighing as much as 12-lbs.

TOOL DIAMETER: The magazine shall be capable of accommodating tools with a minimum diameter of 5.0-in, with adjacent sockets empty.

ACCESS: It shall be possible to move the next tool to be used into position while the machine is in a cutting cycle.

Controls:

DRIVE MANUFACTURERS: Spindle drive motor and axis drive servo motors shall be designed and built by a single vendor. This shall include the motor controllers. Mixing of one controller brand with a different manufacturer of motor shall not be acceptable.

ENCODERS: Positioning shall be maintained by an absolute encoder on each axis of motion. This shall be designed such that in the event of a power loss, the system shall maintain position data sufficient to continue operation when power is restored without the need to re-zero (home) the machine.

DATA INPUT: The control shall be designed to operate from memory loaded from a USB Port; information down loaded from a host computer via serial port; and information loaded from Manual Data Input (MDI) using the keyboard.

CONSTRUCTION: The control shall utilize solid-state transistorized or integrated and modular construction. Plug-in circuit boards shall be coded to facilitate identification and location in the control and shall be arranged as convenient plug-in elements of quick disconnect modules with minimum connectors. Built-in test points, test procedures and instructions shall be provided for isolation and identification of defective components and circuitry.

MEMORY: The control shall be provided with a minimum of 1-gigabyte of usable part program storage. Control memory shall be expandable in discrete increments up to 16-megabytes, as a minimum. Control memory shall be non-volatile.

POWER RECOVERY: The control shall recover from power outages. Upon power resumption, the control shall automatically reload/reboot the executive and bring itself back, by operator initiation, to a state where the operator can initiate part program load and restart.

MODES: Provision shall be made to allow operation in automatic, single block, Manual Data Input (MDI) and manual modes.

INPUT: It shall be possible to MDI in symbolic RS 274D data format and execute the statement in a record by record mode of operation, that is, one line at a time. If the MDI mode interrupts an automatic or single block mode, provision shall be made to re-enter at the point of interruption.

The control shall be capable of four-axes positioning and contouring (with optional B-axis when specified); helical (rise per radian) programming; and inverting X, Y, or X and Y axes to produce mirror image movements without any required change in the original program commands.

Feed rates shall be programmable in both inch and metric systems.

A block delete and record delete feature shall be included in the control to allow specific routines to be bypassed.

The operator shall have the capability of jogging linear axes incrementally in steps of 0.0001 inch, 0.001 inch, and 0.01 inch, and continuous.

The control shall be capable of controlling acceleration and deceleration of axis feed rates and traverse moves, maximizing axes movement speeds, while reducing stress to the machine.

The control shall be equipped to provide manual rapid traverse override, allowing positioning moves in a cycle to be slowed. It shall be possible to override from 0-100 percent of the programmed value, as a minimum, unless a feed hold is provided. If a feed hold is provided, override shall be from 1-100 percent of the programmed value, as a minimum, or a button by be provided which will override the rapid traverse a fixed amount based on a machine parameter. The button shall be capable of reducing the rapid traverse to no more than 100 inches per minute.

The control shall be equipped to provide manual feed rate override from 1-100 percent of the programmed value, as a minimum, unless a feed hold is provided. If a feed-hold is provided, override shall be from 1-100 percent of programmed value, as a minimum. This shall be by potentiometer or tool table data override, as elected by the operator.

The control shall be equipped to provide manual spindle speed override from 50-120 percent of the programmed value, as a minimum.

The control shall be capable of accepting a programmed dwell of a minimum of 99.99-sec.

The control shall be provided with a tool recovery method, which shall allow the operator to jog away from the work to check the tool during any cutting move, including thread cutting and canned cycles, and return the tool to the correct position automatically. Threading cycles shall restart at the beginning of the threading cycle and return the tool to the correct position automatically.

Ranges and Capacities:

TRAVEL:

1.1.1.43 Minimum X-Axis Travel = 40-in.

1.1.1.44 Minimum Y-Axis Travel = 26-in.

1.1.1.45 Minimum Z-Axis Travel = 25-in.

1.1.1.46 Minimum Spindle Nose to Table Surface = 4.2-in maximum

TABLE:

1.1.1.47 Table Width = 24.0-in. minimum.

1.1.1.48 Table Depth = 54.0-in minimum.

1.1.1.49 Payload Capacity = 1750-lbs maximum.

SPINDLE:

1.1.1.50 Spindle Minimum Operating Speed: 50-rpm or less.

1.1.1.51 Spindle Maximum Operating Speed: 12,000-rpm or more.

1.1.1.52 Spindle Speed Increments: 1-rpm or finer.

1.1.1.53 Spindle Torque @ 2000-rpm = 90.0 ft-lbf.

1.1.1.54 Spindle Motor Power = 30-hp continuous duty minimum.

1.1.1.55 Spindle Taper Size = Cat-40.

FEED RATES:

1.1.1.56 Rapid Traverse = 1400-ipm minimum.

1.1.1.57 Cutting Feed Rate = 0.1-ipm to 833-ipm minimum range.

1.1.1.58 Jog Feed Rate = 500-ipm minimum.

ACCURACY:

1.1.1.59 Full Travel Positioning Accuracy: ±0.0002-in.

1.1.1.60 Repeatability: ±0.0001-in.

1.1.1.61 Spindle Radial Run-out: 0.0004-in TIR measured 1-in from spindle nose.

1.1.1.62 Spindle Face Axial Run-out: 0.0002-in TIR.

1.1.1.63 Z-Axis Parallel with Spindle Centerline: ±0.0005-in per 24-in of travel, not to exceed 0.0007-in overall.

1.1.1.64 X-Axis Travel Square with Z-Axis Travel: ±0.0005-in per 24-in of travel, not to exceed 0.001-in overall.

1.1.1.65 Y-Axis Travel, Square with X-Axis and Z-Axis Travel: ±0.0005-in per 24-in of travel, not to exceed 0.001-in overall.

1.1.1.66 Table Flatness: ±0.0005-in per 12-in length, not to exceed 0.001-in overall.

Additional Components and Features:

THROUGH SPINDLE COOLANT: The system shall include high pressure through spindle coolant. This shall provide coolant at a maximum pressure of no less than 300-psi.

CHIP CONVEYOR: The system shall include an integrated chip conveyor system to remove chips from the cutting area to a recycling bin. This shall automatically detect jams and cause the machine to react to clear the jam or stop the conveyor in order to prevent damage to the equipment. If the system is unsuccessful in clearing the jam automatically, the conveyor shall stop operation and alert the operator of the problem. Stopping the conveyor in the middle of an operation should not necessarily cause the machine itself to shut down.

HARD DRIVE & ETHERNET INTERFACE W/USB SUPPORT: The system shall include a 20-GB or larger hard drive for storage of program files, and a USB connection to support either a flash disk. The Ethernet component shall allow quick and easy data transmission between the machine and a network or PC. High-speed data transfers shall allow DNC of large files at up to 1000 blocks per second. The Ethernet interface shall work with Windows XP, ME, 2000 Pro & Server, NT 4.0, 98 and 95. IPX/SPX or TCP/IP protocol and be setup from the control screen.

VISUAL PROGRAMMING SYSTEM: The system shall include a graphical interface for creating simple G-code programs. The operator shall select the operation desired (e.g., bolt-hole circle or pocket milling), and then choose a part template from the display. The system will prompt the operator to fill in required data. (E.g. part dimensions, speeds and feeds, etc.) The system shall then generate the G-code program for the operation. The system shall allow the operator to modify the existing templates or create new templates. Using a conversational interface, the operator shall be able to insert correct G code commands, such as ”spindle forward “ from a menu, into the program.

VISUAL PROBING SYSTEM: The system shall integrate Renishaw's probing hardware and Inspection Plus software with the Visual Programming System. This shall improve the automated setup and inspection processes. Basic, everyday language in a conversational format shall guide the operator through the process, step by step. The operator shall input basic information in response to the prompts, and the control will do the programming. In addition to tool and part setups, the use of macros, which shall be included, and advanced programming methods shall allow for such operations as in-process tool and part inspection, first-off part measurement, and automatic compensation for thermal changes.

FULL 4TH AXIS CAPABILITY: The system shall include all wiring and controls necessary to support a fully integrated 4th-axis rotary table. The table itself is not part of this system, but may be added to the system at a later date as a simply plug-n-play rotary table or indexer. The table, when added, must support programming any angle, perform circular cuts on the outside of your parts, and/or machine complex contours such as impellers. The table, when added, shall run directly from the machine’s control, for seamless operation and uncomplicated programming. The addition of the table at a future date shall not utilize the same serial port as the DNC network connection. If an additional port is necessary for control of the 4th axis, it shall be provided as part of the system provided in response to this purchase description. The vendor shall identify makes and models which may be fully integrated as part of the system quote. This will allow RIA to evaluate possible future system expansion.

EARLY POWER FAILURE DETECTION: The system shall automatically detect power failure before the system is affected. It shall then react to prevent damage to the system, controls, tools, and fixtures. This may include, but is not limited to storing table position data to prevent the need to zero when power is restored, controlled stop and locking of the spindle to prevent dropping, etc.

LIGHTING: The system shall include high intensity lighting inside the work area to assist the operator in set-up and operation of the equipment.

Accessories:

TOOL HOLDER RACKS: The system shall include a rack system or stand to accommodate no less than (30+1) 40-taper tools and holders.

PULL STUDS: Each system shall include a full complement of pull-studs for through coolant spindle, CT40 holders. This means (1) for each socket in the tool changer.

APPROVAL/SHIPPING

Shipping RESPONSIBILITY: The contractor is responsible for delivery of the equipment to the Rock Island Arsenal. Adequate preserving of equipment surfaces, packing, marking, and skidding of materials for shipment shall be the responsibility of the contractor. If special lifting devices, such as hooks or eyes, are required for ease of handling, they shall be supplied with the equipment. Any special devices shall be returned to the contractor upon request only if they will not be required for future movement of the equipment, and at the contractor’s expense.

SHIPPING SCHEDULE: Be aware, the Rock Island Arsenal will only off-load equipment arriving between 6:00 am and 12:00 am (noon), local time on Mondays through Thursdays except holidays. For information concerning holidays, the contractor should consult the contracting officer. There is no place to stage transporting vehicles awaiting the arrival of contractors. All equipment shall be delivered at the same time, meaning the same day (multiple trucks are acceptable) unless pre-authorized to deliver on multiple days by the RIA-JMTC contracting officer.

RECEIVER: All shipments to Rock Island Arsenal including installation tools and/or replacement parts, as well as the original shipment of the equipment, shall be marked “ATTN: Mr. Kris Davis or Mr. Joe Carpentier, TARA-COT-P”.