Attachment 0001 RIPD Multi Tasking Machines FINAL.docx

25-1-04 MULTI-TASKING MACHINES

GENERAL SYSTEM DESCRIPTION

· The project is to replace (3) current multitasking machines installed in B220 with new units. The units shall include any auxiliary components (listed or not) in order to create a fully functioning system.

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 contractor shall conform and provide equipment conforming to all local and federal codes and standards applicable to the equipment they are providing based on location and purpose of equipment in effect on the date of the opening of solicitation. It is not the responsibility of the government to make modifications to ensure compliance.

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:

1.1.1.1 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.

1.1.1.2 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.

1.1.1.3 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.

1.1.1.4 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)

1.1.1.5 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.

1.1.1.5.1 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.

1.1.1.5.2 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.

1.1.1.5.3 All filters shall be either cleanable or replaceable.

1.1.1.5.4 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.

1.1.1.6 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.

1.1.1.7 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.

1.1.1.8 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.

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

1.1.1.10 Protection shall be provided to prevent damage to components.

1.1.1.11 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.

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

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

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

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

1.1.1.16 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.

1.1.1.17 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.

1.1.1.18 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.

1.1.1.19 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.

1.1.1.20 The unit shall be of watertight construction.

1.1.1.21 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.

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

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

1.1.1.24 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.

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

MOTORS:

1.1.1.26 All motors shall be rated for continuous duty.

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

1.1.1.28 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.

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

1.1.1.30 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 devices 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.

1.1.1.31 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.

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

1.1.1.31.2 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.

1.1.1.31.3 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.

1.1.1.31.4 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.

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

1.1.1.32.1 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.

1.1.1.32.2 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.

1.1.1.33 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-2025 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

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.

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 but not limited to conforming to confined space work requirements when applicable and wearing of Personal Protective Equipment (PPE) where designated.

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.

Responsibilities 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.

COMPONENT SPECIFICATION

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.

Dimensions:

DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high.

COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 40,000-lbs.

Bed CONSTRUCTION: The bed/base shall be a heavily ribbed, close grained casting and shall form a rigid structure supporting the C1-axis main spindle head, W-axis second spindle and the Z-axis milling spindle carriage. The bed/base shall provide access to components housed within for adjustment and servicing. The length of the base and bed ways shall be such that the spindle, tailstock and cross-slide are fully supported and shall not overhang the bed in any position within the machine's rated travel. Means shall be provided for leveling the securing the base on the foundation.

MOUNTING: The bed/base shall be anchored to the foundation using a chemical anchoring system. (Can type anchoring shall not be considered acceptable.)

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

Lathe Main Spindle (C1-Axis) AXIS DEFINITION: This shall be a horizontal centerline rotational axis.

DRIVE: The main spindle shall be equipped with a variable speed, AC spindle motor with a minimum of 30-hp continuous duty. Full horsepower (torque) shall be achieved at or below 300-rpm. All spindle drive shafts and gearing shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground.

SPEED: The spindle shall be capable of infinitely variable speeds of from 0-rpm to at least as fast as 3,300-rpm. Spindle head shafts shall be mounted in precision ball and/or roller bearings. The spindle shall have a maximum torque rating of not less than 2200-lb-ft at 300-rpm continuous duty.

SPINDLE NOSE: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground. The chuck mounting shall be A2-11. The spindle bore shall be no less than Ø4-in to allow the possible addition of a bar feeder in the future. (Note: this purchase description does NOT require a bar feeder.)

POSITIONING: The spindle shall include a C1-axis positioning capability. It shall be capable of positioning resolution of 0.0001° or finer. This feature will allow the rotary positioning necessary for the full contouring milling operations. The rapid traverse and machining speeds shall include a range of up to not less than 550-rpm. C-axis position shall be continually monitored during both turning and milling operations.

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.

COOLING: The spindle shall have a thermal controlled cooling jacket/system. This will extend the life of the spindle and minimize distortion during heavy machining operations.

FLOOD COOLANT: The system shall include a flood coolant system above the chuck for removal of chip nests prior to tool exchange.

AIR BLAST: The system shall include an air blast through the spindle bore to remove chips during I.D. turning operations.

CHUCK:

1.1.1.34 This spindle shall be provided with a fully functioning 15-in, through-hole, 3-jaw, self-centering, power chuck or larger.

1.1.1.35 The chuck shall have a 3-in bar capacity through hole or larger.

1.1.1.36 The chuck shall have quick change top jaws.

1.1.1.37 The system shall allow for M-code automatic chuck jaw opening and closing.

1.1.1.38 The system shall confirm the status of the chuck jaws (Open/Close) prior to execution of machining operations.

1.1.1.39 The system shall allow M-code programming to change the hydraulic pressure applied to opening and closing of the chuck jaws.

Lathe Second Spindle (C2-Axis) AXIS DEFINITION: This shall be a horizontal centerline rotational axis.

DRIVE: The second spindle shall be equipped with a variable speed, AC spindle motor with a minimum of 30-hp continuous duty. Full horsepower (torque) shall be achieved at or below 300-rpm. All spindle drive shafts and gearing shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground.

SPEED: The spindle shall be capable of infinitely variable speeds of from 0-rpm to at least as fast as 3,300-rpm. Spindle head shafts shall be mounted in precision ball and/or roller bearings. The spindle shall have a maximum torque rating of not less than 2200-lb-ft at 300-rpm continuous duty.

SPINDLE NOSE: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground. The chuck mounting shall be A2-11. The spindle bore shall be no less than Ø4-in to allow the possible addition of a bar feeder in the future. (Note: this purchase description does NOT require a bar feeder.)

POSITIONING: The spindle shall include a C1-axis positioning capability. It shall be capable of positioning resolution of 0.0001° or finer. This feature will allow the rotary positioning necessary for the full contouring milling operations. The rapid traverse and machining speeds shall include a range of up to not less than 550-rpm. C-axis position shall be continually monitored during both turning and milling operations.

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.

COOLING: The spindle shall have a thermal controlled cooling jacket/system. This will extend the life of the spindle and minimize distortion during heavy machining operations.

FLOOD COOLANT: The system shall include a flood coolant system above the chuck for removal of chip nests prior to tool exchange.

AIR BLAST: The system shall include an air blast through the spindle bore to remove chips during I.D. turning operations.

CHUCK:

1.1.1.40 This spindle shall be provided with a fully functioning 15-in, 3-jaw, self-centering, power chuck or larger.

1.1.1.41 The chuck shall have quick change top jaws.

1.1.1.42 The system shall allow for M-code automatic chuck jaw opening and closing.

1.1.1.43 The system shall confirm the status of the chuck jaws (Open/Close) prior to execution of machining operations.

1.1.1.44 The system shall allow M-code programming to change the hydraulic pressure applied to opening and closing of the chuck jaws.

Lathe Second Spindle Carriage (W-Axis) AXIS DEFINITION: This axis shall be a linear travel axis. The centerline of the second spindle (C2-axis) center shall be collinear with the main spindle (C1-axis) spindle at every point in the carriage travel.

TRAVEL: The carriage shall travel on the same linear guides as those used by the steady rest bracket, but separate from those used to provide the Z-axis carriage base travel. The maximum length of travel shall be no less than (120-in minus the width of the steady rest bracket).

CONSTRUCTION: The frame shall be a heavily ribbed, close grained casting and shall form a rigid structure supporting the tailstock center.

POSITION: The carriage position shall be controllable through programming or through Manual Data Input (MDI).

THRUST: The force applied to the material to be machined shall also be controllable through the use of M-code programming. The range of force applied shall be from 225-lbs to 2240-lbs.

DRIVE: The linear travel shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s). Ball screws shall be cooled by passing temperature controlled liquid through the core. This coolant shall be separate from the cutting coolant. Power shall be transmitted to the screws through hardened and ground gearing, by timing belt, or by direct coupling to the servo motors. 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 high resolution (16,000,000-pulses/rev) encoders or glass scales with positive air pressure system to prevent contamination. Linear resolution shall be 0.0001-in or less. All servo motors shall be of the same manufacture as the system controls manufacturer. (I.e. if the system controls are Fanuc based, then the servo motors shall also be manufactured by Fanuc.)

Carriage Base (Z-Axis) AXIS DEFINITION: The Z-axis or longitudinal milling motion shall be provided by movement of the carriage base on way surfaces supported by the machine base/bed. It is defined as the axis parallel to the W-axis.

TRAVEL: The system shall provide Z-axis travel of not less than 120-in.

FEED RATES: The system shall provide a maximum rapid traverse feed rate of not less than 1400-ipm and a maximum cutting feed rate of not less than 1000-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

LINEAR POSITIONING: Positioning and repeatability shall be measured in accordance with ISO 230-2 standards. The system shall maintain a bidirectional positioning of 0.0004-in and repeatability of 0.0002-in.

CONSTRUCTION: The carriage base shall be a close grained casting forming a rigid structure supporting the cross-slide frame. The carriage base 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 supporting surfaces for the cross-slide shall be such that the spindle head is fully supported and shall not overhang the frame in any position within the machine's rated travel.

BEARINGS: The carriage base 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. The ways shall be replaceable, full width and thickness, one piece in length, held against locating stops or keys, and mechanically fastened to the machine in a manner ensuring permanent alignment. 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.

DRIVE: The linear travel shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s). Ball screws shall be cooled by passing temperature controlled liquid through the core. This coolant shall be separate from the cutting coolant. Power shall be transmitted to the screws through hardened and ground gearing, by timing belt, or by direct coupling to the servo motors. 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 high resolution (16,000,000-pulses/rev) encoders or glass scales with positive air pressure system to prevent contamination. Linear resolution shall be 0.0001-in or less. All servo motors shall be of the same manufacture as the system controls manufacturer. (I.e. if the system controls are Fanuc based, then the servo motors shall also be manufactured by Fanuc.)

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.

Cross-Slide (Y-Axis) AXIS DEFINITION: The Y-axis or horizontal milling motion shall be provided by movement of the cross-slide on way surfaces supported by the carriage base. It is defined as the axis perpendicular to the W-axis and parallel to the foundation.

TRAVEL: The system shall provide Y-axis travel of not less than 19-in.

FEED RATES: The system shall provide a maximum rapid traverse feed rate of not less than 1000-ipm and a maximum cutting feed rate of not less than 1000-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

LINEAR POSITIONING: Positioning and repeatability shall be measured in accordance with ISO 230-2 standards. The system shall maintain a bidirectional positioning of 0.0004-in and repeatability of 0.0002-in.

CONSTRUCTION: The cross-slide frame shall be a close grained casting forming a rigid structure supporting the cross-slide frame. 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 supporting surfaces for the milling spindle carriage shall be such that the spindle head is fully supported and shall not overhang the frame in any position within the machine's rated travel.

BEARINGS: The carriage base 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. The ways shall be replaceable, full width and thickness, one piece in length, held against locating stops or keys, and mechanically fastened to the machine in a manner ensuring permanent alignment. 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.

DRIVE: The linear travel shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s). Ball screws shall be cooled by passing temperature controlled liquid through the core. This coolant shall be separate from the cutting coolant. Power shall be transmitted to the screws through hardened and ground gearing, by timing belt, or by direct coupling to the servo motors. 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 high resolution (16,000,000-pulses/rev) encoders or glass scales with positive air pressure system to prevent contamination. Linear resolution shall be 0.0001-in or less. All servo motors shall be of the same manufacture as the system controls manufacturer. (I.e. if the system controls are Fanuc based, then the servo motors shall also be manufactured by Fanuc.)

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.

Milling Spindle Carriage (X-Axis) AXIS DEFINITION: The X-axis or slant milling motion shall be provided by movement of the cross-slide on way surfaces supported by the cross-slide frame. It is defined as the axis perpendicular to the W-axis and at an angle to the foundation.

TRAVEL: The system shall provide X-axis travel of not less than 34.2-in.

FEED RATES: The system shall provide a maximum rapid traverse feed rate of not less than 1500-ipm and a maximum cutting feed rate of not less than 1500-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

LINEAR POSITIONING: Positioning and repeatability shall be measured in accordance with ISO 230-2 standards. The system shall maintain a bidirectional positioning of 0.0004-in and repeatability of 0.0002-in.

CONSTRUCTION: The milling spindle carriage shall be a close grained casting forming a rigid structure supporting the cross-slide frame. 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 supporting surfaces for the milling head shall be such that the spindle head is fully supported and shall not overhang the frame in any position within the machine's rated travel.

BEARINGS: The milling spindle carriage 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. The ways shall be replaceable, full width and thickness, one piece in length, held against locating stops or keys, and mechanically fastened to the machine in a manner ensuring permanent alignment. 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.

DRIVE: The linear travel shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s). Ball screws shall be cooled by passing temperature controlled liquid through the core. This coolant shall be separate from the cutting coolant. Power shall be transmitted to the screws through hardened and ground gearing, by timing belt, or by direct coupling to the servo motors. 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 high resolution (16,000,000-pulses/rev) encoders or glass scales with positive air pressure system to prevent contamination. Linear resolution shall be 0.0001-in or less. All servo motors shall be of the same manufacture as the system controls manufacturer. (I.e. if the system controls are Fanuc based, then the servo motors shall also be manufactured by Fanuc.)

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.

Milling Spindle Head (B-Axis) AXIS DEFINITION: The B-axis or milling spindle head rotational motion shall be defined as the axis perpendicular to the milling spindle carriage.

TRAVEL: The system shall provide B-axis travel of not less than 225° of rotation.

POSITIONING: The milling spindle shall have a 240° travel range, with positioning of 0.0001 degrees as well as full contouring capability. The travel range shall be 30° above the spindle centerline to the left (of operator’s position) to 210° to the right (30° above centerline) to allow for angle machining of inclined faces for versatility of cutting tools. It shall incorporate a high precision, high rigidity roller cam design. This feature will allow the rotary positioning necessary for full contouring milling operations.