Attachment 1 Draft Statement of Work.pdf

Draft Statement of Work for a Small Computer Numerical Controlled (CNC)

Vertical Machining Center (VMC) for Tobyhanna Army Depot

1.0 General Scope

1.1 This Draft Statement of Work (SOW) is for the turn-key design, supply, delivery, off-loading, transporting, locating, installation, cleaning, assembly, set-up and training for one each Computer Numerical Controlled (CNC) Vertical Machining Center (VMC) at Tobyhanna Army Depot (TYAD) in Tobyhanna, PA 18466. It would include all materials, supplies, freight, delivery, tools, equipment, consumables, labor, and supervision for the turn-key design, supply, delivery, off-loading, transporting, locating, installation, cleaning, assembly, set-up and training for the machine. This requirement would only include new machines and new associated equipment. Used and refurbished machines and used and refurbished equipment would be unacceptable and would not be considered. All repair and replacement parts for the machine and associated equipment would need to be new. All repair and replacement parts would need to be available for purchase and supplied from within the continental United States.

1.2 Power available for the machine is both 208V/3 Phase/60Hz and 480V/3 Phase/60 Hz. For machines that are not designed and constructed for this power, the Contractor would be required to supply, install, and connect the necessary transformers that permit the use of this available power by the machine.

1.3 TYAD currently uses CNC Software’s MasterCAM Computer-Aided Manufacturing (CAM) software for the programming of all on-site VMCs. The proposed VMC would need to be CNC programmable using MasterCAM Computer- Aided Manufacturing (CAM) software. The Contractor would need to develop and supply the appropriate post-processor to achieve the necessary CNC programming compatibility. The Contractor’s post-processor would need to be provided to Automation Support Branch personnel by the Contractor in accordance with section 3.0 Cyber Requirements for loading onto the Government network.

1.4 Minimum Specifications, Characteristics and Features for the Machine:

1. The machine shall have both conversational and numerical control programming capability.

2. X-axis travel shall be 42.0-48.0 inches.

3. Y-axis travel shall be 24.0-30.0 inches.

4. Z-axis travel shall be 24.0-30.0 inches.

5. All axes shall incorporate direct drive servos.

6. Table working surface shall be 50.0-66.0 inches by 24.0-30.0 inches.

7. X, Y and Z positioning accuracy shall be at least +/- 0.0002 inches or better by 10 pass VDI 3441 Method.

8. Repeatability of all axes shall be at least +/- 0.0001 inches or better by 10 pass VDI 3441 Method.

9. Maximum cutting feed rate shall be at least 1250 inches per minute. Rapid transverse rate for X and Y shall be at least 1400 inches per minute and 1200 inches per minute for Z.

10. Drive encoders shall have a minimum of 1,000,000 counts per revolution.

11. The machine shall also be equipped with a remote jog control with a display screen.

12. Spindle nose-to-table distance shall be 6.0 or less to 30.0 or more, inches.

13. Table shall be furnished with five each T-Slots, minimum, evenly spaced across the table.

14. Table shall have a weight capacity of 3,800 pounds, minimum.

15. Spindle taper shall be CAT40 Big Plus Dual Contact.

16. The spindle shall be direct drive and be designed to permit a continuous spindle speed of 15,000 rpm, minimum.

17. The spindle shall be 20 horsepower one minute rated, minimum.

18. The spindle shall be direct drive.

19. The spindle shall have a bearing lubrication system and utilize a thermal chiller.

20. The automatic tool changer (ATC) shall be random access and have a 30 tool minimum capacity. The machine shall allow for the assignment of tool pockets.

21. The tool changer shall be capable changing tools in 1.5 seconds or less.

22. The maximum tool diameter shall be at least three (3) inches.

23. The maximum tool length shall be at least 11.5 inches.

24. The machine shall be equipped with an 18 inch, minimum, color monitor screen.

25. The machine shall be equipped with a flood coolant and washdown delivery system.

The Contractor shall furnish and install all filters and pumps for the system.

26. The machine shall be equipped with a through-spindle coolant delivery system that provides up to 300 psi, minimum, coolant to the cutting tool. The Contractor shall furnish and shall install all filters and pumps for the through-spindle coolant delivery system.

27. At a minimum, the machine computer shall be equipped with a nonvolatile solid state storage device, 8GB of random access memory, and utilize a processor with at least two physical cores dedicated to the operating system the user interacts with. The machine shall be capable of making rapid cornering moves without stopping when changing direction.

28. The machine shall be capable of up to 10,000 block look-ahead, minimum.

29. The machine shall be capable of S-curve motion and double arc smoothing.

30. The machine shall allow graphical verification of a solid or wire frame models and tool path to verify the part program in both conversational and numerical control modes.

31. The machine shall be able to create contour programs using lines and arcs.

32. Mirror images shall be capable of being milled in the same manner on both halves.

33. Conversational programming shall allow the machining of pockets with islands and boundaries as well as permitting a helical ramp feature when plunging.

34. The machine shall be capable of importing 2D data from Computer Aided Design (CAD) .dxf files to create a conversational program.

35. The machine shall be able to save tool and material parameters for multiple and future use.

36. The machine shall be capable of analyzing the machining program to automatically optimize the number of tool changes for reduced cycle time.

37. The machine controls and power cabinet shall be temperature controlled within their normal operating range.

38. The machine shall support Industry Standard Numerical Control codes, EIA/ISO or G-code, to allow the use of existing part programs.

39. The machine shall allow the creation and editing of numerical control programs and indicate if there are syntax errors.

40. The machine shall at minimum be proven to receive files from Tobyhanna’s DNC system. The system sends files over serial RS-232 from a Tobyhanna provided workstation using a method commonly known as drip-feeding.

41. The machine shall allow features from a numerically controlled program to be brought into a conversational program.

42. The conversational programming shall allow a two dimensional shape to be moved along a contour to create a surface using the conversational program.

43. The machine shall allow the machining cycle to be interrupted, the machine repositioned and then the cycle resumed at the point it was interrupted.

44. The machine shall permit mid-program restarts without the need of additional programming.

45. The machining program shall be capable of producing the surface finish selected automatically.

46. The graphics screen shall allow for touching a feature and automatically displaying the code that can then be edited as needed.

47. The program shall be capable of computing the run time of the machining operation.

48. Feed and speed adjustments shall be capable of being made and stored in part programs.

49. The machine shall be equipped with an interactive help feature.

50. The machine shall allow for offline programming while the machine is running.

51. The machine shall be equipped with door safety interlocks.

52. The machining area shall be fully enclosed and equipped with a coolant mist collection system that clears the coolant mist generated during the machining process from the enclosed machining area.

53. The X, Y and Z axes servos shall be direct drive.

54. The machine shall be equipped with way covers that telescope, an automatic central lubrication system and a way lubricant separation system.

55. The machine shall be equipped with light emitting diode (LED) lights to illuminate the entire machining area.

56. The machine shall provide a system capable of granular access permissions.

Granular access permissions are used to grant system privileges, allowing you to construct site-specific roles with privileges to match your requirements. Required system privileges capable of this should include but are not limited to running machine code programs, editing machine code programs, editing machine parameters, and administrative machine functions. The system must accommodate the following roles at a minimum: Operator, Setup Technician, and Administrator.

57. The machine shall be equipped with an automatic chip extractor auger or conveyor system for removal of chips from the machining area.

58. The machine shall come equipped with a Renishaw part probing capability with at least a 1.0 um repeatability.

59. The machine shall be capable of both conversational tool and part probing. Part probing shall determine a part’s position regardless of orientation.

60. Machine shall come equipped with an oil skimmer system.

61. An optional eight (8) inch (200 mm) rotary table shall be provided and be capable of horizontal or vertical mounting.