Attachment 1 Salient Characteristics.pdf

SALIENT CHARACTERISTICS

CONTROLLED CNC TURNING CENTER

THE PURCHASE DESCRIPTION SET FORTH BELOW REFLECTS THOSE CHARACTERISTICS WHICH

ARE ESSENTIAL TO THE MINIMUM NEEDS OF THE GOVERNMENT

1. SPECIFICATIONS:

1.1. SCOPE: This specification covers the requirements for one each (1 ea.) slant bed designed conversationally controlled turning center lathe machine with ancillary support for initial installation and training. The size and capacity of the machine shall be not less than specified below.

2. EQUIPMENT DESCRIPTION: The equipment shall consist of one each slant bed-type CNC turning center with conversational CNC control. The machine shall primarily be programed by use of conversational programming and have the capability to be programed using NC/G-code programming.

2.1. SALIENT CHARACTERISTICS: Machine shall have the following salient characteristics at a minimum.

2.1.1. Design / Construction:

2.1.1.1. Bed: Machine bed shall be a True Slant Bed Design on a heavily ribbed fine-grade cast iron frame.

2.1.1.2. Ways: Machine Ways shall include heavy-duty linear rails for X, and Z-axis.

2.1.1.3. Ball Screws: Ball screws shall be premium grade double-nut, pre-tensioned type anchored at both ends.

2.1.1.4. Machine Weight: Machine shall weigh no greater than 17,000 lbs.

2.1.1.5. Spindle: Machine spindle shall be manufactured of chrome-molly and be equipped with ABEC class 7 P4 angular contact and roller bearings that are permanently grease packed and precision balanced. Spindle meet the following requirements.

2.1.1.5.1. Spindle Nose: A2-11

2.1.1.5.2. Spindle Bore: 4.5” minimum to 6” maximum

2.1.1.5.3. Spindle Speed Range: 0-2800 RPM

2.1.1.5.4. Spindle Motor Horsepower: 24hp at 241 rpm

2.1.1.5.5. Spindle Torque: 523 ft-lbs.

2.1.1.5.6. Maximum Bar Capacity: 4” minimum

2.1.1.5.7. Spindle Chuck Size: 12” diameter

2.1.1.6. Tailstock: Machine shall be equipped with a programmable tailstock that meets the following requirements.

2.1.1.6.1. Quill Travel: 4.33”

2.1.1.6.2. Quill Diameter: 2.75”

2.1.1.6.3. Quill Taper: MT5

2.1.1.7. Automatic Turret: Machine shall be equipped with a 12 position bi-directional automatic turret with live tooling capabilities. Turret shall meet the following minimum requirements.

2.1.1.7.1. Turret Index Time (Adjacent): 1 Second

2.1.1.7.2. Turret Index Time (Furthest location): 2.5 Seconds

2.1.1.7.3. Tool Shank Width: 1.26" x 1.26"

2.1.1.7.4. Maximum Boring Bar Diameter: 1.97"

2.1.1.7.5. Live Tool RPM: 4,000

2.1.1.7.6. Live Tool HP (1 min.): 8 hp.

2.1.1.7.7. Live Tool Spindle Torque (1 min.): 31 ft.-lbs. at 1,500 rpm

2.1.1.7.8. Turning Holders: Turning holders shall utilize 1" square shank tooling.

2.1.1.7.9. Boring Bar Holders: Boring bar holders shall be able to accept a minimum of a 1.5” boring bar.

2.1.1.7.10. Tooling: VDI 50

2.1.1.8. Coolant System: Machine shall be equipped with a high volume coolant system that delivers coolant to the coolant nozzle(s) on each turret station.

2.1.1.8.1. Coolant Capacity: 69 gallons

2.1.1.9. Splash Guarding: Machine shall be equipped with full coverage chip and coolant splash guarding.

2.1.1.10. Lubrication System: Machine shall be equipped with an automatic lubrication system. Machine shall be equipped with a low oil-level alarm.

2.1.1.11. Power Requirements: Machine shall be built to NFPA 79 and operate with power system which is 480V, 3PH, 60 HZ or quote package should include step down transformer to machine operation voltage.

2.1.2. Capacity: (Minimum requirements)

2.1.2.1. X Travel: 12”

2.1.2.2. Z Travel: 40”

2.1.2.3. Swing Over Bed: 26”

2.1.2.4. Distance Between Centers: 43”

2.1.2.5. Max. Turning Diameter:14”

2.1.2.6. Max. Turning Length: 36”

2.1.2.7. Swing Over Cross slide: 19”

2.1.3. Motion: (Minimum Requirements)

2.1.3.1. Z-axis Rapid Feed Rate: 940 ipm

2.1.3.2. X-axis Rapid Feed Rate: 740 ipm

2.1.3.3. Positioning Accuracy: -/+ 0.0002”

2.1.3.4. Repeatability: -/+ 0.0001”

2.1.3.5. Minimum Command Increment: .0001"

2.1.4. CNC Features: Conversational CNC control that includes the following Programming, Verification and Operational features.

2.1.4.1. AutoCalc: Machinist shall be able to enter the known dimension and the control will decipher the rest.

2.1.4.2. Auto Save

2.1.4.3. Auto Tool Nose Radius Comp.

2.1.4.4. Blend Arcs

2.1.4.5. DFX Transfer: Feature shall allow importation of CAD .dxf files directly into the control even while machine is running another program

2.1.4.6. 600 block look ahead

2.1.4.7. Processing Speed: 4,000block

2.1.4.8. Calc-Assist

2.1.4.9. Canned Cycle Blocks

2.1.4.10. Canned Hole Cycles

2.1.4.11. Comment Block

2.1.4.12. Constant Surface Speed, Selectable

2.1.4.13. Context Sensitive Help

2.1.4.14. Custom Grooving Profiles

2.1.4.15. Cutoff Cycle Blocks

2.1.4.16. Data Block Repeat

2.1.4.17. Diameter/ Radius Programming mode

2.1.4.18. Drilling &Boring w/Inserted Drill

2.1.4.19. Pocketing Routines

2.1.4.20. Drill Tip Compensation

2.1.4.21. Font Magnification

2.1.4.22. Hole Cycle Blocks with automatic drill tip compensation

2.1.4.23. Grooving Cycle Blocks

2.1.4.24. ID/OD Profile Turning

2.1.4.25. ISO/EIA NC Support

2.1.4.26. Inch-Metric Toggle

2.1.4.27. Industry Standard NC (ISNC)

2.1.4.28. Leadscrew Compensation

2.1.4.29. Lines & Arcs

2.1.4.30. M Code Auxiliary Functions

2.1.4.31. NC Editor

2.1.4.32. NC Macro Package (NCMP)

2.1.4.33. On Screen User Prompt

2.1.4.34. Parts Counter

2.1.4.35. Part Zero Shift

2.1.4.36. Peck Mill

2.1.4.37. Program Manager Functions

2.1.4.38. Program Parameters

2.1.4.39. Program Review with Cut/Copy/Paste

2.1.4.40. Rigid Tapping

2.1.4.41. Roughing Stock Allowance

2.1.4.42. Slots

2.1.4.43. Speed/ Feed Override while Running

2.1.4.44. Stick Lettering

2.1.4.45. Text Input Capabilities

2.1.4.46. Thread Cycle Blocks with capability to machine multi-lead threads

2.1.4.47. Tool setup and review w/Graphics

2.1.4.48. Turret Index Control (Auto/Manual)

2.1.4.49. 99 Work Offsets (G-Code)

2.1.4.50. 99 Tool Offsets

2.1.4.51. Automatic Error Check

2.1.4.52. Verification Graphics and simulation with 3D Solid Rendering and dynamic rotation that works on conversational or NC programs.

2.1.4.53. Data Block Search

2.1.4.54. Fast Draw Graphics Engine

2.1.4.55. Graphics Display (Tool Path, Solids, Projection in 3 Planes, Isometric)

2.1.4.56. Graphics Error Verification

2.1.4.57. Graphics Scaling

2.1.4.58. Graphics Zoom

2.1.4.59. Real Time Tool Simulation

2.1.4.60. Auto Interrupt Cycle

2.1.4.61. Automatic Tool Home

2.1.4.62. Backlash Compensation

2.1.4.63. Basic Remote Jog

2.1.4.64. Control and Machine Diagnostics

2.1.4.65. Coolant Select (Dual)

2.1.4.66. Distance To Go

2.1.4.67. Dynamic Variable Look Ahead (capable of over 10,000 blocks @ 900 ipm)

2.1.4.68. Feed Hold Button

2.1.4.69. Feed-Rate Override

2.1.4.70. Programmable Feedrate

2.1.4.71. Spindle Load Monitor

2.1.4.72. Easy Tool Setup: Feature shall automatically calculate feed rate and spindle speed in the program when a tool cutting speed and chip load are set.

2.1.4.73. Simplified Part Setup: Feature shall allow machinist to teach offset for each axis by touching the part

2.1.4.74. 4GB RAM Memory

2.1.4.75. 2.7GHz Pentium 4 Processor

2.1.4.76. 128 GB Solid State Hard Drive

2.1.4.77. Auxilary Graphics Screen w/ Shelf (19” screen)*

2.1.4.78. USB Port (2)

2.1.4.79. LCD Remote Jog

2.1.4.80. NC / Conversational Merge: Feature shall allow machinist to call all or part of an NC program into a conversational program

2.1.4.81. Radial or Axial Milling: Control shall be equipped with multiple milling strategies that include lines and arcs, circle, frame, slot, axial flats, and/or lettering.

2.1.5. Offline Programming: Machine shall be provided with Offline Software for Programming and Training.

Software shall be same as machine control.

2.1.6. Remote Hand wheel: Machine shall be equipped with a remote hand wheel

2.1.7. Flood coolant system: Including splash back and chip pan (installed)

2.1.8. Work light: installed

2.1.9. Oil Skimmer: Installed

2.1.10. Power Requirement: Machine shall be built to NFPA 79 to accept 460 VAC, 3 phase, 60 Hz or quote package should include step down transformer to machine operation voltage.

2.1.11. Work holding and tooling Package: Work holding and tooling package shall include the following

a. 12” Hydraulic Chuck with a minimum of a 4” through hole

b. Three sets of soft jaws

c. Three sets of hard jaws

d. The following Kennametal tooling is required to maintain consistency for tooling uniformity:

a. KM50 LCM VDI RIGHT ANGLE RH Ø50 X 50MM (Order# 1144841)

b. CLAMPING UNIT SPARE PARTS PKG 5 each (Order# 1023726)

c. CLAMPING UNIT SPARE PARTS PKG 2 each (Order# 1023725)

d. KM50 LCM VDI RIGHT ANGLE LH Ø50 X 50MM (Order# 1144843)

e. KM50 CMI VDI AXIAL RH Ø50 X 70MM (Order# 1144852)

f. KM50 CMI VDI AXIAL RH Ø50 X 140MM (Order# 1144854)

g. KM50 CMI VDI AXIAL LH Ø50 X 70MM (Order# 1144849)

h. KM50 RCML AXIAL VDI50 X 70MM (Order# 2032953)

i. KM50 RCML AXIAL VDI50 X 140MM (Order# 2032954)

3. TECHNICAL MANUALS: Three (3) complete sets of technical manuals covering operation, service and maintenance, and part-listing shall be provided.

4. QUALITY ASSURANCE PROVISIONS – Inspection and acceptance of the supplies, performed at destination by Code 983 and shall consist of type and kind; condition; operability, if readily determinable; preservation; packaging.

5. PRESERVATION, PACKAGING AND PACKING – The equipment shall be packaged, packed and preserved for shipment to reach ultimate destination undamaged. Package shall be prominently marked “NOT FOR OUTSIDE STORAGE”. Yellow packaging, packing, preservation and marking are prohibited.

6. Additional Requirements:

6.1. Machine Hardware: Machine shall include any necessary lifting, leveling, and floor attachment hardware for machine installation.

6.2. Nameplate: A nameplate shall be permanently and securely attached to each machine the information provided on the plate shall be as 1isted below.

a. Nomenclature

b. Manufacturer’s name

c. Manufacturer’s model designation

d. Manufacturer’s serial number

e. Power input (volts, total amps, phase, frequency)

f. Amp rating of 1argest motor

g. Short circuit/over-current protection rating

h. Contract Number or Order Number

i. National Stock Number or Plant Equipment Code

j. Date of manufacture

6.3. Operating and Maintenance Manual: Machine shall be provided with operating and Maintenance Manual (O&M), Electrical Manual, Mechanical Manual & Schematics three (3) each shall be provided with the machine and one (1) each searchable electronic copy (PDF) shall be E-mailed to TPOC.

6.4. Verification Test: After delivery the Contractor shall test run the machine at the site to ensure conformance with this purchase description.

6.5. Warranty: This machine shall be warranted against any defects in material, parts, and workmanship for 24 months after the date of installation. The control, servomotors and main spindle motor shall be warranted against defects in material, parts, and workmanship for 24 months after the date of installation.

7. Installation:

7.1. Installation/Foundation Drawings: Not later than sixty (60) calendar days after effective date of contract;

installation requirements and drawings shall be provided to Norfolk Naval Shipyard TPOC.

7.2. Lifting and Handling Equipment: No later than sixty (60) calendar days after effective date of contract, the contractor shall provide a lifting sketch / rigging diagram that meets the requirements listed below.

• The weight of the load.

• The location of the center of gravity.

• The minimum capacity / length of slings.

• The minimum capacity of other standard rigging gear.

• The attachment (lifting) points for the load.

o The attachment points for multiple leg lifts shall be sized such that each attachment point can support half the load’s weight at the anticipated lift angle.

o The attachment point for single leg lifts shall be sized such that the attachment point can support the entire load’s weight.

• Limitations on allowable orientations for any parts making up the lifting assembly.

• For single leg vertical lifts using twisted rope (wire or synthetic), two parallel ropes each capable of supporting the entire load alone shall be required unless a method is used to prevent unlaying the rope.

• A minimum D/d ratio of one shall be required where wire rope slings pass over any object, or in the eyes of wire rope slings. A minimum D/d ratio of two shall be required where synthetic rope slings pass over any object, or in the eyes of synthetic rope slings.

o "D" represents the diameter of the object the sling passes over.

o "d" represents the diameter of the sling.

o Table 14-3 of NAVFAC P-307 lists efficiency factors at vaious D/d ratios.

• Components in each handling assembly shall be sized based on the worst case distribution of loads.

Note: When making a two, three, or four point lift, the handling gear shall be sized so that two legs can support the load without exceeding the safe working load (SWL) at the lift angle expected, unless an equalizing method is used.

• When non-standard gear is required (i.e. round stock lifting bars) written instructions shall be provided that ensure:

o The proper material is being used, o The item is certified.

o Any special requirements or dimensions are followed to ensure that engineering assumptions are met (i.e. eccentricity of the bearing points).

7.3. Location: Machine shall be installed inside Bldg.171 3rd floor NNSY (Norfolk Naval Shipyard, Portsmouth, VA 23709).

Note: Machinery must be moved to and from the 3rd floor location by use of Navy bridge crane. NNSY governmental personnel will be the only authorized user for the bridge crane and rigging of the lathe. The contractor is to remain on site during the rigging process to ensure the lathe is rigged properly.

7.4. Mechanical Installation: The Contractor shall provide all labor, fluids, (with the exception of coolant) piping, interconnecting hoses, and any other materials to move, locate, set level, align, lubricate, and make ready to operate all equipment required by this contract. All machinery shall be installed to original manufacturer's tolerances.

7.5. Electrical Installation: The Contractor shall provide all labor, wiring, cables, disconnects, connectors, breakers and any other materials for complete installation of any necessary electrical equipment and electrically connect machine to building.

8. Training: The contractor shall provide training to familiarize Norfolk Naval Shipyard personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be performed at customer facility between 7:20 am and 3:50 pm excluding any federal holidays.

8.1. Operator / Programmer On-Site Training: Training shall be provided at the receiving activity. Training shall include preparation of part programs, and preparation of equipment for safe operation. The trainees shall be provided instruction for all aspects of machining operations. Trainees shall be provided instruction for the care, use and operation of all attachments and accessories. Training shall be provided for three (3) operators/programmers. The training period shall not be less than four (4) consecutive, eight (8) hour work days. A training manual (which could be an additional operator’s manual) shall be provided for each student.

8.2. Maintenance Personnel: Maintenance training shall include trouble-shooting and methods of correction if the equipment malfunctions, with particular emphasis on minimizing equipment down time. Training shall be provided for three (3) maintenance personnel. Training shall cover troubleshooting and maintain the machine.

The training period shall not be less than one (1) eight (8) hour workday.

9. FACILITIES ENTRY REQUIREMENTS:

9.1. Initial Entry: Contractor provide a SECNAV 5512 and a CNRMA Installation Access Screening Request form that will be provided by the technical point of contact. These documents will be endorsed by the TPOC and forwarded to the NNSY Pass Office. Contractor shall submit documents approximately two weeks before arrival.

9.2. Vehicle Entry: The company name shall be displayed on each door of the Contractor's vehicles in a manner and size that is clearly visible. All vehicles shall display a valid state license plate that complies with State Vehicle Code. Vehicles shall meet all other requirement of the State Vehicle Code, such as safety standards, and shall carry proof of insurance and state registration. Passes will be issued for vehicles to enter the shipyard.

A separate pass is required for entering the Controlled Industrial Area (CIA).

9.3. Portable Electronic Device (PED): In accordance with COMSUBLANT/COMSUBPACINST 2075.1C, the use of Portable Electronic Devices (PEDs) while in or on Department of Navy Controlled Industrial Areas are prohibited. A portable electronic device (PED) is defined as any non-stationary electronic apparatus with singular or multiple capabilities of, but not limited to recording, storing, and/or transmitting data, voice, video, or photo images e.g.: cell phones, laptops, tablets and wearable devices such as fitness bands and smart watches.

10. Critical time Constraints: The Installation and training shall be performed between the hours of 7:20 am and 3:50 pm excluding any federal holidays.

11. Technical POC: Russell Harris, C983 (Russell.r.harris@navy.mil) Phone: 757-396-1500

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Provide machine foundation in accordance with the manufacturer's design requirements.

( ) (XX) b. Furnish labor and material handling equipment for off-loading and placing item on foundation.

( ) (XX) c. Provide and install anchor bolts and nuts.

( ) (XX) d. Set and rough level the machine on its foundation.

( ) (XX) e. Level and align machine.

( ) (XX) f. Connect machine to the provided utilities hook-up.

( ) (XX) g. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests.

( ) (XX) h. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

(XX) ( ) i. Material for performance testing at Government facility.

( ) (XX) j. Material for performance testing at Contractor's facility.

( ) (XX) h. Provide utilities hook-up within 20 feet of the machine