Attachment 1 - SOW OD Grinder.pdf

WORK STATEMENT SPECIFICATION

for

Computer Numerical Controlled Cylindrical OD

Angle Grinder

1.0 Scope: This purchase specification provides the minimum requirements for four count Computer Numerical Controlled (CNC) Compact Cylindrical Outside Dimension (OD) Angle Head Grinder and Ancillary Equipment. The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.

2.0 Applicable Documents: The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of request for proposal shall apply:

U.S. Department of Labor

CFR Title 29, Chapter XVII, Part 1910 – Occupational Safety and Health Regulations

(Applications for copies shall be made to the Superintendent of Documents, Government Printing Office, Washington, DC 20402)

Electronic Industries Alliance

J-STD-001C – Requirements for Soldered Electrical and Electronic Assemblies

(Application for copies shall be made to the Institute for Interconnecting and Packaging Electronic Circuits, 2215 Sanders Road, Northbrook, Illinois 60062-6135)

National Fire Protection Association (NFPA)

NFPA - 70 The National Electrical Code, 1996

NFPA - 79 Electrical Standards for Industrial Machinery, 1997

(Application for copies should be made to the National Fire Protection Association, One Batterymarch Park, P.O. Box 9101, Quincy, Massachusetts 02269-9101) or the most current version of the International Electric Code IEC 60204-1

Underwriters Laboratories Inc.

UL 508 Standards for Safety for Industrial Control Equipment

(Application for copies should be made to Underwriters Laboratories, Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096 or the most current version of the International Electric Code IEC 60204-1.

2.1 Order of Precedence: In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence.

3.0 Salient Characteristics:

3.1 General Requirements: The Computer Numerical Controlled CNC Angle Head OD Grinder shall be new and one of the manufacturer’s current models capable of operation in accordance with the requirements herein. The machine base shall be of cast frame (not a welded steel frame). The CNC grinder shall be capable of operation in manual, semi-automatic, or fully automatic cycle. The grinder shall use standard International Organization for Standardization (ISO) programming format for computer numerical controlled machine tools. The programming shall include all required software and hardware necessary to program and operate the CNC grinder from the machine’s control panel. The control shall include basic level Question and Answer with Graphics conversational assist programming for basic plunge and traverse grinding. The CNC control shall accept programs from an off-line programming system. The CNC grinder shall have a V & Flat guideway system, precision hydrodynamic bearing for the wheel spindle, flood coolant system, work light, full enclosure, spare parts list, maintenance and instruction manuals, standard set of wrenches and keys for the CNC grinder and its accessories. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Controlled Axes: The CNC grinder shall have as a minimum of two (2) controlled axes that can be run in both simultaneous linear and simultaneous contouring modes. Axes shall be defined as X and Z. There shall be an integral torque limiting system which electronically senses axis overload which will shut down the machine to an E-stop condition. The ball screws shall have absolute position encoders or equivalent that divide the rotation of ball screw to a minimum of 40M pulses. Encoder should have a resolution of 0.00001 (ten millionths of an inch). The position of all axes is to be known by the controller at all times including times of power loss, crashes or E-stop. The grinder will not require batteries to support the absolute position encoders. The grinder will not require to return to a home position at any time.

3.1.2 Travel: The minimum requirements for axis travels are: X-axis (wheel-head) travel minimum 16.50” inches, Z-axis (Saddle) minimum of 25.50” inches.

3.1.3 Capacities: The minimum swing over the table shall be 12.50” inches with a minimum grinding diameter of at least 7.50”. Distance between centers shall be a minimum of 15.5” inches.

3.1.4 Wheel-head: Wheel-head shall be set to an angle of 60 degrees in reference to the Z-axis. Spindle motor shall be a minimum of 10 HP. Wheel spindle shall be supplied with force fed lubrication with pressure check. Wheel size shall be (ODxWxID) up to 24” x 4” x 10.0” (with a special wheel flange) and a maximum peripheral speed of 8800 feet per minute (fpm). Max wheel width for standard wheel flange shall be 3.94”. Mounted to the wheel-head shall be a Z-axis part feature locator.

3.1.5 Work-spindle: Minimum horsepower to drive the workpiece will be a minimum of 3hp.

Spindle speed shall have a range of between 25 revolutions per minute (rpm) and 650 rpm with MT#4 center hole. Dead center and live Work-head. The footstock shall have an MT#4 center taper with a hydraulic quill travel of at least 1.9” inches and a manual taper adjustment of +/- 0.0031” inches.

3.1.6 Machine Construction: The machine base shall be of cast iron construction. The work area shall be completely enclosed.

3.1.7 Ball Screws: The ball screws shall be direct coupled to the axis motors with Zero backlash couplings with absolute precision encoders for each linear axis.

Cutting feedrate for X-axis shall be a minimum of from 0.00005” inches per minute (ipm) to at least 230 inches per minute and for the Z-axis shall be from 0.00002” to at least 230” ipm.

Rapid federate shall be at least 1150” inches per minute for the wheel-head (X-axis) and 775” inches per minute for the saddle (Z-axis).

3.1.8 Accuracy and Alignment: The grinder shall have a least input increment of 0.00001” inches (0.1 micron). The bed should be designed to minimize influence from coolant and be thermally stable and symmetric to allow for thermal compensation.

3.1.9 Lubrication: An automatic lubrication system for the machine ways is required.

3.1.10 CNC Control System: The CNC grinder shall have as a minimum of 90 Gigabyte (GB) program storage, two (2) USB Ports, a RS232C Port, and Ethernet interface. The CNC grinder shall be fully programmable from the machine’s controller as well as accepting off-line ISO G-code programming. It will include the necessary software and memory to accept programs generated as described in the previous sentence. The CNC grinder shall have as a minimum the following features:

a. 15 inch minimum color LCD monitor with two (2)USB ports.

b. 100 GB hard drive with 90 Gigabytes of program storage.

c. Solid-state drive with Ethernet Interface for hardwired and wireless types.

d. Auto-Assist at the machine programming software.

e. Portable Remote Jog Handle.

f. Rapid Traverse Override Switch.

g. Solid 3-D graphics and 2-D graphics display, operator switchable.

h. The control system shall have resident G-code and M-code definitions and explanations for their use resident in the CNC control. Additionally, there will be two hardcopies of the same information.

i. The CNC control will accept all standard Windows based protocol formats such as, but not limited to: .pdf, .doc, .xls, .txt, .wmv, .avi, .jpg, and .tif. All formats listed shall be able to display work instruction documents, safety and training videos and job related memos through the CNC control display panel without the need for a secondary PC station.

j. The CPU (main processor) for the CNC control shall be upgradeable at any time to the most current processor technology available – ie, both the WINDOWS operating system and the CPU.

k. There will be at least two (2) USB Ports and one (1) RS232C Port as well as an Ethernet port.

l. At least two (2) Megabytes of RAM memory in the CNC control.

m. Software License to allow user-written or third party written user software programs for peripheral devices. ie, bar code readers, cameras, etc.

n. Serial Communication at a minimum of 9mb transfer speed per second.

o. Touch-Screen performance, QWERTY keyboard and soft key control panel data entry.

p. Ball screw pitch error compensation.

q. Wheel data pages, Minimum of 75.

r. Auto-assist programming software to generate basic plunge and traverse cycles.

s. Message function – written into the program to advise operator of specific tasks associated with the current process.

3.1.11 Work Light: The CNC grinder shall be equipped with a work light inside the enclosure of the work area.

3.1.12 Voltage: The CNC grinder shall be supplied configured to operate on 480 Volts, 3 phase, 60-hertz electrical power. (Note: the use of an external transformer to match the machine’s power requirements is acceptable.)

3.2 System of Units: The equipment shall display all units of measure in the U.S.

Customary System of Units (first) and be capable of displaying both U.S. Customary System of Units and Scientific Units (second) where applicable.

3.3 Equipment Location: The CNC grinder will be located in a typical machine shop environment. There is paved access to all entrances; door access provided is twelve feet opening. When machine is placed it must be kept 3 feet from walls. Aisle ways are six feet wide minimum.

3.4 Electrical Power Requirements: The CNC grinder shall be designed to operate on 480 VAC, 3 phase, 60-hertz electrical power. The electrical system shall conform to National Fire Protection Association (NFPA) 79 or to International Electrical Standard IEC 60204-1. All electrical wiring and components shall be sized for 230 / 460 VAC operations. Use of a multi-tap transformer is acceptable.

3.4.1 Electrical Noise: The electrical power at the Anniston Army Depot (ANAD) is subject to noise. If the CNC grinder requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the CNC grinder. If the CNC grinder is subject to interference from adjacent machinery, the CNC grinder shall include the proper shielding to prevent malfunctions.

3.5 Safety and Health Requirements: The CNC grinder shall be designed and manufactured in accordance with ANSI B11.6 or International Machine Tool Standards ISO 230-2. The manufacturer shall ensure that the CNC grinder and all equipment and accessories used on the machine shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910. If a conflict arises between the ANSI B11.6 and the OSHA standards, the more stringent standard shall apply.

3.5.1 Noise Level: Noise emitted by the CNC grinder shall be no greater than 80 decibels as measured per ANSI S12.23-1989. The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the equipment into conformance with this requirement shall not interfere with visibility needed for safe operation of the CNC grinder. Operators shall be able to use this equipment without the need for hearing protection.

3.5.2 Ergonomics: The equipment shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

3.6 Reliability: Evidence of the reliability of the proposed CNC grinders shall be included with the contractor's proposal. The contractor shall cite at least five (5) similar CNC grinders sold over the last ten (10) years and include the following information for each CNC grinder: customer, contract or purchase order number, and customer point of contact information (phone number, e-mail, etc.). The reliability of the CNC grinder cited will be a factor in the past performance evaluation of the contractor's proposal.

3.7 Maintainability: The CNC grinder shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts.

The contractor shall provide evidence that repair parts and service for the CNC grinder are readily available. The contractor shall also provide information on the normal maintenance actions required for the CNC grinder including type of maintenance, required interval, mean-time to perform maintenance and number and skill of people required to perform the maintenance actions. The CNC grinder maintainability will be a factor in the past performance evaluation of the contractor's proposal.

3.7.1 Construction: The CNC grinder, equipment and accessories shall be constructed of quality material to the maximum extent possible.

3.7.2 Components: The components used to manufacture this CNC grinder shall be the manufacturer’s latest make and model. The contractor shall only use components that will be readily available for a minimum of ten (10) years after installation or can be easily replaced with newer components of the same type. This includes not only contractor-manufactured items but also those supplied by sub-contractors.

3.7.3 Warranty: The CNC grinder shall be covered by the manufacturer’s standard commercial warranty for a period of two years – parts and labor. The warranty shall be written in the name of the Anniston Army Depot. During the warranty period, the contractor shall be responsible for the repair of any defects in equipment parts or workmanship. The contractor shall respond to requests for service within 48-hours after the request.

3.8 Nameplate: A nameplate shall be attached to the CNC grinder and shall contain, as a minimum, the following information:

a. Nomenclature.

b. Manufacturer’s name.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Short-circuit/over current rating.

g. Contract number or purchase order number.

h. National stock number (if applicable).

i. Date of manufacture.

3.9 Lubrication Plate or Chart: A lubrication plate or chart shall be attached to the CNC grinder. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of (s) with SAE number or lubricant identifier.

3.10 Environmental Compliance: The CNC grinder provided under this contract shall meet all applicable Environmental Protection Agency (EPA) restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user’s health and shall be adhered to during the manufacture, service, transportation, storage and operation of the CNC grinder.

3.10.1 Recovered Materials: The contractor is encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

4.0 Acceptance Testing & Verification:

4.1 Conformance: The CNC grinder shall meet the requirements of this specification and conform to the manufacturer’s own drawings, specifications, standards, and quality assurance practices. The Government reserves the right to, at any time during the contract period; require proof of such conformance or to inspect the CNC grinder to determine compliance with the requirements of this specification.

4.1.1 Test Setup and conditions: Unless otherwise specified, ANAD shall supply all tooling and material(s) as outlined in 4.2 and 4.3. The contractor shall conduct all tests required by the Government. The government will provide test instruments and equipment with calibration traceable to the National Institute of Standards and Technology (NIST) and shall provide certification of calibration as specified.

4.2 Operational Test: Upon completion of the CNC grinder installation, the CNC grinder shall be operated in accordance with the Manufacturer’s standard operating procedure for a period of one (1) hour. During these tests, the contractor shall demonstrate proper operation of all CNC grinder controls, functions and features. The government will provide the materials necessary to perform the tests. All tests must be witnessed by the ANAD Contracting Officer or Contracting Officer's Representative. The proper operation of all controls and features shall be verified during this test period. Should a malfunction occur during any test, the contractor will correct the problem and repeat the test(s).

4.3 Performance Test: Unless otherwise specified, the performance test shall consist of the tests listed in ASME B5.57. The Government reserves the right to specify any or the entire test listed in these standards.

4.4 Acceptance: The Government will accept the CNC grinder only after the contractor successfully completes the requirements of paragraphs 4.1, 4.1.1, 4.2 and 4.3 herein. Final acceptance will be at Anniston Army Depot. Failure of the CNC grinder to meet the performance requirements specified shall be cause for rejection.

5.0 Installation and Delivery

5.1 Delivery: The contractor shall complete the installation of all equipment and have acceptance made within one hundred and eighty (180) calendar days after award of the contract.

5.2 Shipping, Handling, and Storage: The contractor shall be responsible for all shipping, storage, and handling of the CNC grinder and all materials. The Government shall not be responsible for furnishing any labor, equipment or warehouse space, for the loading, unloading, and storing of any materials. The Government will make available, if possible, space for a contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area. Should the contractor not wish to furnish a trailer for equipment storage, then the contractor shall coordinate with the Contracting Officer, a date at which time the contractor may deliver his equipment to the building.

5.3 Installation: The contractor shall be responsible for installing the CNC grinder to include all labor and materials required. The contractor shall be responsible for insuring that the installation is compatible with existing facilities. The contractor shall provide along with the bid, all of the installation requirements for the proposed offering, in this case, a (CNC grinder). This documentation is to include as a minimum, the following:

a. Floor plan drawing of the CNC grinder showing the floor space requirements.

b. Space required around the machine after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate weight of the machine with accessories and attachments.

f. All utility requirements, including capacities of required utilities and approximate locations of utility connections to the machine.

g. Industrial waste disposal requirements, if any.

h. Ventilation requirements, if any.

A site layout for the equipment is included with this specification for reference. Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours (Monday – Thursday 0600 to 1530 and every other Friday 0600 to 1430). The area near where the equipment is to be installed is an active working area. The contractor shall not interfere with on-going Government operations and production unless authorized by the Contracting Officer or the Contracting Officer’s Representative.

5.3.1 Site Visit: A site visit is recommended to insure that the proposed equipment will be compatible with existing facilities.

5.3.2 Electrical: All electrical work shall comply with American National Standards Institute (ANSI) Publication C2 – National Electric Safety Code and with National Fire Prevention Association (NFPA) Publication No. 70 – National Electric Code or the International Electric Code. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings or equivalent International Electrical Code Standards for Machine Tools. Workmanship shall be in accordance with standard commercial practices.

Runs shall be installed perpendicular and parallel to existing facilities and the equipment to be installed. When equipment is installed near existing power lines, equipment shall be located for proper clearances in accordance with ANSI C2. New equipment shall not be connected to Government power without prior approval of the Contracting Officer or the Contracting Officer’s Representative [COR] assigned to the project. No high voltage work will be accomplished without prior approval of the Contracting Officer or the assigned COR. All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

5.3.3 Trades: Coordination of trades installing the equipment shall be the responsibility of the contractor.

5.3.4 Foundation / Hardware: All foundation hardware and foundation requirements as determined by the by the machine builder shall be furnished by the contractor and included in the bid price.

5.3.5 Utilities: The Government will provide utilities within 20 feet of the equipment installation site. The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor in the installation manual noted above.

5.3.6 Electrical: The Government will connect power to all contractor furnished fused disconnect device. The contractor shall furnish and install a main fused disconnect device separate from the equipment. The fused disconnect device shall be the correct size and type required the equipment voltage and comply with the requirements of paragraph 5.2.2. The Government will furnish only one voltage to the site.

5.3.7 Equipment Protection: The contractor shall protect surrounding equipment and shop area from damage due to dust, debris etc., during the installation.

5.3.8 Site Cleanup: The contractor shall remove all debris, scrap material, trash, etc.

from the job site daily. ANAD will furnish a dumpster for all trash and all construction materials at the job site, and will be responsible for emptying said dumpster. ANAD will provide an outdoor location for the cleanup of contaminated material if requested by the contractor. No equipment will be provided by the Government to perform any of the work performed by the contractor.

6.0 Documentation: The contractor shall provide documentation to the government as listed below. Three copies each of the following technical data shall be provided as specified on the attached DD Form 1423 with the CNC grinder. The contractor shall also provide three CDs that each contain copies of the delivered documentation.

6.1 Content: The manuals shall include electrical, hydraulic, and pneumatic schematics, as applicable; parts lists, trouble shooting procedures, preventive maintenance requirements, lubrication schedules, calibration procedures, etc. Catalogs shall fully describe optional tooling, fixtures, and attachments available for the equipment furnished. In addition, any other technical data normally furnished with the equipment shall be provided. All technical data shall be furnished in the English language and be IAW with the following data item descriptors (DIDs):

Operator' Manual CDRL A01 DI-TMSS-80527A Engineering Support Manuals CDRL A02 DI-TMSS-80527A Engineering Drawings CDRL A04 DI-SESS-81003B

Equipment Manuals CDRL A05 DI-TMSS-80527A

7.1 Coolant Recovery Systems and Filtration: The standard machine shall include all preparations for the coolant system. Tank, pumps, separator and filtration shall be specified and purchased separately from the machine. Separator and filtration shall utilize both magnet and synthetic or paper filtering as to minimize recirculating grinding contaminants. Tank shall be able to hold a minimum fifty gallons of metal working fluids. System shall be capable of using synthetic, semi-synthetic and oil based coolants. Tank and system shall be able to be pumped and cleaned without displacing the grinding center and/or any adjacent shop equipment.

7.2 JIB Crane: A Jib Crane and hoist with minimum lift capacity of 475 pounds and adequate reach for machine shall be included for wheel change and storage.

7.3 Mist Collection Unit/System: LOSMA Darwin 600 or EXO Mist Collection Systems or Equal to.

7.4 Automatic Wheel Balancer System: An automatic wheel balancing system shall be utilized. Wheel balancing system shall communicate with the CNC control to automatically perform grinding wheel dressing cycle when anomalies are detected in the grinding surface of the grinding wheel.

7.5 Grinding Wheels: Three each grinding wheels per machine for a total of twelve grinding wheels shall be supplied capable of grinding a thirty-two-micron finish on industrial hard chrome at specified wheel surface footage (8800 fpm). See 3.1.4 (ODxWxID) up to 24” x 4” x 10.0”

8.0 Training – On-Site: The contractor shall provide as a minimum training to the following type of personnel on-site at ANAD:

Operators – 3 days

Programming Training – 1 day Maintenance Personnel – 1 day

Training shall be provided for the operation, programming and maintenance of the equipment.

Training shall be conducted at Anniston Army Depot during normal Depot working hours. All training costs shall be included in the total bid price.