Attachment 1_Statement of Work for Internal Dimension Grinders 03FEB21.docx

Statement of Work Computer Numerical Controlled Cylindrical Internal Diameter Grinder

1.0 Scope: This purchase specification provides the minimum requirements for five count Computer Numerical Controlled (CNC) Compact Cylindrical Internal Diameter (ID) Grinder, five count coolant recovery systems, five count coolant mist collection and filtration systems and ten count arbor tool sets.

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 CNC ID Grinder shall be new and one of the manufacturer’s current models capable of operation in accordance with the requirements herein. The machine shall be a cast iron 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 grinder 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 grinding operations. The CNC control shall accept programs from an off-line programming system. The CNC grinder shall have a Turcite V & Flat guideway system on X axis, a hydrostatic guideway on Z-axis, 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 allowing multi-surface ID, and face grinding in a single chucking. Axes shall be defined as X, and Z. There must 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 divides the rotation of ball screw to a minimum of 40M pulses. The 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 shall not require batteries to support the absolute position encoders. The grinder shall not require to return to a home position at any time.

3.1.2 Axis Travel. The minimum requirements for axis travels are: X-axis (Work-head cross-slide) travel minimum 7.5” inches, Z-axis (table) minimum of 19.50” inches.

3.1.3 Basic Capacity. The grinder shall allow a work piece weight minimum of at least 300 pounds (lbs.). with a maximum grinding length of at least 7.5” inches. The grinder shall have a swing within the chuck guard of at least 15.5” inches. Range of the grinding bore shall be from a minimum of 0.2”inches to a maximum of at least 11.75” inches. Range of outside dimension (O.D.) grinding capability shall be a minimum of 7.5” inches.

3.1.4 Work Spindle. The work spindle shall have a speed range of from 100 to 750 revolutions per minute (rpm). Spindle nose and spindle bore shall be 3.94”inches in diameter and 2.76” inches in diameter respectively. Spindle speed shall be infinitely variable through the CNC program.

3.1.5 Wheel Spindles: The CNC grinder shall be supplied with belt driven wheel spindles with a maximum spindle speed of at least up to 35,000 RPM. Multiple wheel spindles can be supplied to cover the entire range of RPM.

3.1.6 Machine Construction: The machine base shall be of cast iron construction.

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

Cutting feed rate for the X axis shall be a minimum of 0.00005” inches per minute to at least 230 inches per minute. Cutting feed rate for Z axis shall be a minimum of 0.00002” inches per minute to at least 230” inches per minute. Rapid federate shall be 750” inches per minute for the cross-slide (X-axis) and table (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 shall be designed to minimize influence from coolant and be thermally stable.

3.1.9 Coolant Systems and Filtration: The standard machine shall include all preparations for the coolant system. Tank, pumps, separator and filtration are not supplied as part of the base machine and shall be specified and purchased separately from the machine.

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

3.1.11 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 shall 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 min 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 shall 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 the operator of specific tasks associated with the current process.

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

3.1.13 Voltage: The CNC Mill 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 three feet from walls. Aisle ways aresix feet wide minimum.

3.4 Electrical Power Requirements: The CNC grinder shall be designed to operate on 230 or 460 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 CNCgrinder 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 American National Standards Institute (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 similar CNC grinders sold over the last ten 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 without the use of remanufactured or reclaimed machine components.

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 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:

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.

4.0 Ancillary Items

4.1 Coolant System/Separator: The contractor shall offer with the machine a coolant separation system for filtering and separation of metallic and abrasive materials from the grinding coolant. The system shall have both magnetic and paper filter means to separate contaminants from the coolant. System shall be specifically built with proper electrical and mechanical interface for use with the grinder offered by the contractor.

4.2 Grinding Wheels and Arbors: The contractor shall offer with the machine ten each quills (arbors) and grinding wheels to cover the spindle speed ranges available for their specific ID grinder offering. Arbor sizes and wheel specification (sizes, grit, material, etc.) to be determined at the time of solicitation award.

4.3 Work-holding: Contractor shall offer with the machine an air chuck and associated components for use on the ID grinder. Chuck supplied by the contractor shall include any necessary preparation on the machine tool for interface along with all mounting components. Chuck should be a 10” diameter 3-jaw design with 3.00” through hole. Coolant nozzles and a set of top jaws shall be included.

4.4 Mist Collection System: Contractor shall offer with the machine a system for collection of mist and smoke generated from the grinding operation. System shall be sized correctly and be mounted on the machine or next to the machine as to minimize space. Mist Collection System shall be supplied with easy access to the filtering section for ease of maintenance. Filters shall be of a progressive type system design providing filtration of incoming mist to a level of not more than one micron. System shall include proper electrical interface, machine prep, piping and fittings to properly connect the system to the machine.

5.0 Acceptance Testing & Verification

5.1 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.

5.1.1 Test Setup and conditions: Unless otherwise specified, ANAD will 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 will provide certification of calibration as specified.

5.2 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).

5.3 Performance Test: Performance Test shall consist of demonstrating the ID Grinder’s ability to operate to the manufacturer’s own specifications and produce to the published dimensional requirements, tolerances and finish. An initial performance test shall be accomplished at the manufacturer’s facility and serve to demonstrate the machine’s ability to meet the government’s intended purpose for the machine. Documentation of the machine’s initial performance test/accuracy shall be supplied with the machine at delivery.

Performance Test at the customer site shall consist of the following.

· Necessary tooling shall be mounted in the machine including centers, grinding dogs, grinding wheels, dresser.

· Dress the grinding wheel.

· Produce an artifact on the grinder. Customer will supply a part semi-finished on two diameters. The part shall match the material requirements of the parts which are intended to be produced on the grinder. The part shall be mounted between centers or in a chuck and the required diameters will be ground to finish.

Accuracy Level: +/-.015 on fractions, +/-.005 on decimals, +/-.0002 on ground diameters.

Measuring Instruments: Required micrometers, combination set, .0001 dial test indicator, 6" rule, gage blocks, surface condition comparison gages.

5.4 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.

6.0 Installation and Delivery

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

6.1.1 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.

6.2 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 will 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. 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.

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

6.2.2 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.

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

6.2.4 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.

6.2.5 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.

6.2.6 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.

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

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

from the job site daily. The depot 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.

7.0 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 contains copies of the delivered documentation.

7.1 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 in accordance with (IAW) the following data item descriptors (DIDs):

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

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.

9.0 Scope Change: 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.