B08 Attachment 0001 RIPD E4000-24-3-05 (23-12-26).docx

GENERAL SYSTEM DESCRIPTION

The purpose of this project is to obtain a 6-in Boring Mill similar in function to the existing machines at RIA-JMTC with the added capability to machine castings with specific geometric tolerances. This will require an outboard tool support feature. The contractor will be required to provide the machine as well as all labor and materials necessary to perform the specified machining and to prove out the base capabilities of the machine (including accuracy and repeatability).

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.

DESIGN

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 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.

1.1.1.7 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.

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

1.1.1.9 Protection shall be provided to prevent damage to components.

1.1.1.10 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.

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

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

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

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

1.1.1.15 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.

1.1.1.16 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.

1.1.1.17 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.

1.1.1.18 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.

1.1.1.19 The unit shall be of watertight construction.

1.1.1.20 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.

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

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

1.1.1.23 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.

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

MOTORS:

1.1.1.25 All motors shall be rated for continuous duty.

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

1.1.1.27 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.

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

1.1.1.29 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.

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. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises 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.

1.1.1.30 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.

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

1.1.1.30.2 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.

1.1.1.30.3 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.

1.1.1.30.4 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.

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

1.1.1.31.1 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.

1.1.1.31.2 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.

1.1.1.32 No Common Access Cards (CAC) will be issued in relation to this project.

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 conforming to confined space work requirements when applicable.

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.

AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

COMPONENT SPECIFICATION

General Description:

The machine shall be a numerically controlled, multifunction, boring mill, complete with automatic tool changer, control pendant, machine table, bolt-on rotary indexer, and chip conveyor. The machine shall be capable of automatically performing in any sequence, milling, drilling, tapping, boring, and counter-boring operations. It shall be capable of controlling the axis motions independently, and in any combination of simultaneously controlled motions of X, Y, Z, W, B and U-axes. The B-axis shall be a removable 1° indexing table mounted to the primary table. The machine and its numerical control unit shall constitute a completely functional system with operations programmable by means of USB port, Ethernet connection, downloading from a host computer, and manual data input (MDI). The system shall be used to machine large weldments and castings, mild steel, stainless steel, bronze, aluminum, titanium, and possibly carbon-fiber composite material. It shall be an open system without an enclosure that could restrict loading of parts and fixtures but safety barriers will be provided and installed by the contractor as necessary for safe operation of the equipment. The equipment will also include a method of tooling support for accurately machining bored holes in cast components identified in this document (including equipment features, test materials, programming, tools and anything else necessary to verify the ability of the machine to produce the required features).

Equipment: The supplier shall furnish all equipment normally considered by him to be standard for his machine, whether specifically called for in this purchase description, or not. 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 14-ft wide by 14-ft high, and shall not exceed 25-ft in length.

COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 70,000-lbs.

INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 43-ft wide and 34-ft deep, including the operator’s area and all necessary service access clearance zones. Maximum height shall not exceed 20-ft. Width is defined as left-to-right when the operator is standing facing down the axis of the spindle.

Machine Base CONSTRUCTION: The machine shall be of heavy construction throughout and all parts shall be of such size and strength to properly sustain the maximum allowable loads imposed upon them with an adequate safety factor with minimum wear. The machine shall be free from chatter and vibration when rough or finish machining metal parts at rated horsepower with the proper tools, speeds, and feeds. All castings shall be fully stress-relieved, high tensile cast iron.

STABILITY: All axes shall be provided with means of holding axis components in place to permit accurate cuts under full horsepower without drifting. Servo control shall be utilized, preventing measurable, undesired motion, without distortion.

LINEAR AXIS CONTAMINATION: Way wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement.

WORK ZONE: The system shall include safety barriers and/or devices necessary for protection of the operator while allowing for loading/unloading of the table.

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

DRIVE MECHANISM COOLING: All linear axis shall include active cooling of the drive mechanism (e.g. ball screws) to minimize thermal growth and wear.

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

X-Axis AXIS DEFINITION: The X-axis shall be defined as cutting tool travel in a horizontal plane, perpendicular to the centerline of the spindle.

FEED RATE: The system shall provide a maximum cutting feed rate of not less than 700-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

FABRICATION: 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 height of any bearing supporting surfaces shall be such that the moving load is fully supported and shall not overhang the frame in any position within the machine's rated travel.

BEARINGS: The frame 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. 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: Motion shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s) with a minimum diameter of 3.9-in or an equivalent (2) ball screw system with each screw diameter not less than 2.5-in. 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 glass scales with positive air pressure system to prevent contamination. The system shall provide no less than 6,700-lb of axial force. All servo motors shall be of the same manufacture as the system controls manufacturer. (i.e. if the system controls are Fanuc based, then any 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 ball screws. The system shall include a bottom wash system to remove chips from the locating cones area below the pallet.

Y-Axis Y-AXIS: The Y-axis shall be defined as cutting tool travel in a vertical plane, perpendicular to the centerline of the spindle.

FEED RATE: The system shall provide a maximum rapid traverse feed rate of not less than 900-ipm and a maximum cutting feed rate of not less than 700-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

FABRICATION: 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 height of any bearing supporting surfaces shall be such that the moving load is fully supported and shall not overhang the frame in any position within the machine's rated travel.

BEARINGS: The frame 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. 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: Motion shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s) with a minimum diameter of 3.1-in or an equivalent (2) ball screw system with each screw diameter not less than 2.25-in. 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 glass scales with positive air pressure system to prevent contamination. The system shall provide no less than 6,700-lb of axial force. All servo motors shall be of the same manufacture as the system controls manufacturer. (i.e. if the system controls are Fanuc based, then any 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 ball screws. The system shall include a bottom wash system to remove chips from the locating cones area below the pallet.

W-Axis W-AXIS: The W-axis shall be defined as cutting tool travel caused by movement of the table or the column along the centerline of the spindle.

FEED RATE: The system shall provide a maximum rapid traverse feed rate of not less than 900-ipm and a maximum cutting feed rate of not less than 700-ipm. This shall be program controlled. The program increments shall be no greater than 1-ipm.

FABRICATION: 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 height of any bearing supporting surfaces shall be such that the moving load is fully supported and shall not overhang the frame in any position within the machine's rated travel.

BEARINGS: The frame 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. 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: Motion shall be powered by an AC or a DC brushless motor(s) driving a precision, preloaded ball screw(s) with a minimum diameter of 3.9-in or an equivalent (2) ball screw system with each screw diameter not less than 2.5-in. 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 glass scales with positive air pressure system to prevent contamination. The system shall provide no less than 6,700-lb of axial force. All servo motors shall be of the same manufacture as the system controls manufacturer. (i.e. if the system controls are Fanuc based, then any 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 ball screws. The system shall include a bottom wash system to remove chips from the locating cones area below the pallet.

Z-Axis (Quill) Z-AXIS: The Z-axis shall be defined as extension and retraction of the primary spindle.

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 ball screws. The system shall include a bottom wash system to remove chips from the locating cones area below the pallet.

U-Axis (Large Bore Capability) U-AXIS: The U-axis shall be defined as the motion of the tooling at the secondary spindle to allow motion of the cutting tool radially away from the centerline of the spindle. This will allow variable diameters and faces to be cut using a single tool. This is the axis that will require the outboard tool support. Note: If this function can be incorporated into the primary spindle, this axis is not required.

B-Axis B-axis or rotational motion shall be provided by a bolt-on rotary indexer capable of bidirectional rotation. The rotation of the table shall be controlled clockwise and counter-clockwise in both feed and rapid traverse by programmed numerical control and by MDI.

4th AXIS: The machine shall be equipped with a 1° indexing, programmable, bolt-on rotary table. An integral positioner is not acceptable.

FEED RATES: The system shall provide a maximum rapid traverse feed rate of not less than 6-rpm and a maximum cutting feed rate of not less than 6-rpm. This shall be program controlled. The programmable increments shall be no greater than 1-°/min.

LIFTING: Table and way configuration shall be such that the table cannot be lifted from its ways by machining forces.

LOCKING: The table shall be provided with means for locking a pallet in place. Lock up shall be sufficient to allow no measurable movement during full horsepower cuts at linear axis travel limits.

FIXTURE MOUNTING SIZE: The indexer top shall be at least 60-in x 84-in.

T-SLOTS: The indexer top shall be provided with (11) parallel, longitudinal, T-slots running the full length of the plate parallel to the long edge. The T-slots shall be machined to accept 0.8125-in T-nuts, and machined parallel with each other on 5.000-in centers held within 0.001-in full length.

CROSS-SLOTS: The indexer top shall be provided with (5) parallel, locating cross-slots running the full length of the plate parallel to the short edge. The center cross slot shall be 0.8125±0.0005-in wide, 0.75-in deep, and square to the center T-Slot within 0.001-in full length. The other cross-slots shall be machined to 0.8125±0.0005-in wide, 0.75-in deep and parallel with the center cross-slot to within ±0.001-in full length on 15.000-in centers.

LOCATING HOLE: The indexer top shall be provided with one fixture locating hole. The 2.5000 +0.0004/-0.0000-in diameter, 0.75-in deep hole shall be located at the intersection of the centerlines of the center T-Slot and the center Cross-Slot within ±0.001-in.

FLATNESS: The indexer top shall be flat and true so that, when mounted on the table and swept with an indicator mounted in the spindle, the entire pallet top shall fall between two planes no more than 0.0005-in apart (not to exceed 0.00015-in per foot).

HEIGHT: The total distance from the machine table surface to the fixture mounting surface (indexer top) shall not exceed 29.5-in.

Primary Spindle DRIVE: The spindle shall be equipped with an infinitely variable speed, AC spindle motor. Full horsepower (torque) shall be achieved at or below 70-rpm. All spindle drive shafts and gearing shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground. The spindle shall be capable of infinitely variable speeds. Spindle head shafts shall be mounted in precision ball and/or roller bearings. See ranges and capacities for speed, horsepower and torque requirements.

MATERIAL: The spindle shall be machined from alloy steel, precision ground and fitted in the spindle head assembly. It shall be a minimum of 6.1-in in diameter, and shall be mounted in a minimum of three, duplex mounted, Class 7 or better, angular contact bearings. Bearing preload shall be adjustable.

SPINDLE LUBRICATION: The spindle head shall be provided with a separate, positive means of lubricating the components housed within it.

COOLING: The spindle shall have a thermal controlling cooling jacket/system. This will extend the life of the spindle and minimize distortion during heavy machining operations. The cooling may be combined with the spindle lubrication system.

FLOOD COOLANT: The system shall include a flood coolant system or air blast system around the spindle nose for removal of chip nests prior to tool exchange.

THROUGH SPINDLE COOLANT: The system shall include a flood coolant system through the spindle nose for removal of chip nests prior to tool exchange.

SPINDLE NOSE: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground.

TOOL HOLDER: The spindle nose shall provide positive tool-holder location for tooling meeting the requirements of ISO Standard 7388/1 CAT#50 with “Big Plus” face contact. Positive, pullback and retention of the tool-holder shall be provided. Provision shall be made to allow manual loading of tool holders into the spindle nose, as well as automatic loading, using the tool changer.

ORIENTATION: Spindle orientation shall be provided, with the ability to stop within 1-deg of any given radial position.

Secondary Spindle DRIVE: The spindle shall be equipped with an infinitely variable speed, AC spindle motor. Full horsepower (torque) shall be achieved at or below 70-rpm. All spindle drive shafts and gearing shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground. The spindle shall be capable of infinitely variable speeds. Spindle head shafts shall be mounted in precision ball and/or roller bearings. See ranges and capacities for speed, horsepower and torque requirements.

MATERIAL: The spindle shall be machined from alloy steel, precision ground and fitted in the spindle head assembly. It shall be a minimum of 6.1-in in diameter, and shall be mounted in a minimum of three, duplex mounted, Class 7 or better, angular contact bearings. Bearing preload shall be adjustable.

SPINDLE LUBRICATION: The spindle head shall be provided with a separate, positive means of lubricating the components housed within it.

COOLING: The spindle shall have a thermal controlling cooling jacket/system. This will extend the life of the spindle and minimize distortion during heavy machining operations. The cooling may be combined with the spindle lubrication system.

FLOOD COOLANT: The system shall include a flood coolant system or air blast system around the spindle nose for removal of chip nests prior to tool exchange.

SPINDLE NOSE: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground.

TOOL HOLDER: The spindle nose shall provide positive tool-holder location for tooling meeting the requirements of CAPTO-C8. Positive, pullback and retention of the tool-holder shall be provided. Provision shall be made to allow manual loading of tool holders into the spindle nose, as well as automatic loading, using the tool changer.

Machine Table QUANTITY: The machine shall be equipped with 1 work table.

SIZE: The table shall be at least 70.9-in x 165.4-in.

T-SLOTS: The table top shall be provided with (13) parallel, longitudinal, T-slots running the full length of the plate parallel to the long edge. The T-slots shall be machined to accept 0.8125-in T-nuts, and machined parallel with each other on 5.000-in centers held within 0.001-in full length.

CROSS-SLOTS: The table top shall be provided with (11) parallel, locating cross-slots running the full length of the plate parallel to the short edge. The center cross slot shall be 0.8125±0.0005-in wide, 0.75-in deep, and square to the center T-Slot within 1.000-in full length. The other cross-slots shall be machined to 0.8125±0.0005-in wide, 0.75-in deep and parallel with the center cross-slot to within ±0.001-in on 15.000-in centers.

LOCATING HOLE: The table top shall be provided with one fixture locating hole. The 2.5000 +0.0004/-0.0000-in diameter, 0.75-in deep hole shall be located at the intersection of the centerlines of the center T-Slot and the center Cross-Slot within ±0.001-in.

FLATNESS: The table top shall have a flatness of 0.0005-in-per-foot concave, not to exceed 0.0022-in total across the entire table top.

Tool Changer MOUNTING: The tool changer shall be solidly mounted with vibrations sufficiently dampened to ensure proper alignment with the spindle, and ability to change tools during cutting cycles without transferring vibrations into the machine tool or work-piece. If the tool changer is floor mounted, means shall be provided for securing the unit to the foundation. All necessary leveling devices and hold down bolts required for the installation shall be provided by the manufacturer. Apparatus for precision locating and holding the unit in place shall be provided by the manufacturer. If the tool changer is mounted on the machine, the manufacturer shall provide means to allow safe access to the magazine and changing of tools.

CONTROL: The tool changer system shall be capable of tool selection automatically by MDI and by command in the parts program. It shall be possible to move the next tool to be used into position while the machine is in a cutting cycle.

Ranges and Capacities The machining center shall meet the following requirements. Requirements are exact except where specified as minimum or maximum.

Work-Piece on Machine Table

1.1.1.33 Maximum Work-piece Weight (minimum) 80,000-lbs

Work-Piece on Rotary Indexer

Linear Axis:

Primary Spindle

Secondary Spindle