CNC Small Wire EDM Spec.pdf

Delivery required in 90 days from receipt of order.

Specifications for Small CNC Wire EDM at Arnold Air Force Base, TN;

Arnold Engineering Development Complex (AEDC)

Provide all materials, labor, and equipment necessary to provide a new fully functional Small CNC Wire EDM Machine. Refurbished or remanufactured parts are not authorized for this requirement.

Machine General Requirements o Casting shall be Fine Grain Dianite Casting Material for added weight over conventional castings o Flat Floor Machine Mounting without modification to existing floor system o Linear shaft Motors on X, Y, U, & V Axis (no rotary motors/ball screws) o Linear motion guide ways on all axis with replaceable rails and trucks o Linear Glass Scales on X, Y, U, & V Axis (2 millionths absolute scales) o U-V Taper Unit should be able to cut 15 deg. up to 8” with the option to cut 45 deg.

with wide- angle guides and flush cups o Auto oiler o Submerged rethreading capability o Automatic wire alignment program and fixture o Program/Fixture to calibrate angle alignment o All-Axis Absolute Control System for not having to return to zero point after power failure o Thermal Stability System o Table maximum work piece weight 1,100lb.

o 3-sided drop tank encloser for ease of part set-up o Submerged and non-submerged machining capability o Automatic fluid level control for submerged machining o Dielectric System with necessary components; storage tank, pumps, filter, ion exchange resin canister, and controls.

o Fast fill pump o Deionizer, Ion exchange resin type o Dielectric Chiller o 1 piece 4-sided hardened worktable for holding parts o Ceramic Table Insulation o Automatic Wire Threader o L-cut wire chopper o Jumbo wire spooler to hold 22lb. spools o AC-Servo (closed loop) Torque Control Wire Tensioning System o Designed to accommodate wire sizes from 0.004” to 0.012” diameters.

o Necessary components to operate with 0.004, 0.010” & 0.012” wire guide sets to be supplied with the machine o Multi tap transformer, with line filtering and voltage stabilization o Uninterruptable Power Supply (UPS) to control for safe shutdown o Average machining current, 50 amps

Travel o X-axis travel Minimum 15.5”.

o Y-Axis travel Minimum 11.5”.

o Z-Axis travel Minimum 8.5”.

o U travel Minimum +2.4”.

o V travel Minimum +2.4”.

Controls o Manufacturer’s controller with minimum 19” touch screen Color LCD o Optical Servo Drive System Fiber Optics between the control, servo amps, and liner shaft motors o Standard control for all axis simultaneous machining o Machine run graph and simulation for all axis o Automatic power adjust capability for hard to machine workpieces and continued wire breakage o Conditions and offsets loaded for various materials for rough cut and skim cut operations o Controller shall have maintenance page for keeping up with maintenance requirements o Lan Connection port and USB memory port o 2D-CAM Programming o Fully automatic roughing machining o Corner control o Entrance control o Short circuit control o High speed power supply o 1Gbyte Memory, or manufacturer’s standard (DNC) memory with Ethernet drip feed capabilities o Controls equipped with conversational programming capability o Machine restart to stop one program and start another without losing settings o Advance with LCD screen remote pendant/handheld controller o Program dry run capability o Precision Pickup function o Conversational programming capability

General o Machine shall be built to NFPA 79 and operate with AEDC power system which is

480V, 3PH, 60 HZ or quote package shall include a multi tap step down transformer to machine operation voltage. Internal Line Filter and Surge protection.

o Machine shall include lifting, leveling, and floor attachment hardware o Hour Meter o Machine shall be equipped with necessary hardware to connect to shop air

(regulators, filters, oilers, etc)

Accuracy o Resolution for all Axis shall be +/- .000004” Minimum o Positioning for X, Y, & Z Axis shall be +/- .00001”/12”

Documentation o Operating and Maintenance Instructions and Manuals including:

Operating instructions Electrical Manual, & Schematics Manufacturers Controls Operating & Maintenance Manual Mechanical Manual & Schematics Maintenance Requirements Parts Listing Recommended Operational Spares o Provide two hard copies of each manual and one DVD based electronic copy to be received with unit

Verification o After delivery the Contractor shall provide assembly, startup and test run the machine at the site in accordance with functional tests for accuracy required by ISO/ANSI Standards.

o A test plan based on applicable ISO/ANSI standards shall be provided with delivery of machine for government approval.

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

o Ten Year Accuracy guarantee on Linear Drive System.

o Extended warranty if offered

Maintenance, Parts and Service o The Contractor or representative shall be capable of responding to a repair service call on-site within 36 hours and repair parts delivery within 48 hours after placement of order.

Packaging/Delivery o Provide all preservation, packaging, and packing to ensure safe delivery of the machine and related components to AEDC (FOB Arnold Air Force Base, TN 37389). Deliver Machine to AEDC for off-loading by AEDC personnel.

Installation/Training (These services shall be included in machine cost) o Installation will be at the Arnold Air Force Base, TN; Arnold Engineering

Development Complex’s Model Shop, West Shop, Building 451. Installation and acceptance testing of the machine shall be accomplished by Model Shop personnel and supervised by factory trained servicemen.

o Casual hands-on training on machine features and operation shall be accomplished beginning at machine startup following machine installation. Followed by two days of on-site formal training for up to five operators, including four to six hours of Conversational Programing. An additional two days of on-site formal training in machine controls and mechanical maintenance training shall be provided for up to five maintenance workers. (Total four days of formal on site O&M training shall be provided).