Abrasive_waterjet_specifications.doc

PURCHASE DESCRIPTION

For

ABRASIVE WATERJET CUTTING CENTER

MINIMUMUM REQUIREMENTS

General: The waterjet abrasive cutting machine shall be new (not a prototype) and one of the manufacturer’s standard current production models capable of operations in accordance with the requirements herein. The machine shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. Designs with separate catcher tank (independent of cutting unit) will not be allowed.

Measuring/Indicating Devices: All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine shall be graduated in dual, inch-pound units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located so as to allow reading from the operator’s normal workstation.

Safety and Health: Covers, guards, and other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance, and repair of the parts. All machine parts, components, mechanisms, and assemblies furnished on the machine shall comply with all of the requirements of 29 CFR 1910.

Caution-Warning Plates: Corrosion resistant “Caution” or “Warning” plates shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

Audible Noise: Audible noise emitted by the equipment under no load shall not exceed 79 dBA at the operator’s workstation or at any other point at a distance of three (3) feet from the equipment as measured on the “A” weighted scale of a standard Type II sound level meter.

Prohibited Materials: Asbestos, mercury, lithium or polychlorinated biphenyl (PCB) shall not be used in any part or component of the system. Lithium batteries used in the computer system are exempt from this requirement.

Environmental Protection: The machine shall be so designed and constructed that under the operating, service, transportation and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prescribed by federal, state, or local statutes in effect at location of installation.

Nameplate: A corrosion resistant metal nameplate identifying the machine shall be securely attached to the machine. The nameplate shall contain the following information:

Nomenclature

Contractor’s Name

Contractor’s Model Designation

Contractor’s Serial Number

Power Input (volts, total amps, phase)

Date of Manufacture

Construction: The abrasive waterjet cutting machine shall be constructed of parts which are new, without defects, and free of repairs. The cutting axes and tank shall be one unit to guarantee the cutting accuracy listed herein. The machine structure shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion. Processes such as welding, plugging, or filling with solder or paste shall not be used for reclaiming any defective part(s). All screws, pins, bolts, and other fasteners shall be installed in a manner as to prevent change of tightness. The machine shall be manufactured, tested and shipped as a complete unit from the manufacturer’s location within the USA.

Castings/Forgings: All castings/forgings shall be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solders or paste shall not be used on casting or forgings for reclaiming any parts of the machine.

Welding, Brazing or Soldering: Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

Surfaces: All surfaces of castings, forgings, molded parts, stampings and welded parts shall be clean and free from sand, dirt, fins, sprues, flux, and other harmful or extraneous materials. External surfaces shall be smooth, and all edges shall be either rounded or beveled unless sharpness is required to perform a function.

Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

Painting: The machine shall be painted in accordance with the manufacturer’s commercial practice. Yellow or orange safety color-coding shall be used for designating physical hazards.

Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28.

Interchangeability: All replaceable parts shall be manufactured to definite standards, tolerances and clearances in order that any such parts of a particular type or model can be replaced or adjusted without modification of the equipment.

Maintainability: The machine shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, and repair of parts.

Components: The abrasive waterjet cutting machine shall consist of, but not limited to, the following described principle components, attachments, and accessories necessary to meet the operational and performance requirements specified herein.

Table: The machine footprint shall be 12’11” x 7’10” and provide a working envelope capable of housing a 10’6” x 5’5” piece of material. The bed shall have 4” x 14 gage galvanized steel support slats. The bed shall have means for leveling the machine on a flat mounting surface. The base shall have access doors or removable plates as necessary for servicing components housed within. The table must be capable of supporting 400 pounds per square foot of load. The contractor shall provide the necessary anchor bolts, leveling screws and related hardware to secure machine components to the floor, if design requires.

Y-axis: The cantilever Y axis shall be controlled by closed loop, digital drive motors that requires no periodic tuning. The resolution shall be 1 micron with linear scale. The y-axis shall have full travel and a motor controlled, precision Z-axis.

Computer Control System (CCS): The waterjet abrasive cutting system shall be provided with a fully automatic, solid-state, integrated circuit, 64-bit, multiple microprocessor based-type personal computer integrated with CAD/CAM software and 17 inch color LCD flat panel display. The unit shall provide for 3-axis simultaneous contouring capabilities and automatic control for all machine functions. The Computer Control System (CCS) shall consist of, but not limited to, the following functions and features:

a. Ergonomic swivel pendant mount

b. Inch/Metric switchable

c. 160GB part program storage

d. 17 inch color LCD flat panel display (min)

e. Built-in DVD ROM/CD-RW & USB mass storage device ports

f. On-screen help including operation, programming and alarm help

g. Hour meter

h. Real time 3D graphics

i. Sequence stop

j. 99 programmable homes

k. Unidirectional positioning

l. Helical interpolation

m. Feedrate programming

n. Cycle time reduction function

o. Graphical data input of fixed cycles and 2D graphics display

p. Coordinate calculation

q. Coordinate shift-rotation-copy

r. User defined logical operators, variables, math and trig functions

s. Linear & circular interpolation

t. Decimal point programming

u. Automatic zero referencing

v. Manual Data Input (MDI) capabilities

w. Positioning display - all axis

x. Linear feed display – ipm

y. Automatic acceleration and deceleration all axis

z. Software travel limits

aa. Array nesting

bb. Interactive, menu driven screen(s) w/inputs

cc. Graphical display of input values and online help

dd. Programmable mirror image

ee. Geometry enlargement/reduction

ff. Controlled depth etch capabilities

gg. Nozzle Taper control of up to (59° (If A-Jet Option Selected)

hh. Controlled high/low pierce pressure

ii. Scribe capabilities

jj. Part Preview

kk. Collision detection/prevention

ll. Corner compensation and automatic corner passing

mm. Saw cut operation

nn. Percent utilization Software: Software shall run on the latest version of Windows® and be specifically designed for abrasivejet and waterjet machining. Contractor shall provide free upgrades and 50 seats for as long as the receiving activity has possession of the machine.

Pump System: The pump shall be a 30 HP direct drive crankshaft type pump with variable frequency drive controller, capable of obtaining and maintaining the designed operating pressure, 60,000 psi, without the use of hydraulic assistance. Pressure attenuators are not allowed to maintain operating pressure. Pump must drive 0.012” orifice at 60,000 psi.

SAFETY ITEM: When unit is shut down must release high pressure water from the entire system including all waterlines and head unit.

High Pressure Tubing: The high pressure tubing that supplies pressurized water to the cutting head via the X and Y axis must be made of 3/8” stainless steel tubing, ¼” tubing supply lines will not be allowed.

Electrical System: The machine shall be designed to operate from a single 460 volt (±3%), 3 phase, 60-hertz (Hz) (±1 hertz) power source. The machine shall consist of independent electric servo drives. All electrical equipment shall comply with NFPA-79 standards to accommodate Metals Technology shop power availability.

Cutting Head: One piece nozzle body with integrated diamond orifice warranted to last 500 hours. This one-piece integrated nozzle eliminates the need for rebuilding the nozzle assembly, simply replace the whole assembly when needed.

600 pound abrasive delivery: Pressurized abrasive tank for holding 600 pounds of garnet must be supplied. The tank must include the appropriate air valves and pressure regulators to provide pressure sufficient to move garnet from the tank to the z-axis from up to 20 feet away.

Capacities: The sizes and capacities of the machining center shall meet the minimum requirements of Table I below:

TABLE 1

TRAVELS

TABLE

NOZZLE

SPEED

3.5 Accuracy/Repeatability: The machining center shall conform to the following accuracies/alignments of Table 2:

TABLE 2

AXIS REPEATABILITY

Solids Removal System: The solids removal system shall be a ¾ yd hopper and of steel construction. The system shall be operated by a ½ hp motor with a garnet removal rate up to 5.6 lbs/min. The solids removal system shall have a steel shielding over the suction line and have gravity return to main water tank. The solids removal system shall use 230 VAC 10 A and have a variable frequency drive/motor combination that allows for automated back flushing of the cutting tank.

Precision Optical Locator: A device to allow for accurate location of parts on the machining table or specific features on existing parts will be included. The locator must provide more accurate locating than the machine specifications. Operators must be able to place parts in any orientation, and the software will automatically rotate the tool path to match the placement of the part. Must accurately detect features less than 0.001”. USB camera with microscope lens is provided to zoom in on features, locate, and select with software integrated into the cutting program. Camera resolution must be capable of supporting 2592 x 1944 pixels.

Tilting Head for Taper Elimination: Method for eliminating taper must be provided. A nozzle that automatically rotates up to 9 degrees controlled by the software is required. The software can easily enable this mode with a single click. The software calculates the taper requirements continuously, not by average.

Collision Sensor/Terrain Follower: A Collision Sensing Terrain Follower that allows the waterjet to automatically and accurately cut parts from materials with irregular or warped surfaces without the need for special programming. The device is a ring that fits around the nozzle body and automatically sets the appropriate stand-off height to achieve accurate cutting. The device must be smaller than 3” in diameter.

Responsibility for Inspection: The contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The contractor may utilize his own or any other

Facility suitable for the performance of the inspection requirements specified herein. Purchaser reserves the right to perform any of the inspections set forth in the specification when such action is deemed necessary to assure supplies and services conform to prescribed requirements. The contractor shall provide all tooling, fixturing, measurement indicating devices, material and programs required of the compliance, accuracy alignment and machining acceptance tests.

Responsibility for Compliance: The machine shall meet all requirements of Section 3. The inspections set forth in this specification shall become a part of the contractors overall inspection system or quality program.

Quality Conformance Inspection: Quality conformance inspection shall be conducted on machine prior to being offered for acceptance under the contract. Quality conformance inspection shall be conducted at origin and could be monitored by purchasing personnel. The inspection shall be in accordance with par. 4.5, 4.6.

Origin Acceptance Test: All components (pump, table, and controller) must be tested together as a complete system prior to shipment. Cut a sample part using the complete system to ensure adherence to specifications before shipment.

Destination Acceptance: Final inspection, testing and acceptance shall occur at destination. The acceptance test shall be in accordance with par. 4.5.

Examination: The machine shall be visually examined to determine compliance with all requirements within Section 3. Buyer may select part for cutting to specification during installation.

Training: Basic on-site training must be provided during machine installation.

Warranty: The machine shall have a two year parts and labor limited warranty.

Manuals/Drawings: The contractor shall furnish one (1) hard copies of all technical manuals/drawings containing all information necessary for the programming, operation and maintenance (parts lists, electrical schematics, ladder logic and I/O diagrams) of the waterjet abrasive cutting system. One (1) complete set of manuals/drawings shall be sent to the receiving activity concurrent with machine delivery.

Installation Drawings: The contractor shall provide to the receiving facility, engineering installation drawings showing the necessary compressed air, water, and electrical utilities of the waterjet abrasive cutting system.

Documentation: All documentation, i.e. operation manuals, maintenance manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and grammatically correct.