New_REACT_Wire_SOW.DOC

STATEMENT OF WORK

FOR

Electrical Discharge Machine (EDM)

FOR

76 CMXG/MTAFF

AFMC OC-ALC/OBCA

25 JULY, 2017

Revision:01

Item Description: 76 CMXG MTAFF Shop Scope:

The Contractor shall provide all labor, tools, equipment, material, parts, quality control and transportation necessary to install one (1) Electrical Discharge Machine (EDM) CUT E600 or equal in Building 9001, Post BB23 for the Oklahoma City-Air Logistics Complex (OC-ALC), at Tinker Air Force Base (TAFB) The Contractor shall also provide Personal Protective Equipment (PPE) and clothing, to include reflective clothing (belt, vest, etc); hearing and eye protection, to include prescription safety glasses; safety harnesses; fall protection equipment; lifting equipment and any incidentals necessary to perform the requirements of this Statement of Work (SOW).

The Contractor shall be responsible for insuring all services, parts and components provided under this contract are in IAW the terms and conditions outlined in this SOW.

Item Description:

Wire Cutting Electronic Discharge Machine Requirements:

1.0 Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify. The machine shall include all components, parts and features necessary to meet the performance requirements specified. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair. The Wire EDM system shall be complete so that when installed and connected to the specified utility sources it can be used for any operation for which it was designed.

1.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.19-2010. 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.

1.2 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

1.3 Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Each lubricant reservoir shall have at least a 24-hour capacity. All lubrication points shall be accessible.

1.4 Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

1.5 Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

1.6 Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

1.7 Tank. The contractor shall provide an EDM system with a work-tank volume capable of fully submerged cutting the maximum specified part size. The EDM tank shall have a drop down door with a method to disable the water flow if the door is open.

1.8 Footprint. The EDM shall be designed to fit in the available footprint stated in Table 1. Height in this instance is measured from the floor. The operators must be able to operate the EDM given the available footprint. The included chiller can be separate from the machine but must indicate its overall dimensions and location of electrical and fluid connection.

1.9 Base Frame. The base frame shall be a stress relieved, heavy duty, cast iron or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

1.10 Worktable. The worktable shall be of stainless steel construction, designed to support and withstand the maximum capacity work-piece weights and tool thrust loads. The table shall be machined flat with an open center and a series of threaded holes at a 50 mm pitch for universal clamping.

1.11 Wire Guidance and Control. The wire shall pass through upper and lower closed style precision diamond guides that can be simultaneously positioned to facilitate conic and angular machining. The machine shall be capable of automatic wire threading in the event of a wire break. Wire tension and feeding shall be programmable. Wire spool capacity shall be as specified in Table 1.

1.12 Dielectric System. The dielectric system shall have sufficient fluid capacity to fully submerge the largest workpiece required. Water conductivity control shall be automatic using a resin system to deionize the water. The system shall provide means for recirculating and filtering the fluid through an included chiller to maintain a stable operating temperature to ensure accuracy. The included filter and resin bottle shall be designed and located such that they are replaceable.

1.13 Work Light. A work light shall be provided that complies with NFPA 79 requirements, have a protective shield and be adjustable to illuminate the work area.

1.14 Remote Pendant. A hand held pendant control shall be provided which provides manual positioning control of all axes at selectable feed rates. The hand held pendant control shall have sufficient length cord to allow observation of the workpiece by the operator. The control pendant functions shall include but not limited to the features in Table1.

1.15 Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

1.16 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 3 phase 480 VAC. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete. This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only.

1.17 Arc Flash. All electrical enclosures shall be marked for arc flash hazard per NFPA 79.

1.18 Motors. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number. Motor horsepower shall match the manufactures design and construction drawing.

1.19 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

1.20 Human Machine Interface (HMI) and Controller Features. The HMI shall include a screen with keypad/keyboard interface capable of controlling and displaying machine functions and status as listed in Table1.

1.21 Software Features. The supplied software shall be installed and run on a Windows 7/10 operating system. The software shall include but is not limited to the features listed in Table 1.

2.0 Installation. Contractor shall provide a turnkey installation, to include the necessary personnel and equipment required for the off-loading, securing and placement of the machine to the final location on the same delivery date of the machine, utility hookups, fluids, and all other requirements necessary for the operation of the equipment prior to the government acceptance. The contractor shall be responsible for all necessary certifications and permits required, for shipping, EPA, or other, by any government agency, local, state, or national. The contractor shall be responsible for the crating and shipment of machine tool to final destination IAW standard commercial practice.

1.

Tinker AFB will provide utilities connection points within 25 feet of the machine, according to the manufactures machine floor layout/machine envelope plan.

2.

The machine is to be uncrated and installed after delivery by contractor.

3.

The contractor shall provide machine dimensions and utility requirements in proposal.

2.1 Standard Equipment. All standard equipment required for proper operation of the machine (such as special tools, clamps, filters, spools, guides, etc.) shall be furnished. A list of these items shall be provided with the proposal.

2.2 Technical Data. The contractor shall also furnish 2 digital copies of the technical manuals and drawings in Adobe's Postscript (*.PDF) file format on CD-ROM(S). The digital manuals and drawings shall be organized, indexed and referenced similar to the equivalent hardcopy format (i.e. volume, manual, section, etc.). Standard manuals/drawings shall be in the English language.

2.3 Training. Training shall be provided for personnel in the operation, programming, and maintenance of the equipment for a period of 4 working days (no weekend training). Training shall be performed at the Tinker AFB, Oklahoma, and shall be started the week after the final acceptance of the machine. Training shall include but not be limited to the following:

1.

Familiarization with the equipment, including description of each system, description of safety and emergency features, and familiarization with related technical data to be provided.

2.

Demonstration by contractor of all operation, safety, maintenance and emergency aspects of the equipment.

3.

Hands on operation by receiving activity personnel with assistance from the contractor.

4.

Upon completion of training, receiving personnel shall be familiar with related technical data to fully operate and maintain the equipment as well as writing, editing, and verifying programs.

All printed training aids shall be supplied at no additional cost to the government, be in the English language, and become the property of the U.S. Government. During training if the machine has problem/issue that requires troubleshoot/ repair by the contractor, the contractor shall make up for machine down time for troubleshoot/ repair and the time to troubleshoot/repair the machine during training shall not be counted as the training time.

Table 1: Requirements Maximum Machine footprint

Electrical Power Supply

Includes transformer (if needed) for compatibility with facility 480 VAC 3 PHASE 60Hz

Minimum Workpiece Capacities

Wire Capacities

Accuracy

Glass scales on X, Y axis

Controller Features

15" or larger color swivel/adjustable mounted monitor and minimum of 8 GB on-board memory user file storage

Keyboard/keypad input with alpha numeric characters, USB port for file transfer

Remote pendant with: emergency stop, wire feed stop, axes jog and incremental positioning for X, Y, Z, U and V

Manual data input (MDI) to access the machine main functions, measurements and manual machining

Integrated collision protection to stop the tool during a collision without damage to the machine components.

Wire break alarm and automatic rethreading

Diagnostic display of the current job variables and consumables status.

Programmable power settings for machine startup and shut down to save energy

Measurement controls: Glass Scales on the X and Y axes. Encoder on Z, U and V.

Table 1: Requirements (continued) Software Features

File management for organization of jobs loaded to internal memory with graphic preview of job on screen

DXF import and export, Solidworks, Step, IGES and Parasolid file import

4 axis with taper and advanced conic functions

Create wire-path code from imported model surfaces

Pocketing (no-core) cutting abilities

Create/ edit or import of cutting geometry and definition of machining conditions for job

Surface recognition for toolpath extraction

Part scaling and rotations, Edge/Corner find, center hole find, middle find for parallel edges

Align the X and Y travel to an edge of a part and between two holes

Units selectable between Imperial and Metric.

Dielectric System

Included accessories

Included 0.010 (0.25) in (mm) diameter wire spool for startup

Included resin bottle for startup

Included upper and lower wire guides for wire spool

Included clamps and tools to hold workpiece to worktable

Background:

This project includes the delivery and installation of one (1) Wire EDM for 76 CMXG. The 3D metal printers can produce parts that are built by fusing the first layer to a build substrate/plate. Electrical discharge machining (EDM) is needed for dedicated removal of 3D printed parts from build plates.

Requested Services:

Purchase, delivery and installation of one (1) Wire EDM CUT E600 or equal for CMXG located in Building 9001, Post Location BB23. The Contractor shall be responsible for the removal of all debris. The Contractor shall provide an on-site four (4) day training for up to four (4) operators on the Shop floor in Building 9001, including training documentation. The training time is defined as follows, one (1) week broken out as follows: 1/2 day Monday and 8:00 AM to 5:00 PM Tuesday to Thursday with 1/2 day on Friday.

Hours of Operation:

The Contractor shall perform the work required under this contract during the following days and hours: Monday through Friday, 8:00am till 5:00pm. These dates and hours exclude Federal Holidays, base closures due to inclement weather, and furlough days.

Emergency Procedures:

The Contractor personnel shall follow the direction of the Government personnel with regard to emergency procedures, such as fire, tornado, active shooter, bomb threats, or other emergency. It is the responsibility of the Contractor to provide guidance and to establish procedures for its employees to respond to an emergency. It is the Contractor’s responsibility to account for their employees following an emergency evacuation. The Contractor personnel shall participate with the Government personnel in all fire and tornado drills at no additional cost to the Government.

Health & Safety on Government Installations:

While performing work under this contract the Contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. During the execution of the contract, the Contractor shall notify the CO, COR, and Government Contract Administrator (CA) within one (1) business day of any damage to Government property in which the dollar value exceeds $500,000.00 and within two (2) work days, for any damage to Government property less than $500,000.00.

Mishap notifications shall contain, as a minimum, the following information:

Contract, Contract Number, Name and Title of Person(s) Reporting

Date, Time and exact location of accident/incident

Brief Narrative of accident/incident (Events leading to accident/incident)

Cause of accident/incident, if known

Estimated cost of accident/incident (material and labor to repair/replace)

Nomenclature of equipment and personnel involved in accident/incident

Corrective actions (taken or proposed)

Other pertinent information

If requested by the designated CO, the Contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office. Contractors will not dispose of contract data related to a mishap until notified to do so by the CO.

76 CMXG Electrical Discharge Machine