UBHM STATEMENT OF WORK REVISED Jan 6.doc

STATEMENT OF WORK

FOR

UNIVERSAL BEARING HONING MACHINE

1. OVERVIEW: The purpose of this Statement of Work (hereafter referred to as “SOW”) is to obtain a proven, experienced, and qualified contractor who is capable of designing, manufacturing, and installing a new universal bearing honing machine in the Bearing Shop, Building 3001, at Tinker AFB, Oklahoma.

2. GENERAL INFORMATION

2.1. Equipment: The universal bearing honing machine is used to precisely hone aircraft bearing raceways. This equipment is capable of honing a wide range of antifriction ball and roller bearings.

3. EQUIPMENT DESCRIPTION

3.1. Scope of Work: The contractor shall deliver a fully operational machine with the capability to hone raceways on a wide range of ball and roller bearings. The Contractor shall provide all labor, tools, parts, materials, equipment, transportation, and incidentals necessary to travel to Tinker AFB, OK to install, perform acceptance tests, and provide technical training for the new universal bearing honing machine in accordance with the manufacturer specifications and this SOW. The Contractor shall coordinate any visits to the Bearing Shop with the Bearing Shop’s engineer to prevent interruption to production.

3.2. Design: The contractor shall provide new and unused equipment, capable of performing its intended function in accordance with the operation and performance requirements specified in this SOW. The equipment shall be complete in that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed if appropriate stones, tools, fixtures, drivers, change-over parts, mandrels, and stone holding fixtures (hereafter referred to as “accessory options”) are installed on/used with the machine. The bearing honing machine shall be predominantly a manufacturer’s current production models which, on the date the solicitation is issued, has been designed, engineered, and sold, or is being offered for sale, through the manufacturer’s advertisements, published catalogs, brochures, or website. Products such as a prototype unit, pre-production model, or experimental unit are not acceptable. NO PROTOTYPES WILL BE ACCEPTED. Some minor customization of a base production model machine and/or regularly offered standard options may be acceptable, but shall be disclosed and described in offerors proposal.

3.3. Specifications:

3.3.1. Operating Range: The universal honing machine shall be capable of honing aircraft antifriction ball and roller bearings in the size ranges described in Tables 1 and 2 below. The contractor shall describe, either by the spreadsheet or table, each required operating range; their machine’s operating range; and whether their machine’s range is a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts. In addition, the contractor shall provide a standard equipment catalog, equipment specific brochure, corporate website showing equipment specification sheets, or other documentation showing the equipment being proposed is predominantly a regularly offered and produced piece of equipment and set of accessory options complying with the requirements of this SOW.

Table 1: Ball Bearing Ranges

Table 2: Roller Bearing Ranges

3.3.2. Machine Characteristics: The contractor shall describe, either by the spreadsheet or table, each required characteristic and whether it is a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts of their machine.

· Infinite speed control of the spindle drive.

· Numerical Control (hereafter referred to as “NC”) of the horizontal slide for horizontal adjustment of the diameter of the linear oscillator, the raceway radius of the rotary oscillator, and movement for loading and unloading.

· NC of the vertical slide for the rotary oscillator for automatic adjustment of the center of the ball track on ball bearing inner and outer rings.

· NC of the vertical slide for the linear oscillator for automatic adjustment of the raceway on cylinder roller bearing inner and outer rings and NC superimposed stroke.

· NC of the horizontal slide for adjustment of one centering roller on the different part diameters.

· Infinite and automatic adjustment of the amplitude, oscillating frequency, and contact angle.

· Optional stone indexing devices.

· Adjustable stone contact pressure.

· Tool drive of the linear oscillator.

· Infinite adjustment of the amplitude of the linear oscillator.

· Fully automatic operating sequence for the ball and roller bearing with time control.

· Total tooling change-over time when switching from one size of bearing to another size of less than 25 minutes.

3.3.3. Machine Setting Parameters: The contractor shall describe, either by the spreadsheet or table, each required setting parameters range; their machine’s range; and whether their machine’s range is a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts.

· NC rotary axis for part spindle speed: 0-3000 revolutions per minute.

· Rotary oscillator frequency: 0-1200 double strokes per minute.

· Rotary oscillator amplitude: +/-10° variable.

· Adjustment of contact angle: +/-55°.

· Linear oscillating frequency: 0-2000 double strokes per minute.

· Linear oscillating amplitude: 0-0.23622 inch manual infinitely adjustable.

· Angle adjustment: +/-30° infinite manual adjustment.

3.3.4. Work Piece Loading: Work piece loading into holding fixtures shall be accomplished manually rather than by NC or other automated means. The contractor shall describe whether their machine has manual work piece loading as a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts.

3.3.5. Control: The machine shall possess a built–in NC operation with Human Machine Interface (HMI). The control panel shall be swiveled to allow the operator to see the control screen during operation. The contractor shall describe, either by the spreadsheet or table, whether their machine has each of these control features as a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts.

3.3.6. Numerical Axis:

In order to minimize the setup time, the machine shall have 5 NC linear axes. The contractor shall describe, either by the spreadsheet or table, whether their machine has each of these NC axis as a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts.

· NC-axis 1: Horizontal unit slide for positioning and correction of position of the rotary and linear oscillator as well as movement during loading and unloading.

· NC-axis 2: Vertical unit slide for adjustment and correction of rotary oscillator position during part change-over and approaching the raceway profile center point as well as movement for parts with double row raceways.

· NC-axis 3: Vertical unit slide for adjustment and correction of linear oscillator position during part change-over and NC superimposed stroke as well as movement for parts with two or multi-row raceways.

· NC-axis 4: Adjustment and correction of vertical position of pressure rollers on different part widths.

· NC-axis 5: Adjustment and correction of horizontal position of the left hand centering roller on different part diameters.

3.3.7. Enclosure: The universal honing machine shall be housed within a self-contained enclosure. The enclosure shall provide for containment of coolant and chips generated by honing operation and for operator safety in the event of a broken tool. The enclosure shall be provided with interlocked sliding door(s) and shall enable the operator easy access to the machine for the loading/unloading of tools, parts, and raw materials. The enclosure shall have bright cold work lights with an on/off switch. The contractor shall describe, either by the spreadsheet or table, whether their machine has each of these enclosure features as a “standard” feature of their base machine, a regularly offered “option” for their machine, or something that is a “custom” feature that can only be provided by a modification to the base machine and/or standard optional parts.

3.3.8. Electrical Control Cabinets: The electrical control cabinets shall be freestanding with safety locks and a main power switch and shall conform to the National Electric Code (NEC) standards in force as of the solicitation date.

3.3.9. Hydraulic and Honing Oil System(s): The hydraulic and honing oil system(s) shall include all pumps, valves, piping, filters, flow controls, and pressure regulators necessary for the machine to perform all the functions presented herein. A means shall be provided for controlling fluid temperature not to exceed 120°F during normal operation. The hydraulic system shall conform to ANSI/NFPA/JIC T2.24.1 standards in force as of the solicitation date. The contractor shall provide a list of the recommended honing oil(s) to be used in the universal honing machine. In addition, the contractor shall identify and provide the supply sources for each of these items, their individual stock numbers/part numbers, and material safety data sheets (MSDS) on each item requiring an MSDS. This information shall be supplied to the Bearing Shop’s engineer 90 days before the equipment installation. The engineer will verify the supply sources, secure the chemical approval from the Bioenvironmental Group, and procure the honing oil for the acceptance tests.

3.3.10. Lubrication System: Means shall be provided to ensure adequate lubrication for all moving parts of the machine. Each lubrication reservoir shall have visual indicators for determining fluid levels. All oil holes, grease fittings, and filler caps shall be easily accessible. Low lubricant level warning messages shall be displayed on the control screen when lubrication fluid reaches minimum safe operating levels.

3.3.11. Lubrication, Hydraulic, Cooling, and Honing Oil Plates: A fluid information plate shall be securely attached to the machine for each separate type of fluid used by the machine. The following minimum information shall be furnished on each plate:

· Fluid fill points

· Service interval

· Type of fluid

· Fluid viscosity

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

· Contractor name

· Contractor model designation

· Contractor serial number

· Contract number

· Power input (volts, total amps, and phase)

· Date of manufacture

3.3.13. Equipment Components: The universal honing machine shall be designed and built using commercially available components. Any components not commercially available must be fully disclosed in the equipment proposal along with justification for their use, manufacturer name, stock number/part number, and lead time from delivery to order receipt.

3.3.14. Accessory Options (Tools, Fixtures, Drivers, Change-Over Parts, Mandrels, Stones, and Stone Holding Fixtures): The contractor shall provide a list, either by the spreadsheet or table, of nomenclatures, stock numbers/part numbers, and prices of each of the specific recommended tools, fixtures, drivers, change-over parts, mandrels, stones, and stone holding fixtures to accommodate the honing processes for each of the ball / roller bearing in the size ranges described in Tables 1 and 2.

3.3.15. Documentation: The contractor shall provide three (3) sets of the following documentation in the contractor’s format, written and printed in English: operation, tools and fixtures set up procedures, programming, trouble-shooting guidelines, electrical maintenance, mechanical maintenance, NC maintenance, parts lists, electrical schematics, hydraulic system schematics, lubrication system schematics, honing oil system schematics, cooling system schematics, pneumatic system schematics, mechanical drawings, ladder logic diagrams, and warranty information. Two (2) sets of subject documentation shall be in paper copy with each document as listed above bound or otherwise separately assembled as individual volumes in a manner determined by the contractor. One (1) set shall be in a digital/electronic form on compact disks (CDs).

3.3.16. Back-Up Capability: The contractor shall provide a means to restore the machine to factory settings in case of catastrophe failure of any portion of the total system.

4.0. EQUIPMENT INSPECTION, INSTALLATION, AND ACCEPTANCE:

The contractor shall ensure that the installation and equipment are in compliance with the NEC in force as of the date of the solicitation. The contractor shall coordinate with the Bearing Shop engineer approximately ninety (90) days prior to delivery of the machine to setup a contractor or contractor representative survey of the installation site to ensure that all utilities and the foundation meet manufacturer requirements. The contractor shall correct any deficiencies identified in the installation inspection and acceptance tests, and provide physical evidence and/or documentation substantiating those corrections to the contracting officer and Bearing Shop engineer. The government will not accept the machine until concurrence between the engineer and contracting officer that the corrective measures adequately address the deficiencies identified, and the bearing honing machine is technically compliant and operationally performs in accordance with the manufacturer’s specifications and the requirements of this SOW.

4.1. Acceptance Tests:

The contractor shall have up to three (3) business days to complete two (2) rounds of acceptance tests after the completion of the equipment installation inspection. The Bearing Shop’s engineer will select six (6) different sizes of ball and roller bearings designated for performing acceptance tests. The contractor shall setup and run the acceptance tests. (Note: The contractor shall supply the honing stones for the acceptance tests.) The Bearing Shop engineer will perform bearing raceway inspection and analysis as follows in accordance with the criteria in Table 3 below:

· Visual inspection for damage to the raceways.

· Visual inspection for signs of heat damage to the raceways.

· Surface roughness.

· Surface roundness.

· Stock removal.

· Run out.

Table 3: Acceptance Tests

5.0 TRAINING:

The purpose of the training sessions is to ensure that the Plant Services’ mechanics, electrical/electronic electricians/technicians, and Bearing Shop’s machinists fully understand their respective roles and functions relative to the preventive maintenance, repair, calibration, and operations of the universal bearing honing machine. On-site training shall be conducted during the respective shops’ operating hours of 0545 to 1430 Central Daylight Time or Central Standard Time, as appropriate, and does not conflict with government holidays. The contractor shall provide all training materials in English. On-site training shall be held in two (2) sessions.

5.1. Training Session I:

The Training Session I shall commence either the day after the Bearing Shop’s engineer approves the completion of the equipment installation, and acceptance tests or it shall be scheduled no later than two weeks from the day that the Bearing Shop’s engineer approves the completion of the equipment installation, and acceptance tests.

The contractor shall have up to ten (10) business days to complete at a minimum the following training objectives:

· Overview of the equipment and demonstrate equipment capabilities (audience: management, engineers, and Bearing Shop personnel not to exceed sixteen (15) personnel total).

· Mechanical: Detailed explanations of equipment mechanisms, troubleshooting techniques, equipment setup, preventive maintenance schedules and procedures, corrective repairs, calibration schedules and procedures, programming procedures (audience: mechanics and Bearing Shop’s machinists not to exceed seven (7) personnel total).

· Electrical/Electronic: Detailed explanations of the equipment electrical/electronic systems, troubleshooting techniques, preventive maintenance schedules and actions, corrective repairs, calibration schedules and actions, programming procedures (audience: Plant Services’ electrical/ electronic electricians/technicians and Bearing Shop’s machinists not to exceed seven (7) personnel total).

· Programming: Procedures of programming NC controls, program reset and reload, and troubleshooting techniques (audience: NC programmers and Bearing Shop’s machinists not to exceed seven (7) personnel total).

· Honing operations: Thorough training for four (4) Bearing Shop’s machinists on the honing operations of the machine to include detailed comprehension and understanding of how to properly perform the following operations:

· Tool, fixtures, and stone selection.

· Equipment setup.

· Equipment startup.

· Programming procedures.

· Honing procedures.

· Making adjustment to the honing process.

· Troubleshooting techniques.

· Tool and driver change-over.

· NC control reset back to default settings.

· Any operator performed preventive maintenance.

5.2. Training Session II:

The contractor shall conduct a three (3) business day refresher training event in four (4) weeks after the completion of Training Session I. During this Training session, the contractor shall work closely with the Plant Services’ mechanics, electrical/electronic electricians/technicians, and Bearing Shop’s machinists to augment and close gaps identified in Training session I materials and instruction, resolve technical issues that arise during the time between sessions, and provide additional training otherwise deemed as necessary. The Bearing Shop engineer will provide a list of issues, concerns, and topics to the contractor approximately two and one-half weeks after the end of Training Session I. The contractor shall address at a minimum these issues, concerns, and topics in the Training Session II materials and instruction. Alternative Training plans will be considered, please provide details.

6.0. WARRANTY:

The contractor shall provide a standard commercial warranty on the equipment and all of its accessories. The period of the warranty shall begin upon the acceptance by the Bearing Shop’s engineer. Any required warranty works to correct defects in material and workmanship or premature wear and failure of any machine parts or accessories shall be performed at Tinker AFB, OK at no additional cost to the government.

7.0. Manufactures of Bearings:

Below are a list of different Bearing Manufactures - Timken

Split Ball Bearing – Division of MPB

Fafnir Bearing

TRW, Inc.

NTN Co. (Japan)

BII

FAG Aerospace

MRC (Marlin Rockwell Corp.)

SKF

6 January 2010