Draft_PD_-_Milling_Machine.rtf

file_0.wmf

15 Apr 2014

PURCHASE DESCRIPTION

CNC KNEE-TYPE MILLING MACHINE

1.0 SCOPE.

1.1. Scope. The following sets forth the minimum requirements for the procurement of three

(3) computer numerically controlled (CNC) knee-type milling machines. The machine shall be complete with the equipment and accessories necessary to provide the full capabilities described herein.

2.0 APPLICABLE DOCUMENTS.

General. The documents listed in this section are cited in section 3 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in section 3 of this specification, whether or not they are listed.

Government Documents.

Specifications, Standards, and Handbooks. The following specification forms a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

STANDARDS

FEDERAL

FED-STD-H28A - Screw Thread Standards for Federal Services (1994 edition) MILITARY MIL-STD-130N – Identification Marking of U.S. Military Property (2012 edition)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright- Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853)

2.2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

CODE OF FEDERAL REGULATIONS (CFR)

U.S. DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR 1910 - General Industry, OSHA Safety and Health Standards (29 CFR 1910), (2012 edition)

(Application for copies should be addressed to the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-0001)

Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASME B5.1M – T-Slots, Their Bolts, Nuts, and Tongues. (1985 edition)

(Application for copies should be addressed to the ASME International, Three Park Avenue, M/A 10 E, New York, NY 10016-5990)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4414 - Pneumatic Fluid Power – General Rules and Safety Requirements for systems and their components. (2010 edition)

ISO 4413 – Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and their Components. (2010 edition)

(Applications for copies should be addressed to the International Organization for Standardization, Case Postale 56, Geneva, Switzerland CH-1211)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 - Motors and Generators. (2011 edition)

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1847, Rosslyn, VA 22209)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 - National Electrical Code, (2014 edition)

NFPA 79 - Electrical Standards for Industrial Machinery, (2012 edition)

(Application for copies should be addressed to the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269-9101)

TELECOMMUNICATIONS INDUSTRY ASSOCIATION/ ELECTRONIC INDUSTRIES ASSOCIATION (TIA/EIA) STANDARDS

TIA TIA-232F - Interface Between Data Terminal Equipment And Data Communication Equipment Employing Serial Binary Data Interchange. (1997 edition)

(Address application for copies to the Telecommunications Industry Association, Standards and Technology Department, 2500 Wilson Blvd., Arlington, VA 22201)

TECHAMERICA ELECTRONIC INDUSTRIES ASSOCIATION (EIA) STANDARDS

TECHAMERICA-EIA-267-C - Axis And Motion Nomenclature For Numerically Controlled Machines. (1990 Edition)

TECHAMERICA EIA 274D - Interchangeable Variable Block Data Format For Positioning, Contouring, And Contouring/Positioning Numerically Controlled Machines (R1988)

(IHS, Customer Service and Technical Support , 15 Inverness Way East , Englewood CO 80112, Phone: 800-624-3974 303-792-2181, Fax: 303-792-2192, Email:

globalcustomerservice@ihs.com )

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

Design. The machine 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 catalogs or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer and technical POC in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the equipment shall be graduated in the inch/pound system.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the equipment, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

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.

Mercury Restriction. The equipment shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the equipment.

Lead. Lead and materials containing lead shall not be used on or in the equipment.

Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the equipment shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.10.1 Material Safety Data Sheet/Safety Data Sheet (MSDS/SDS). The contractor shall not transport or use any chemical, material or substance used in the performance of this purchase description (PD) on Tinker AFB before written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The contractor shall be responsible for submitting all material safety data sheets (MSDSs) or safety data sheets (SDSs) to 72 ABW/CEIE. Contractor shall comply with the effective dates for SDS requirements in accordance with the Occupational Safety and Health Administrations (OSHA) Hazardous Communication Standard, Title 29, Code of Federal Regulation (CFR) Part 1910.1200.

Contractor shall maintain copies of manufacturer MSDSs/SDSs for all chemicals and MSDSs/SDSs shall be readily accessible at all times by contractor personnel as well as government employees.

Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. Shall a low oil condition occur, the machine shall enter an emergency stop condition upon completion of the current operation. All oil holes, grease fittings, and filler caps shall be accessible.

Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

Construction. The equipment 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 equipment to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

Threads. All threaded parts, either US or SI, used on the equipment and its related attachments and accessories shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

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

Workmanship. Workmanship of the equipment 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.

Maintainability. The equipment shall be designed and constructed to permit Maintenance Personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair.

Consistent with required maintenance and design of the equipment, the contractor shall provide any special tools required to service the Unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair, or replacement of parts.

Components. The CNC knee type milling machine shall consist of, but not limited to, the following described principle components: base, column, knee, saddle, table, ram, spindle, quill, servo motor ballscrew assemblies with precision feedback devices, CNC system, attachments, and accessories necessary to meet the operational and performance requirements specified herein.

Computer Numerical Control (CNC). The knee-type milling machines shall be provided with a fully automatic, solid-state, integrated circuit, 1 GHz microprocessor based-type computer numerical control. The control system shall conform to EIA 274-D, EIA 267-C, and EIA TIA/EIA-232-F standards. The control shall be an Acu-Rite MillPWR G2 (or equivalent) and shall provide for 3-axis contouring capabilities, automatic control for all machine functions and function as a 3-axis digital readout (DRO) system during manual handwheel operation of X, Y and Z axes.

CNC Features. The Computer Numerical Control (CNC) system shall consist of, but not limited to, the following functions and features:

Position-trac/find home to reestablish workpiece zero after power loss.

12” flat panel color LCD display with 3D graphic feedback.

Internal part program storage capacity 2.4 GB flash (user).

Software travel limits.

Tool length and diameter offset compensation enabling direct input of part geometries.

Bolt hole calculations full & partial circles, linear row/column, rectangular frame/array.

Mirror/repeat/rotate functions.

Pocket program function-continuous closed contour, irregular shape w/multiple passes.

Alphanumeric Engraving function –arranged vertical, horizontal, diagonally or on arc.

Blend function inserts a radius between two lines, two arcs, or a line and an arc.

Program pre-view program function detail feature and program restart at any step.

Feedrate override.

Remote stop/go switch. Start and stop movement via a hand-held switch.

DXF file input to enable loading part geometry from a CAD file.

Edit capabilities by group and one block at a time.

bb) Program size limit 9,999 steps. cc) G80 Series drill cycles.

dd) Multiple datum (fixture offsets) 99

ee) Error compensation, linear and bi-directional non-linear. ff) Tool library.

gg) M and G code programming. hh) Spindle speed override.

ii) Feedrate override. jj) Coolant on/off.

kk) Filename filter search.

ll) Linear (G01) & circular (G02,G03) interpolation. mm) Decimal point programming.

nn. IPM, IPR programming and dwell. oo) Hour meter.

pp) Plane selection G17 to G19.

oo) Manual Data Input (MDI) capabilities. pp) Software travel limits.

Coolant System. The coolant system shall include a sump or reservoir, a power driven pump and all necessary piping. The sump or reservoir shall have at least five (5) gallon capacity to permit full pressure flow of both flood and mist coolant. The system shall have means for draining, cleaning and include a baffle or a strainer which is easily removable for cleaning. Means shall be provided to permit the operator to direct and control the amount of coolant with flexible coolant delivery nozzles.

Hydraulic System. The hydraulics system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

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

Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 480 volts, three phase, 60 hertz. 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. In addition, the contractor shall supply full documentation of the electrical requirements of the machine, including voltage and current requirements and any power conditioning requirements.

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

Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. 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 be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Cooling System. The machine shall consist of an heat exchanger cooling system, integrated into the unit, to maintain temperature for any heat sensitive components, i.e. computer/controller cabinets and spindle motor.

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Limit Switches. The machine shall be provided with electrical limit switches to prevent over travel during power feed and rapid traverse of the linear axes at both extremes of travel. The limit switches, upon being actuated, shall disable all machine motion. A visual display shall be provided on the operator's control panel indicating which axis tripped the limit switch.

3.3.6 Additional Feature/Accessories. The following additional features and accessories shall be provided with the machine:

Power feed Z-axis knee travel including installation.

6”swivel vise.

Machine Size and Capacity.

Size and Capacity Table I Characteristic

Axis Travels Size/Capacity X Axis (longitudinal) Travel 34” Y Axis (cross) Travel 16” Z Axis (knee) Travel 16” Ram Travel 21.0” Ram Swivel (degrees) Spindle Nose to Table (Min-Max) 3.0”-24.0” Spindle to Column (Min-Max) 1.5" - 17.5" Table

Width X Length 10"x 50" Load Capacity 850 lbs T-Slots (No. x Width) 3 x 5//8"

Feedrates (X & Y) inches per minute - Max 100 ipm Spindle

Horsepower (30 minute duty rating)

3 HP

Taper R8 Spindle Speed (rpm) 60-4,200 Quill Travel 4.5” Quill Diameter 3.375” Quill Feed (inches per revolution) 0.0015/0.003/0.005 Head Tilt (front-back) degrees 45-0-45 Head Tilt (left-right) degrees 90-0-90

Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the machine shall be as specified in Table II.

Table II

AXIS POSITIONING

REQUIREMENT

Linear axes (full travel): X, Y, Z +/-0.0005”

AXIS REPEATABILITY

Linear axes: X, Y & Z +/-0.0003”

ALIGNMENT

Parallelism, Table Surface to Table Cross Travel 0.0008"/12" Parallelism, Table Surface to Table Longitudinal Travel 0.0008"/20" Parallelism, Table Surface to Ram Transverse Movement 0.0008"/12" Squareness Perpendicularity of Quill Travel to table surface 0.0008”/5" Squareness of Table Surface to Knee Travel 0.0008"/12" Squareness of Longitudinal Travel to Cross Travel 0.0008"/20" Runout with 12” long bar @ root @ Tip

0.0002” TIR

0.0004” TIR

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.

Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

Points of lubricant application Servicing interval Type of lubricant Viscosity Military or Federal Specification for each lubricant (If applicable) Size and type of each lubricant filter

Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's name Manufacturer's model designation Manufacturer's serial number Power input (volts, total amps, phase, and frequency) Contract Number Date of manufacture

Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text.

Technical Data. Three (3) hard copies and one (1) electronic copy(s) of technical data shall be provided with the machine. Technical data shall contain technical information, specifications, instructions for the operation, programming, electrical & mechanical maintenance (parts lists, electrical schematics, ladder logic and I/O diagrams) of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. One

(1) complete set of manuals/drawings shall be sent to the receiving activity 30 days prior to the ship date and the remaining two (2) sets concurrent with machine delivery.

Training. Training shall be provided to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. Training shall be scheduled for 24 hours over three (3) consecutive workdays for up to six

(6) students. Training shall be conducted on-site at TAFB during the shop hours of 0530 to 1415 hours. Training shall not be scheduled for weekends or federal holidays.

4.0 QUALITY ASSURANCE.

4.1. Final Inspection/Acceptance. Inspection and acceptance of the machine shall be at destination by the customer. Inspection and acceptance shall consist of a type and kind; quantity; condition. Contractor shall provide one (1) hardcopy of alignment/inspection test report or ball- bar results conducted at origin indicating compliance with accuracy/repeatability requirements.