PURCHASE SPECS --- CNC--- 30 July 2012.doc

PURCHASE SPECIFICATIONS

for the

COMPUTER NUMERICAL CONTROL (CNC) ROUTER

809th MAINTENANCE SUPPORT SQUADRON

(809 MXSS)

30 JULY 2012

1. Scope.

This purchase specification covers the detailed specifications and performance requirements for a Computer Numerical Control (CNC) Router and installation at Hill AFB, Utah. The CNC Router shall provide machining capabilities for cutting composite panels into intricate parts. Primary applications include, but are not limited to, contouring, cutting and drilling composite test specimens.

2. Overview.

The acquisition of a CNC Router would allow the laboratory to rapidly cut out test specimens from composite and polymer panels for various materials tests. The testing will support the production of composite structures such as control surfaces and patches for aircraft including A-10, C-130, F-22, F-15, F-16, T-38, helicopters, Ground and Shop Support Equipment and Structures, Vehicles, Missile components, etc.

3. System Design.

3.1. AMERICANIZED ENGLISH: All documents and software submitted by contractor to USAF for the CNC Router must be in Americanized English.

3.2. The CNC Router shall be new and one of the manufacturer's current production models, which, on the date of this solicitation, 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 an experimental unit do not qualify. The machines shall include all components, parts and features necessary to meet the requirements specified herein and be ready for use.

3.3. OVERALL SYSTEM: The CNC Router system shall not exceed an overall footprint size of 108”x85”x79” (LxWxH). The router system shall have a minimum machining area of 48”x48”x9” (XxYxZ). The table shall have a minimum height of 30 inches from the floor to the working surface, bench top models are acceptable with included stand.

3.4. SPINDLE: The spindle shall, at a minimum, be a high frequency, ultra quiet, high speed, air cooled, 7.5 horsepower spindle with a range of at least 18,000 to 24,000 RPMs. It must use a collet ER 25 or similar with manual tool change capability. Automatic tool change is acceptable but not required. RPM range must enable proper feed and speed rates for cutting composite materials up to 0.5 inch thick. Spindle must have easily removable vacuum hood included.

3.5. STATIONARY TABLE: The table shall be of fixed/stationary design which uses heavy duty steel, cast iron or very thick aluminum construction with machined surfaces. The table must have t-slot clamping capability as well as vacuum table setup included; needing only to be attached to a vacuum system for sample hold-down.

3.6. MOVING BRIDGE AND DRIVE SYSTEM: The Bridge shall be a 3-axis moving gantry bridge design which uses ball screws or heavy duty rack and pinion, or equivalent, drive systems to highly accurately position cutter. The drive system shall use highly accurate rail and bearing systems to securely and accurately position each axis. The speed for each axis shall be capable of reaching at least 250 in/min.

3.7. SAMPLE POSITIONING: The system must have a laser pointer for simple home position setup. The system shall use locating pins or similar method to securely position material to be cut. The sample shall be held securely in place using both clamps and a vacuum table.

3.8. DUST CONTROL: The CNC Router shall include a dust collector attachment which allows containment of the majority of dust and chips generated by the cutter. The CNC router shall include a positive blower with at least 10HP, which attains 15inHg at 200 cfm or higher, and include a basic plumbing connection kit.

3.9. CONTROL: The router system shall include a computer numerical control for at least 3 axes, XYZ. It shall be controlled using an electronic closed loop servo control system or equivalent. The CNC router shall be controlled using both the included software controller and an included hand-held remote controller (which allows the operator to move freely around the machine). The controls must allow for automatic tool calibration.

3.10 SOFTWARE: The CNC Router at a minimum must include software applications that fulfill the following requirements:

3.10.1. Control of all XYZ movement and functions of the CNC Router shall be included with system. Must allow operator to quickly and easily program an accurate and efficient cutting path to remove the material cleanly from a part to a thickness of 5” or more.

3.10.2. Basic 2D drawing tools to draw 2D geometric shapes and text complete with editing tools to enable 2D cutting, drilling and engraving. A visual interface with 2D and 3D tools for general purpose machining such as continuous rough cut and finishing operations, drilling, contour cutting, pocketing, and shaping. Capability to import .dxf files from common CAD software.

3.10.3. Automatic calibration of router for position control of cutter.

3.11. SAFETY REQUIREMENTS: Covers, guards, enclosures, and/or other safety devices shall be provided for all parts of the machine that presents safety hazards. The safety devices shall not interfere with the operation of the machine.

3.12. DEVIATIONS: Offerors not meeting one or more of the above requirements should recite the requirement, their deviation and fully justify their solution. Any valid deviations from the above requirements shall be taken into full consideration.

4. OTHER DELIVERABLES.

4.1. WARRANTY: The CNC router shall have a minimum 90 day warranty which warrants all products provided under this contract, under normal use, to be free from defects in materials and workmanship and that system will perform its design function. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be repaired by the contactor at no additional cost to the government. The warranty shall cover the cost(s) of, parts, shipping, and labor expenses. Warranty repairs are to be completed within 15 calendar days of notice of failure. A monitored service phone number shall be provided to government for all service needs and questions.

4.2. INSTALLATION & TRAINING:

4.2.1. The system must be installed by qualified factory trained service technician(s) directly employed by the vendor. Upon completion of installation, after testing is completed and after final acceptance of the machine, basic machine operation and service training must be provided, for a minimum of 3 operators.

4.2.2. Within 60 days following installation, the vendor shall provide intensive hands-on applications training by a qualified applications specialist for a minimum of 3 operators, to be performed on-site at Hill AFB, Utah, for at least two 8 hour days. Training must cover all included software and all component functions.

4.3. All mechanisms requiring lubrication including gears, slide ways, and bearings (except sealed-for-life type) shall be provided with means for lubrication. All oil holes, grease fittings, and filler caps shall be easily accessible. The contractor shall provide all Material Safety Data Sheets (MSDS) for all oils or lubricants required for operation, and all lubrication must be on the Hill AFB approved hazardous materials.

4.4. The Contractor shall supply and deliver operations and maintenance manuals containing all necessary instructions for operation, calibration, maintenance and repair of the CNC router system and its peripheral equipment. The Contractor shall generate the manuals and provide at least two bound hard copies and one .pdf format electronic copy upon delivery of the CNC router system, see CDRL A001.

5. DELIVERY, STORAGE AND HANDLING.

Contractor to make all arrangements necessary, provide all equipment necessary, and cover all costs to deliver all job related equipment, supplies, materials, fabrications, etc. to the job site at Hill Air Force Base, Utah. Contractor to coordinate delivery and off-loading with 809 MXSS/MXEDA as required.

6. INSTALLATION REQUIREMENTS. Contractor shall provide a turnkey installation to include all setup requirements of the new CNC router at its final location. The contractor shall be responsible for the crating and shipment of machine to its final destination IAW standard commercial practice.

6.1. WORK ON-SITE:

6.1.1. COORDINATION: Contractor must coordinate all on-site delivery, work and installation schedules with the USAF project manager.

6.1.2. INSTALLATION TIME REQUIREMENTS: Contractor shall complete the installation of system within 14 days of its arrival.

6.1.3. NORMAL WORKING HOURS: When working in the laboratory the contractor, unless noted otherwise, is to work during normal work hours whenever possible. Normal work hours are defined as 0700 to 1630 Monday through Thursday and 0700 to 1530 on Fridays, however, No training can occur on holidays. Recognized Holidays: The contractor is not required to provide service on the following days: New Year’s Day, Martin Luther King Day, Presidents’ Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans’ Day, Thanksgiving Day, and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

6.2. TOOL CONTROL: If tools and/or equipment are lost, the contractor will report the loss to the customer within 30 minutes of discovering the item is lost. Every effort shall be made to recover the item before reporting it as lost.

6.3. PERFORMANCE/ACCEPTANCE TEST: Performance tests shall be conducted in accordance with the manufacturer’s recommendations and procedures. The contractor shall operate the machine including the spindle for a minimum of 2 hours with no load to ensure proper operation. The contractor shall demonstrate machine operation and perform testing on the machine to ensure conformance with this specification. An acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of a thorough examination and a simple composite coupon machining operation. Acceptance shall be made after the machine has met all requirements. Any abnormal noises, excessive vibration, inaccuracy or other findings shall be cause for re-assessment and contractor must take action to fix any of the problems or findings in the design of the machine that do not meet the performance and/or design requirements or that are a safety concern.

7. AFTER CONTRACT AWARD. After the contract award the successful bidder shall deliver the system within 90 days, fulfill all of the above requirements and demonstrate to the project manager that the system is fully functional and that all included pieces/parts are present and accounted for to receive final acceptance of the CNC router system. Failure to meet all requirements outlined in this PS shall be grounds for rejection.