Waterjet Cutting Center - Statement of Work - 3 Feb 20.pdf

Statement of Work (SOW)

National Museum of the United States Air Force Waterjet Cutting Center

3 February 2020

OBJECTIVE:

The National Museum of the United States Air Force (NMUSAF) requires a Omax Maxiem 1530 waterjet cutting center to manufacture unique and highly complex exhibit components, innovative and modular exhibit assemblies, precision case/artifact furniture, custom exhibit panels, and other products to increase current capabilities and to reduce outsourcing costs for the Museum Exhibits Division. Additionally, this equipment reduces or eliminates physical operations including manually cutting, shearing, drilling and, thus reducing the potential risk of personal injury.

1.0 GENERAL REQUIREMENTS: The following establishes the minimum requirements for the purchase of an abrasive waterjet machine with equipment and accessories specified herein. The contractor shall provide a Waterjet Cutting Center to the following specification:

General: The waterjet abrasive cutting machine shall be 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. The Waterjet Cutting Center catcher tank and cutting table shall be one singular unit.

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.

Audible Noise: Audible noise emitted by the equipment under no load shall not exceed 81 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.

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.

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 table, pump, and controller will all be designed and built in the USA. The machine shall be manufactured, tested and shipped as a complete unit from the manufacturer’s location within the USA.

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:

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

Bridge design is defined as a structure that is supported and driven on both ends of the bridge that carries the cutting head.

Table: The machine footprint shall be 14’1” x 10’10” and provide a working envelope capable of housing a 12’2” x 5’8” 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 system must be of unitized design to eliminate misalignment due to an operator bumping either the cutting head or table during material loading. The base shall have access doors or removable plates as necessary for servicing components housed within. The table must be capable of supporting 300 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.

Table X-Axis: The X-axis shall be controlled by closed loop, digital drives with brushless servo motors that require no periodic tuning. The resolution shall be 1 micron with linear scale. The X-axis shall have full X-axis travel. The linear motion system shall use digital linear encoders to provide instant micron-level cutting head position feedback to the Windows® 10 controller to assure accurate part production.

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 23” LCD flat panel display. The unit shall provide for 3-axis simultaneous contouring capabilities and automatic control for all machine functions.

Software: Software shall run on Windows® 10 and be specifically designed for all abrasive jet and waterjet machining functions. Functions of the software must include automatic and manual lead in/out tools, automatic collision prediction and correction, support tool path fonts and Windows® true type fonts, calculate cutting in software before sending to machine, comprehensive and highly accurate part time estimates and job quoting, generate custom reports, optimal stack height calculator, special cutting quality for minimum taper, easily resize, rotate, or flip part for prototyping or to align with existing features, easily create 3D tool paths from solid models, comprehensive alert system of machine status including email/SMS notifications, customizable pause and alert triggers, comprehensive interactive waterjet reference including articles, videos, and tutorials.

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

TABLE I

TRAVELS

X-Y Travel 9’6” x 4’1”

TABLE

Table Size (W x L) 12’2” x 5’8” Footprint 14’1” x 10’ 10” Operating Weight 15,700 lbs.

Maximum Material Load 300 pounds/sq.ft.

NOZZLE

Z-axis travel, min (H) 12”

SPEED

Traverse rate 500 ipm

Accuracy/Repeatability: The machining center shall conform to the following accuracies/alignments of Table 2: State accuracy over entire travel.

TABLE 2

AXIS POSITIONING REQUIREMENT

X, Y, & Z Linear axes +/-0.003” over entire travel

AXIS REPEATABILITY

X, Y, & Z Linear axes +/-0.001” over entire travel

Electrical System: The machine shall be designed to operate from a 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.

Pump System: The pump shall be a direct drive crankshaft type pump with variable frequency drive controller, capable of obtaining and maintaining the designed operating pressure, 50,000 psi, without the use of hydraulic assistance. Pressure attenuators are not allowed to maintain operating pressure. Pump must drive 0.014” orifice at 50,000 psi.

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” OD X 1/8” ID stainless steel tubing, ¼” tubing supply lines will not be allowed.

5-axis cutting head: 5 axis cutting head is a complete software-controlled, multi-axis accessory that features the flexibility to automatically compensate for taper, as well as cut severe angles up to 60° off vertical. The 5 axis head cuts countersunk holes and precision shapes with beveled edges at angles specified by the user. The accessory supplies additional axes of motion, allowing the operator to fabricate and shape metal edges for weld preparation.

Settling Tank: The settling tank must efficiently clean overflow water from the Catcher Tank for environmental disposal to a public drain. The tank shall be rust resistant and the baffles shall be easily removable. The tank shall have an inlet of 1-1/2” NPT and an outlet of 1” NPT with a clean-out of 1” NPT.

2.0 DELIVERY:

a. Delivery FOB within sixty (60) days of contract award.

b. The waterjet cutting center shall be delivered to:

National Museum of the Air Force (DODAAC FE2300)

2601 E Street, Area B, Bldg. 5, Door 17 Wright-Patterson AFB, OH 45433

POC: Richard Brewer 937-255-7170

3.0 INSPECTION AND ACCEPTANCE

NMUSAF is designated as the office responsible for inspection and final acceptance of supplies or services provided in this order. A receiving report shall be accomplished immediately upon receipt and acceptance of supplies. The POC for Inspection and Acceptance will be Mr. Richard Brewer: Telephone :(937) 255-7170 , e-mail: richard.brewer.7@us.af.mil.

Prior to shipping, internal quality conformance inspections shall follow industry standard. This shall include testing of the complete machine (Table, controller, and pump. A ball bar test containing the specific serial number of the table and pump be performed and reviewed after installation to ensure accuracy of the XY, XZ, and YZ planes prior to acceptance mailto:richard.brewer.7@us.af.mil

4.0 TRAINING

On-site training shall be provided during machine installation. On-site training shall consist of a day and include operation, programming and routine maintenance of the machine. Additional training shall be offered in line with vendor standard for the device. 5.0 DELIVERY

PROCEDURES COMMERCIAL VEHICLES

All vehicles larger than a large pick-up truck are required to be inspected by the Wright- Patterson Air Force Base Commercial Vehicle Delivery Gate (CVDG) prior to entering the installation. Vehicles to be inspected include, but are not limited to, the following:

1. Step van/panel truck

2. Tractor/trailer, box, and flatbed containing cargo

3. Tanker trucks

4. Box Trucks

5. Tour buses

6. Garbage/recycled waste trucks

7. Concrete trucks/mixers, dump trucks

8. Cranes, recreational vehicles, petroleum tanker

This inspection will be conducted at Gate 16A located off State Route

444. The following are exceptions to vehicles utilizing the CVDG:

1. If the vehicle has the product inside (concrete and asphalt trucks) and timely delivery is necessary due to product deterioration it does not need to enter the CVDG. To bypass the CVDG, the contractor shall submit a list containing drivers’ names, social security numbers and the state in which the driver's license is held for those drivers who will be entering the base.

This shall be accomplished 24 hours prior to requested entry time. If entry is requested on Monday, this list must be submitted by Friday at 1630 hours. All lists shall be submitted to the 88th ABW/CE Directorate contract inspector. The only gates that may be used under this exemption shall be 15A, 26A, 38A, and gate 1B. If the driver's name is not on the list, he/she will not be allowed access to the installation through these gates and the base will not assume liability for denied access.

2. If a delivery vehicle must exit, and then re-enter the base to complete its route, the vehicle shall be resealed upon exiting the base. After initially passing through the commercial vehicle delivery gate, trucks shall be resealed at Gates 15A, 38A and 22B. The resealing of the trucks will allow them to continue to any other area of the installation (Areas A, B, or Kittyhawk) without reprocessing through the CVDG. To receive resealing assistance, the drivers shall physically stop at one of the three authorized gates and request the installation entry controller to reseal their truck and provide the next location of their delivery. The controller will reseal the truck and give the delivery driver a pre-clearance form. The driver shall present the pre-clearance form to the entry controller at the next point of installation entry. This reentry can be at any base gate.

3. Wright Patterson Integrated Defense Plan, paragraph 3.10.12.9.2. All irregular deliveries will be sent to the CVDG for inspection. All visitors, which include contractors and commercial vendors without proper background checks and contractor passes, will not be allowed on WPAFB unless escorted by the receiving agency. This will take place after the individual(s) are issued a pre-clearance form at the CVDG. After successful completion of the vehicle inspection, the receiving agency will escort the individual to and from their destination on WPAFB. An inspector at the CVDG will contact the receiving agency, informing them to send an escort to the CVDG. Escorts will remain with the vehicle at all times while it is on

WPAFB.

4. Vehicles may be subject to an inspection at any of installation entry control points during a directed random antiterrorism measure (RAM). Any commercial vehicle, regardless of size, can be directed to the CVDG at the discretion of the installation entry controller.

6.0 WARRANTY

Manufacturer warranty shall be honored by contractor for all products delivered for this requirement.

7.0 INVOICE AND PAYMENT

The contractor shall be paid upon submission of a properly prepared invoice and after final inspection and acceptance has been made. A proper invoice shall cite the contractor’s name and address, invoice number, invoice date, order number, contract line item number (CLIN), description of the supplies or service, unit of issue, unit price and extended price, terms of any prompt payment discount offered, and who to notify in the event the invoice is defective. The contractor shall submit invoice in wide area work flow (WAWF) as shown in this order schedule.