Updated__CNC_Mill_Spec.pdf

14262-15-001B NOT SENSITIVE

SPEC No. 14262-15-001B 6 February 2015

ITEM SPECIFICATION

FOR

CNC MILL

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TENNESSEE 37389

NOT SENSITIVE

IRA-1607

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

3. REQUIREMENTS

3.1 General

3.2 Machine

3.3 Documentation

3.4 Other Requirements

3.5 Submittals

4. VERIFICATION

4.1 Testing

5. PACKAGING

5.1 Preparation for Delivery

6. NOTES

Appendix A – Submittal Procedure

Table of Contents-1

1. SCOPE

1.1. Furnish and deliver a Computerized Numerically Controlled (CNC) Mill to meet the requirements contained within this Specification.

2. APPLICABLE DOCUMENTS

2.1 Government Documents: None

2.2 Non-Government Documents:

2.2.1 International Organization for Standardization:

A. ISO 230-12 Test Code for Machine Tools.

B. ISO 10791-01 Test Conditions for Machining Centres.

2.2.2 National Fire Protection Association:

A. NFPA-79-12 Electrical Standard for Industrial Machinery.

3. REQUIREMENTS

3.1 General: Computer Controlled 4-Axes simultaneous (includes removable rotary table, 4th axis, for additional milling capability) CNC Milling Machine of current design and production for multi-purpose manufacturing. Minimum specifications as follows:

3.1.1 Machine:

A. X-Axis Travel 39.25 inches.

B. Y-Axis Travel 19.5 inches.

C. Z-Axis Travel 20 inches.

D. Replaceable hardened precision ground ways and linear ball/cylindrical roller guides on all axis.

E. Table Working Surface 41.25 inches by 19.50 inches (minimum).

F. Table Loading Capacity: Minimum 1,250 lbs.

G. Spindle Speed: Minimum 12,000 RPM.

H. Spindle Taper: CAT #40 taper.

I. Spindle motor: Minimum 20 HP.

J. Spindle liquid chiller cooling unit.

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K. Minimum tool diameter (adjacent tools) 3.00 inches.

L. Minimum tool diameter (no adjacent tools) 4.75 inches.

M. Minimum 20 tool magazine (CAT #40 Taper).

N. Automatic tool length measuring and breakage detection.

O. Flood and thru spindle coolant, minimum 213 psi.

P. Coolant tank with 95 gallon capacity.

Q. 8-inch or 200 mm Geared Rotary Table with interface.

R. Necessary hardware for anchoring mill to floor.

S. Chip Conveyor: external hinge type.

T. Table Mounted Tool Length Setter/Sensor.

U. Safety features shall include: full cover, impact resistant viewing window, door interlock system, and built in work light.

3.2 Documentation: Documentation to support programming; operating; tooling;

maintenance, parts list and electrical circuit diagrams including board level schematics; (2) sets hard copy and (1) set electronic version:

3.2.1 CNC Control – Include the following features:

A. Color LCD Monitor.

B. USB (2-Ports).

C. LAN Port.

D. Synchronous tapping

E. User macros.

F. Tapping / boring functions.

G. EIA/ISO and Conversational input function.

H. Background tool path check.

I. Macro B

J. Necessary software and machine function for 3D milling.

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K. Machine compensation for backlash, pitch error, rotational axis pitch error, and thermo displacement compensation.

L. Velocity and feed rate control.

M. Helical Interpolation.

N. Overload detection.

O. Program restart.

P. Manual pulse generator.

Q. Part program storage of 2 MB.

R. X, Y, Z, and C simultaneously controlled axes.

S. Inch/Metric conversion.

T. Machine lock.

U. RS 232 Port for data transfer and Ethernet link.

3.3 Other requirements.

3.3.1 Mill shall be built to NFPA 79 and operate with AEDC power system which is

480V, 3PH, 60 HZ.

3.3.2 Qualifications: The Contractor shall have the capability to service the equipment (labor and parts) beyond the warranty period or the equipment shall be able to be serviced by a local qualified representative. The Contractor or representative shall be capable of responding to a repair service call on-site within 36 hours and repair parts delivery within 48 hours after placement of order.

3.3.3 Contractor or technical representative shall be present at startup and assist Government with troubleshooting as required.

3.3.4 Contractor shall provide 20 hours of training for operators, maintenance personnel and programmers in-house.

3.4 Submittals: Contractor shall submit the following to the Government for approval in accordance with Appendix A:

3.4.1 Contractor shall provide cut sheets or product specifications indicating all performance characteristics and ratings.

3.4.2 Operations and Maintenance Manual: Contractor shall provide two sets each of Programming, Operations and Maintenance Manuals; Operating; Tooling; Parts

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List; Electrical Circuit Diagrams, down to and including board level schematics;

(2) Sets hard copy and (1) Set electronic version

3.4.3 Warranty: Contractor shall provide a minimum one year warranty, parts and labor, or manufacturer’s standard warranty, whichever is longer. See item 3.3.2 for service requirements.

3.4.4 Required Submittal Summary:

Table I. Required submittal list

No. Paragraph Reference

Submittal Description Due

1 3.4.1 Cut Sheets 2 weeks following contract award

2 3.4.2 Operation and maintenance manuals, and factory performance test results, see 4.1

At delivery

3 3.4.3 Warranty To begin after acceptance by AEDC

4 3.4.4 Test Date 7 days prior to testing

4. VERIFICATION

4.1. Testing at Contractor's Facility: Contractor shall provide test documentation showing compliance with the functional tests required by ISO 10791 and ISO 230 Test Codes for Machining Centers. Government reserves the right to observe the testing. Notify the Government 7 days prior to testing. Copies of the test documentation/results shall be provided at delivery.

4.2. Testing at the Government Site: After delivery the Contractor shall test the mill machine at the site in accordance with Section 4.1.

4.3. Acceptance: The Government will accept the mill machine upon successful demonstration, testing and training at the Government site.

5. PACKAGING

5.1. Preparation for Delivery: Provide all preservation, packaging, and packing to ensure safe delivery of the CNC mill and related components to AEDC (FOB Arnold Air Force Base, TN).

5.2. Delivery: Deliver CNC mill to AEDC for off-loading by Government personnel.

6. NOTES – Not used

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APPENDIX A

SUBMITTAL PROCEDURE

PART 1 GENERAL

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to shop drawings, product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, manufacturer’s field service reports, samples, operation and maintenance manuals, and other miscellaneous work-related submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract. This section describes the type and content of submittals that may be required for this work. The required submittals are included in the Statement of Work or Specification.

Non-work-related submittals are addressed elsewhere in the contract rather than in the specification and may include items such as: contract progress schedule, permits, payment applications, performance and payment bonds, insurance certificates, and progress reports.

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections of the specification or statement of work.

1.2 SUBMITTAL PROCEDURE

A. Definition: For the purposes of this section, the term “Contractor” denotes the prime Contractor.

B. Listing: At the end of this section is a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents. The listing may not be all inclusive and additional item submittals may be required.

C. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received. Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

D. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the performance of related work and other applicable activities. Transmit related item submittals for the same unit of work so that processing will not

Appendix A-1 be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

E. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. All submittals which are generic and list more information than is specifically required shall be marked to identify required information. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

F. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

G. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

H. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 14 calendar days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

I. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

J. Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance with the contract documents and the approved submittals.

Contractor shall clearly mark the proposed variation in all documentation and specifically point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional cost to the Government. Deviations from contract requirements require

Appendix A-2

Government approval and will only be considered when advantageous to the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 14 calendar days beyond normal submittal review period for consideration by the Government of submittals with deviations.

K. Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance.

The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist.

After item submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

L. Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 14 calendar days.

If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

M. Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

N. Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

1.3 SPECIFIC SUBMITTAL DESCRIPTIONS AND REQUIREMENTS: Submittal requirements for individual units of work are specified in the applicable specification section or Statement of Work (SOW). Except as otherwise indicated in the individual specification sections or SOW, comply with the following requirements for each type of submittal.

A. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and

Appendix A-3 seaming diagrams, and coordination drawings (for use on-site). Shop drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work.

Provide special notations of dimensions that have been established by field measurements. Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy in AutoCAD 2005 through 2010 drawing file format (.dwg). The only permissible text font is ROMANS. Custom fonts and shapes are prohibited. The minimum allowable font size shall be 0.125-inch. The maximum allowable font size shall be 0.25-inch.

B. Product Data: This data includes standard printed information on manufactured products that has not been specially prepared for this contract, including manufacturers' product specifications illustrating size, physical appearance and other characteristics of materials, installation instructions, standard color charts, catalog cuts, illustrations, schedules, standard wiring diagrams, standard product operating and maintenance manuals, and samples of warranty language when the contract requires extended product warranties. General information required specifically as product data includes manufacturers' standard printed recommendations for application and use, compliance with recognized standards of trade associations and testing agencies, the application of their labels and seals (if any), special notation of dimensions which have been verified by way of field measurement, and special coordination requirements for interfacing the material, product, or system with other work. Furnish three hard copies and one electronic copy.

C. Samples: These are physical examples of work, including, swatches showing color, texture, and pattern, color-range sets, and units of work to be used for independent inspection and testing. Samples include fabricated or unfabricated physical examples of materials, equipment or workmanship that illustrate functional and aesthetic characteristics of a material or product and establish standards by which the work can be judged, color samples from the manufacturer’s standard line (or custom color samples if specified) to be used in selecting or approving colors for the project, and field samples and mock-ups constructed on the project site to establish standards by which the ensuring work can be judged. This includes assemblies or portions of assemblies which are to be incorporated into the project and those which will be removed at conclusion of the work. Submit samples for the Contracting Officer's visual review of general kind, color, pattern, and texture for a final check of the

Appendix A-4 coordination of these characteristics with other related elements of the work and for quality control comparison of these characteristics between the final sample submittal and the actual work as it is delivered and installed. Submit one each.

D. Design Data: Design data includes design calculations, mix designs, analyses or other data pertaining to a part of work. Refer to individual sections of the specification or statement of work for required quantities, formats, and signatures or certifications required. Furnish three hard copies and one electronic copy.

E. Test Plans and Reports: Test plans shall include planned testing, including a description of the test, equipment and supplies needed, and step-by-step notation of test activities and tasks. Test reports include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements.

Testing shall have been within three years of date of contract award for the project. Reports also include findings of tests required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

F. Certificates: These include statements printed on the manufacturer’s letterhead and signed by the responsible officials of the manufacturer of a product, system or material attesting that the product, system or material meets specification requirements. Certificates include documentation required of the Contractor, or of a manufacturer, supplier, installer or subcontractor through the Contractor, to further demonstrate the quality of orderly progressions of a portion of the work by documenting procedures, acceptability of methods or personnel qualifications. Examples include confined space entry permits, and text of posted operating instructions.

Certificates shall be dated after award of the project contract and clearly name the project. Furnish three hard copies and one electronic copy of each certificate required.

G. Manufacturer’s Instructions: Preprinted material describing installation of a product, system or material, including special notices and Material Safety Data sheets concerning impedances, hazards and safety precautions.

Furnish three hard copies and one electronic copy.

H. Manufacturer’s Field Reports: Documentation of the testing and verification actions taken by a manufacturer’s representative at the job site, in the vicinity of the job site, or on a sample taken from the job site, on a portion of the work, during or after installation, to confirm compliance

Appendix A-5 with the manufacturer’s standards or instructions. The documentation shall be signed by an authorized official of a testing laboratory or agency and shall state the test results, and indicate whether the material, product, or system has passed or failed the test. Furnish three hard copies and one electronic copy.

I. Operation and Maintenance Data: Data furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer’s help and product line documentation necessary to maintain and install the equipment, and needed by operating and maintenance personnel for the safe and efficient operation, maintenance, and repair of the item. The data is intended to be incorporated in an operations and maintenance manual or control system.

Furnish two hard copies and one electronic copy.

J. Final Design Drawings and Documentation: Final design documentation including drawings, specifications, estimates, and other required deliverables. Electronic documentation submitted shall include every associated component file of drawings and other documentation, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Furnish a CD-ROM of all final design documentation, and drawings in AutoCAD 2005 through 2010 drawing file format (.dwg), to the Contracting Officer for approval prior to applying for final payment. The drawings shall be fully editable using AutoCAD software. In addition, drawings shall be delivered to clearly show the location and arrangement of all materials and equipment. The only permissible text font is ROMANS. Custom fonts are shape files are prohibited. The minimum allowable font size shall be 0.125-inch. The maximum allowable font size shall be 0.25-inch.

K. Record (As-Built) Drawings: Record drawings showing final configuration of work accomplished. Show all changes, additions, and deviations from the original contract drawings and documentation. If no changes occur, furnish certification to that effect. Drawings shall be redlined electronic drawings, unless waived by the Government, and shall accurately show as-built conditions during the progress of the job. Furnish drawings on a CD-ROM, in AutoCAD 2005 through 2010 format, including every associated component file of the drawings, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Submit to the Contracting Officer for approval prior to applying for final payment.

L. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

1. Maintenance agreements. Furnish one hard copy and one electronic copy.

2. Survey data and reports. Furnish one hard copy and one electronic copy.

Appendix A-6

3. Project photographs. Furnish both hard copies and digital files.

4. Keys and other security protection devices.

5. Maintenance tools, spare parts, and overrun or maintenance stock.

Refer to individual sections of the specification for required quantities of spare parts, extra and overrun stock, maintenance tools and devices, keys, and similar physical units to be submitted.

6. Qualification certificates. Furnish one hard copy and one electronic copy.

7. Employee training certificates and documentation showing successful completion of training.

8. Documentation of percentage of recovered material content used during contract.

9. Contractor safety and work plans and schedules.

10. Warranties.

Appendix A-7