1848 Large CNC EDM Sinker Spec_Rev 2.pdf
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- Attached to
- Large CNC EDM Sinker
- Solicitation number
- FA9101_LARGE_CNC_EDM_SINKER
About this file
This document is a Statement of Work (SOW) specifying requirements for a new Large Sinker EDM Machine to be delivered to Arnold Engineering Development Complex (AEDC) at Arnold Air Force Base, Tennessee.
The contractor must provide a fully functional, new (not refurbished or remanufactured) Large Sinker EDM Machine with comprehensive technical specifications across multiple categories. General specifications include direct drive ball screws with C3 class rating in X, Y, and Z axes; linear motion guides with class P rating in X and Y axes and SP rating in Z axis; minimum drive resolution of .000002 inches; intelligent AC servo motors; Z-axis jump speed of 984 inches per minute with 1.6G acceleration; high-speed positioning at 275 inches per minute; 0.05-micron motor resolution; thermal growth compensation; and a dielectric fluid chiller. The machine must feature a three-sided drop-down tank enclosure with rapid fill pumps, triple-filter system, flushing through the head design, high-inertia C-axis with automatic chuck, orbiting machine head capabilities, maximum electrode weight of 400 pounds, automatic fire extinguisher, paper filtration system, 3R electrode compatibility, dielectric fluid emission and suction, auto lubrication, and a 6-inch A/B-axis rotary table. The worktable must measure 50 by 35 inches minimum with capability to accommodate workpieces of 55 by 40 by 15 inches minimum, maximum workpiece weight of 6,500 pounds, machine axis strokes of 35 inches (X-axis), 23 inches (Y-axis), and 17 inches (Z-axis) minimum, and T-slots for mounting.
Controls must include a manufacturer's controller with 19-inch minimum LCD color touchscreen monitor, keyboard, mouse, anti-virus protection, CMCIA memory expansion slot, LAN and USB ports, 256MB data server (DNC), 1GB program storage, pendant controller, intelligent automatic adjustment capabilities for electrode wear reduction and surface finish improvement, simple programming with preselected machining conditions, C-axis-linked orbital rotation, programmable flushing, 3-dimensional lateral servo for spherical/rib/taper shapes, built-in system maintenance monitor, 3-tier operation light, and hour meter. Power specifications require 120 amps maximum peak output current with high-power capability for machining PCD, CBN, and tungsten carbide, fine pulse power supply, latest E-packs for exotic materials and complex shapes with lifetime updates, and transistor pulse technology with ultra-low wear slope control. Accuracy specifications mandate repeatability of ±.0001 inches and positioning accuracy of ±.0001 inches per 12 inches for all axes with a ten-year accuracy guarantee on the linear drive system. The machine must operate at AEDC's standard 480V, 3-phase, 60Hz power or include a step-down transformer and power line filter. The contractor must provide formal training for three individuals, operating and maintenance manuals in digital and hard copies, electrical and mechanical schematics, and lifting/leveling/floor attachment hardware. Verification requires post-delivery functional testing per ISO/ANSI standards, and warranty covers defects in materials, parts, and workmanship for 24 months after installation for all components including controls, servomotors, and main spindle motor. The contractor must respond to repair service calls on-site within 36 hours and deliver repair parts within 48 hours of order placement. Delivery is required within four months from receipt of order, FOB Arnold Air Force Base, with the machine delivered for off-loading by AEDC personnel. Installation shall occur at the Model Shop in Building 451, accomplished by Model Shop personnel supervised by factory-trained servicemen, followed by two-day initial training beginning at machine startup.
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Specifications for Large Sinker EDM Machine at
Arnold Engineering Development Complex (AEDC)
Arnold Air Force Base, TN
Provide all materials, labor, and equipment necessary to provide a new fully functional Large
Sinker EDM Machine. Refurbished or remanufactured parts are not authorized for this requirement.
• General o Direct drive ball screws and linear motion guide ways
▪ Moving column design to allow easier loading and unloading
▪ C3 class screws in the X, Y, and Z-axis
▪ Linear motion guides shall be class P in the X, Y and SP in the Z-axis
▪ Min. drive resolution .000002”
▪ Drive motor type -Intelligent AC servo
▪ Direct drive motor coupling type
▪ Z-axis jump speed shall be 984”/min. and 1.6G acceleration
▪ High speed positioning 275”/min.
▪ 0.05um motor resolution
▪ Thermal growth compensation
▪ Dielectric fluid chiller o Three-sided drop-down tank encloser design with multiple stop locations
▪ Rapid fill tank pumps
▪ Built in triple-filter system that allows filters to be changed without machining interruption
▪ Flushing through the head design o High-inertia style C-axis with automatic chuck and flushing through the head design
▪ Constant burning capability 1-30RPM
▪ .001 deg. min. indexing angle o Machine head shall have orbiting capabilities o Max electrode weight on platen 400 Lbs o Automatic fire extinguisher o Paper Filtration System o Machine shall accept 3R electrodes system o Dielectric fluid emission and suction o Auto lubrication o 6” A/B-Axis rotary table with platen
• Table o Worktable size 50” x 35” min.
o Workpiece size 55” X 40” X 15” min.
o Machine axis Stroke X-axis 35”, Y-axis 23”, and Z-axis 17” min.
o Max workpiece weight 6500 Lbs o Table shall have T-slots for mounting work pieces
• Controls o Manufacturers Controller with 19” minimum LCD color touch screen monitor with keyboard and mouse
▪ Anti-virus protection
▪ CMCIA Slot for Memory Expansion
▪ Lan Connection port and USB memory port
▪ Data Server 256MB (DNC)
▪ 1GB program storage
▪ Pendent controller
▪ Intelligent control system that automatically adjusts settings while machining to reduce electrode wear and improve surface finish
▪ Simple programming with preselected machining conditions, burn processes, machining conditions, and rating of machine processes (wear, speed, and precision, all equal in combination)
▪ C-axis-linked orbital rotation allowing the orbital pattern to be linked to the rotation angle of the C-axis
▪ Programmable flushing
▪ 3-Dimensional lateral servo including spherical, rib, or taper shapes
▪ Built in system maintenance monitor
▪ 3-Tier operation light
▪ Hour meter o 120 Amps maximum (peak) output current
▪ High-power system for machining PCD, CBN, and tungsten carbide
▪ Fine pulse power supply for improved surface finish
▪ Latest E-packs for machining exotic materials, complex shapes, and a wide variety of electrodes
▪ E-pack updates for the life of the machine
▪ Transistor pulse, ultra-low wear slope control, super matte large area finish, narrow gap control, and mirror-finish circuits
• Contractor shall provide:
o Machine shall be built to NFPA 79 and operate with AEDC power system which is 480V, 3PH, 60 HZ or must include step down transformer to machine operation voltage o Power line filter o Initial instructions at installation and formal training for three (3) individuals on controls and operation of the machine o Machine shall include lifting, leveling, and floor attachment hardware o Operating Manual, Electrical Manual, Mechanical Manual, & Schematics, digital and hard copies o Controls Operating & Maintenance Manual, digital and hard copies
• Accuracy o Repeatability for X, Y, & Z Axis shall be +/- .0001” o Positioning for X, Y, & Z Axis shall be +/- .0001”/12” o Ten Year Accuracy guarantee on Linear Drive System.
• Verification o After delivery the Contractor shall test run the machine at the site in accordance with functional tests for accuracy required by ISO/ANSI standard.
• Warranty o This machine shall be warranted against any defects in material, parts, and workmanship for 24 months after the date of installation. The control, servomotors and main spindle motor are warranted against defects in material, parts, and workmanship for 24 months after the date of installation.
• Maintenance, Parts and Service o 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.
• Packaging/Delivery o Provide all preservation, packaging, and packing to ensure safe delivery of the machine and related components to AEDC (FOB Arnold Air Force Base, TN).
o Deliver Machine to AEDC for off-loading by AEDC personnel.
o Delivery required within four (4) months from receipt of order.
• Installation/Training o Installation shall be at the Arnold Air Force Complex’s Model Shop, West shop, Building 451. Installation of the machine shall be accomplished by Model shop personnel and supervised by factory trained servicemen. Two-day initial training on machine features and operation shall be done beginning at machine startup following machine installation.
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