Finalized SOW - Sources Sought Posting -Jig_Grinders_FY23 23-30-1329.pdf

PURCHASE DESCRIPTION FOR THE ACQUISITION OF THREE

(3) HIGH PRECISION JIG-GRINDING MACHINES

SCOPE.

Scope. The content of this specification describes the minimum requirements for the acquisition of three (3) high precision Computer Numerically Controlled (CNC) Jig- Grinding machines. This specification also includes the minimum requirements for technical data, tooling, accessories, ancillary equipment, delivery, unloading, rigging, installation, testing, and training. Delivery, installation, and training will occur at Fleet Readiness Center East (FRCE) aboard Marine Corps Air Station (MCAS) Cherry Point, North Carolina. Materials processed include various types and temperaments of aluminum, iron, titanium, magnesium, and nickel alloys with a focus on High Velocity Oxygen Fuel (HVOF) finishes.

APPLICABLE DOCUMENTS.

General. The documents listed in this section are cited in sections 3 and 4 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 sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract. Not including electrical, safety, military, or environmental specifications such as NFPA, OSHA, MIL, and EPA, FRCE will allow certain exceptions to these standards due to the machines originating country’s practices. Any standard taken exception to shall be explicitly mentioned in the contractor’s proposal. The contractor is to provide the originating country’s alternate standard that shall meet or exceed the US equivalent. FRCE reserves the right to accept or deny any proposed alternative standard.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910 Vol. 5: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

Environmental Protection Agency (EPA)

40 CFR 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions

(Application for copies should be addressed to the EPA Ariel Rios Building 1200 Pennsylvania Avenue, N.W. Washington, DC 20460)

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(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 or https://quicksearch.dla.mil/qsSearch.aspx)

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 listed in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

Attachment A: FRCE Information Brochure Attachment B: FRCE Contract Performance Requirements Attachment C: FRCE Contract Installation Requirements Attachment D: FRCE Drawing: Building 133 Replace3 Jig Grinders Attachment E: FRCE Performance Test Drawing Package

(Applications for these documents should be addressed to the contracting officer)

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

American National Standards Institute, Inc. (ANSI) https://quicksearch.dla.mil/qsSearch.aspx

ANSI B5.1M: T-Slots, their Bolts, Nuts, and Tongues, Revision of ANSI B5.1-

B11/STD B11.0: General Safety Requirements Common to ANSI B11 Machines

B11/STD B11.23: Safety Requirements for Machining Centers and Automatic, Numerically Controlled Milling, Drilling, and Boring Machines

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME Y14.100: Engineering Drawing Practices

ASME Y14.5-2018: Dimension and Tolerancing

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org)

International Organization for Standardization (ISO)

ISO 1328-1: 2013 Cylindrical Gears – ISO System of Flank Tolerance Classification

ISO 3408: Ball Screws

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

Japanese International Standard

JIS 6336: Test Code for Performance and Accuracy of Machining Centers

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA ICS 1: Industrial Control and Systems General Requirements

NEMA ICS 6: Industrial Control and Systems: Enclosures http://www.asme.org/

NEMA ICS 16: Industrial Control and Systems: Motion/Position Control Motors, Controls, and Feedback Devices

NEMA MG 1: Motors and Generators

NEMA Z535.4: Product Safety Signs and Labels

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

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE EIA-274-D: Interchangeable variable block data contouring, format for positioning and contouring/positioning numerically controlled machines

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale PA 15096)

German National Organization of Standards (DIN)

VDI/DGQ 3441: Statistical Testing of the Operational and Positional Accuracy of Machine Tools

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.

REQUIREMENTS.

Design. The item offered 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 catalogue or brochures. The vendor shall provide examples of commercial availability through readily available brochures, websites, listing of recent sales, or other advertisements. The information provided must show the same/similar model quoted in response to the solicitation. If there are modifications between the commercial available model, and the model offered to meet the government’s minimal requirements, those differences may be outlined in the literature provided. 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. 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.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the US Customary Units.

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 machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910. Safety signs and labels on all equipment shall comply with NEMA Z535.4.

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11 standards. 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 easily removed to facilitate inspection, maintenance, and repair of the parts.

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 machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture with the exception of fluorescent lighting where required.

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

Lead. Lead and materials containing lead shall not be used on or in the machine with the exception to radiation, cladding, and lead solder in circuits.

Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited. The machine shall be considered PCB free providing certification to be verified containing less than 5 parts per million (<5ppm) in accordance with 40 CFR part 761.

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

Lubrication. The machine shall be equipped with a system that provides lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements. 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 lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible.

Replacement Parts. 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.

Construction. The machine 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 machine 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, 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 used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein.

Gears. All gears of axis drive trains shall conform to or exceed all provisions of ISO 1328. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

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 machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead and hexavalent chromium free type.

Workmanship. Workmanship of the machine 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.

Components. The machine shall consist of not less than the following components:

Base. The base shall be a stress relieved, heavy duty, ribbed quality casting having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

Table. The worktable shall be a casting of iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights and tool thrust loads. The worktable shall be precision fitted to the scraped ways integrated into the base. The top of the worktable shall be machine finished for a work-mounting surface. The worktable shall have a coolant trough or similar means for draining spent coolant into its reservoir. When equipped with T-slots the number and size of T- slots shall be the manufacturer’s standard.

Machine Ways. Machine ways shall be hardened. The ways shall be of a type suitable for high-grade precision numerically controlled machines covered by this purchase description. Movement of the slides on the way surfaces shall be through adjustable preloaded, re-circulating roller bearing cartridges or nonmetallic way liners having a low coefficient of friction, with excellent slip-stick and damping properties. Protection of the machine ways shall be either telescoping or curtain type way covers equipped with way wipers.

Axes. All axes of the machine shall be actuated through a closed loop, high-gain electrical servomechanism driving re-circulating ball screws and nuts. Ball screws are to be of accuracy ISO 3408 grade C1. Closed loop shall be dual feedback type linear scales with accuracy grade of 3 microns or better. Linear scales shall be fully sealed or mounted in a location with no exposure to the environment. All axes with backlash mechanisms shall support both internal (ID) and external (OD) grinding machining thrusts. Infinitely variable feed drives shall be provided for all axes. Axes shall be machined to accept way bearings of a precise fit to their respective ways. The way bearings shall be an antifriction type and shall be provided with adjustable gibs, guides, or bearings to maintain and adjust alignment of the table to the ways and prevent causing excessive loading of the feed drive motor.

Antifriction, re-circulating ball type linear ways are acceptable. All motion/position control motors, controls, and feedback devices shall conform to NEMA ICS 16. Axes shall be as follows in terms of communicating requirements within this specification:

a) X axis – Table moving under the gantry from front to back of the machine.

b) Y axis – Spindle saddle traverse left and right on the cross rail or the table moving left and right in the case of a fixed spindle saddle design.

c) W axis – Cross rail/spindle saddle vertical motion.

d) Z axis – Vertical motion of the spindle quill.

e) C axis – Rotation axis of the sub-spindle driven by the main spindle.

f) U axis – Traverse axis of the sub-spindle.

g) Grinding Spindle Axis – Rotates the grinding arbor (tool holder)

U Axis. This U axis ways shall be manufactured to the same standard as all other machine ways and support full travel specified in Table I without the support of any modular components including, but not limited to extension plates. The U axis drive system shall offer manual and automatic feed based configurable at the controller. Starting from any point in the U-axis feed range, the in-feed shall have an equivalent positioning accuracy to the outfeed for a travel feed up to 0.075 of an inch.

Grinding Spindle. The grinding spindle shall be connected to the U axis. The grinding spindle shall be modular allowing for mounting and dismounting of different grinding spindles. Table III Spindle Section defines the types of spindles to be provided with machines. The 25,000-rpm spindle shall be only electrically actuated/driven and supported by temperature controlled cooling jacket. Arbor changes on the sub spindle shall be of manual type as tool changer is not a requirement of this specification.

Cross-Rail. The cross rail shall be a casting of iron or iron alloy and proportioned to support and withstand the spindle assembly and tool thrust loads. The cross-rail shall be supported by a dual column design. The dual columns shall remain fixed in the X and Y axes. Cross-Rail shall be precisely fit to the ways of the columns. Cross-Rail shall be supported by a locking mechanism that maximizes rigidity. If required, cross-rail controls shall prevent any crashes with guarding.

Enclosure. Machine shall be fully enclosed; exceptions can be taken to enclosing the top/roof of machine. The enclosure shall prohibit the escape of any grinding particulates or coolant from the machining area while the doors are closed. The enclosure shall prohibit all coolant from escaping anywhere but the coolant return path and the coolant return system shall be seamlessly incorporated into the machine base without any gaps or breaks between the work area and enclosure guarding. Access doors shall be provided at the front-end.

Access door shall be provided on both sides of the machine. Access doors shall incorporate viewing windows. The front access door and enclosure top shall allow crane loading with an unhindered path that opens a minimum of 50 inches wide. The side door nearest the operator control station shall allow access to the cross rail and be permitted to open during set-up of the machining operation and allow all functions including axis travel motions and spindle that is rpm restricted to a safe speed. These set up operations shall be protected by an enabling switch on the remote pendent.

Coolant System. Coolant system including conduits, pumps, chillers, and any other components related to the coolant system shall be able to accept entirely oil based, entirely water based, or a hybrid mixture coolants. Coolant system shall be variable high volume type. A manually adjustable flex hosing shall be used to deliver coolant. A minimum of 2 coolant delivery hoses that maintain position near the sub-spindle throughout spindle and spindle saddle travel shall be provided. A minimum of one (1) flex hose shall be provided near the grinding truing station. A wash down hose shall be provided that is tied into the coolant system. Coolant shall have a return path that is integrated in the enclosure design as define in section 3.3.9. Coolant system shall be serviced by a band paper filter system with a minimum filter efficiency of 10 microns. The coolant system shall include a sump or reservoir, a power driven pump, and all necessary piping. The system shall have means for draining and cleaning. The system shall incorporate a system to temperature control the coolant that is easily programmed at the controller. This temperature control shall be able to be turned off and allow the coolant system to run as intended with a temperature-controlled system.

Particulate Collection System. Spindle shall be supported with a mist collection of Keller ENA-S Mist collector or equivalent. The mist collector shall have a Variable Frequency Drive (VFD) that allows the operator to manually adjust the airflow of the collection unit. This system should be a standalone unit that is mounted to minimize vibrational or thermal effects on the machine. The system shall operate from a 480 VAC, 3 Phase, 60 Hz power source; have a separate fusible and lockable disconnect to provide equipment isolation from the Jig Grinder for maintenance purposes; and be wired to be automatically controlled to work in conjunction with the Jig Grinder. The mist collection unit shall be mounted and piped in a manner that allows for direct recycling of collected and filtered coolant over the band filter paper system described in section 3.3.9 The system inlet ducting/hosing shall enter through the back of the enclosure and terminate at the gantry for collection directly next to the spindle and limit frictional losses or collection pockets through complex hosing routes. The operator shall be able to move inlet nozzle in the machines X-axis direction for prevention of crash. Any clean air filtration shall have a filter with a minimum MERV rating of 8, but not greater than 12. This system shall have an upgraded sound suppressing/dampening system to achieve less than 72 decibels.

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

Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The system 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 volt, 3-phase, 60 Hertz (Hz), 400 amps. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including 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.

Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79.

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

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 handle 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.

Controller Features. The machine controller shall consist of a Fanuc 30i-B CNC Controller incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be both synchronous and independent positioning with exception to the W axis. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, linear interpolation, circular interpolation, programmable interface, part program edit, buffer edit capability, part program storage, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits.

Grinding Method Controls. Jig grinding machine shall be able to perform both ID and OD grinding. Spindle shall be able to both grind in a planetary mode (C axis) and profile/interpolation (X and Y axes move around spindle) mode for all grinding operations.

The operator shall be able to control interpolation in the controller using sub routines or form of conversational programming.

Console. The operator control console shall have at a minimum the following:

a) Windows based operating system

b) Instruction and data input via keyboard and soft keys

c) 15 inch LCD color screen with touch input ability

d) Capability to store up to 200 machining programs and up to 200 different tools – 8 mB of capacity.

e) Portable electronic hand wheel with a selection switch for the X,Y,U,C axis Shall not include W axis control

Grinding operator interface. The operator interface shall at a minimum include the following functionality:

a) Grinding cycles selectable by dedicated menus.

b) W axis automatically determined by set-up height settings.

c) Wheel files and past programs can be easily referred and assist in generating new programs.

d) Using macro based programs, rough and finish grinding; executed in a single push of a button and not require separate part programs.

e) Software that records the last manual infeed interruption and overrides values that can be reflected to the upcoming cycle.

f) Input fields, which requiring inputs and/or are out of range, are highlighted for ease of operator input.

g) Software shall have a code screen, which has quill up/down settings and automatic infeed settings.

h) C axis automatic conversion.

Required Fanuc cycles. At minimum, the machine shall be equipped with the following cycles:

a) Circular interpolation by G02 and by R programing

b) Helical interpolation

c) Wheel diameter compensation C

d) Cutting federate clamp

e) Data protection key (memory protection key)

f) Dry run

g) Dwell: G04 (0.001 ~ 99999.999 sec)

h) Emergency stop

i) External machine zero point shift (J912)

j) Extended part program editing

k) External data input (J913)

l) External tool offset (J910)

m) Feed hold

n) Handle feed: x, y, z, a and b axis, selectable

o) Resolution switch in x1, x10, x100

p) Initial point / r point return in canned cycle

q) G98 (initial point return), G99 (r point return)

r) Input code: EIA RS-244-B/ISO-840

s) Automatic recognition

t) Label skip

u) Machine lock

v) Macro executor (J888)

w) Macro executor +C language exec (J734)

x) Manual feed select: rapid/high/medium/low

y) Handle/ ref z (zero return)

z) Max command value: +/- 99999.99 mm, +/- 99999.999º

aa) MDI Function

bb) Minimum input value: .00004” (.001 mm), .001º

cc) minimum input value: 0.001 mm (0.00004"), 0.001º

dd) Mirror image: any axis

ee) Multi axes simultaneous control

ff) Multi buffer register (5 blocks)

gg) Nano interpolation

hh) Operation history display

ii) Operation panel with 15” LCD color display with PC type key arrangement

jj) Part program editing

kk) Part program storage size 160m (64kB)

ll) Positioning (G00)

nn) Program directory by group: same group of programs will be listed on CRT program protect

oo) Programmable data input: ( G10 ) (tool offsets, work offsets can be changed by program)

pp) Programmable parameter input: (G10 l50)

qq) Rapid traverse override; 0, 2, 15, 50, 100%

rr) Registerable programs: 63

ss) Self-diagnosis: servo system alarms, feedback

tt) System alarm, NC alarms, PC alarms, NC status i/o signal,

uu) Status ladder diagram are shown on CRT

vv) Sequence number search

xx) Sequence number: N1 - N99999 (5 digits)

yy) Single block single direction positioning

zz) Skip function: (g31) aaa) Spindle speed override: 50 - 150% (10 steps in 10% incl) bbb) Stored pitch error compensation: up to 128 points on each axis, max +/- 7 pulses x 100 ccc) Stored stroke check 1 ddd) Subprogram: M98, M99 (up to 4 levels of nesting and 10000 times repeat) up to 9000 subprogram eee) Tangential speed constant control fff) Chopping Cycle Function ggg) Tool function (T code): 3 digits (tool no) hhh) Tool length offset: G43 (+), G44 (-), G49 (off)

iii) Tool offset memory a: 99 sets (h, d 3 digits) offset value ±999.999 jjj) Tool offset pairs 64 (J925) kkk) Work coordinate system change: G92 lll) Work coordinate set: (G54 ~ G59) mmm) Z axis command neglect nnn) Custom software size 4mb (J738#4m) ooo) Addition of custom macro common variables 600 ppp) (J887) customer macro variables #100 ~ #199, #500 ~ #999 qqq) Bi-directional pitch error compensation (S656) $4,275.00 rrr) Custom macro function (J873) sss) 100 sets common variables ttt) Data server function (S737) uuu) Fast data server + fast Ethernet ATA flash card type (K214)

vvv) High speed skip (J848) www) Inch / metric conversion (J876)

xxx) Number of registered programs expansion 1 (J953) yyy) Part program storage 8mb (20,480 m) (J959) zzz) Stored limit check before move (J749) aaaa) Stored stroke check 2, 3 (J840) bbbb) Tool offset memory c (J937) (length / diameter / geometry / wear memory)

Universal Serial Bus (USB) Connection Port. A minimum of one (1) Standard

USB connection port for the transfer of process information to the system control shall be provided. All protocol documentation shall be supplied.

Ethernet Connection Port. An RJ-45 connection port for Ethernet shall be readily available on the exterior of the machine. The CNC controls shall have the capability to upload and download part program results using standard Ethernet protocol.

CNC and Control Restoration Data. The contractor shall be responsible for the generation of all program logic and documentation necessary for machine operation. The Programmable Memory Controller (PMC) program, CNC parameters and all data required for configuring a new control and any other configured or programmed electronic device shall be provided in electronic format on read-only optical disc and delivered with the equipment. For safety and security reasons, the vendor shall not provide encrypted files containing proprietary cycles PMC, PLC programs/data.

Motors. Motors shall be rated for continuous duty. 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 in accordance with paragraph 3.7 to identify manufacturer, model number, 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).

Remote Pendent. One (1) handheld pendent shall be connected to machine at the operator’s station to enable the operator to control machine functions. The control pendant functions shall include at least, but not limited to emergency stop, machine stop, axes jog, and axes positioning via manual electronic hand wheel. Remote pendent shall include an enabling switch that shuts down all machine functions when not in contact with operator.

The remote pendent shall have sufficient travel range to allow operator access to the worktable while holding the pendent.

Work light. A work light, whether built-in or added on, shall be provided. The light shall comply with NFPA 79 requirements, have a protective shield, and provide maximum light to the work area.

Electrical Outlet. One (1) 120V duplex standard Type B receptacle shall be supplied at the operator station.

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70 and be in accordance with Attachment C, Paragraph 3.1.8 (See Attachment D for source location).

Hour Meter. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) run time shall be considered to meet this requirement. The CNC control shall allow up to 99,999.9 hours recorded with a minimum resolution of 1 second.

Size and Capacity. The size and capacity of the machine shall be not less than specified in Table I.

Table I Size and Capacity

Characteristic Size/Capacity Table Minimum Dimensions 52 X 47 inches Cross Rail (W axis) Minimum Column Spacing

53 inches

Front door/Enclosure Top Width opening 50 inches Table Capacity 4000 pounds X Axis Travel 42 inches Y Axis Travel 37 inches Z Axis Travel 5 inches W Axis Travel 30 inches X, Y, Z Minimum Feed 0.00004 inches X, Y Rapid Traverse Rate 150 inches per minute Z Rapid Traverse Rate 90 inches per minute W Axis Travel 30 inches Z and U Axis Minimum Traverse Rate .004 inches per minute U Axis Outfeed Travel 4.5 inches U Axis Infeed Travel 0.75 inches U Axis Outfeed/Infeed Minimum Feed 0.00004 inches C Axis Minimum Feed .001 deg Temperature Controlled Coolant System 52 gallons

Grinding Spindles. Modular spindles shall be provided in order to meet the requirements specified in Table III

Table III Grinding Spindles

Low RPM Spindle

Tool Holding Interface HSK A40 Spindle Maximum RPM 25,000 Spindle Minimum Power 2 HP Quantity Provided 6

High RPM Spindle Tool Holding Interface Manufacture’s Standard Spindle Required RPM 80,000 Spindle Minimum Achievable RPM 20,000 Spindle Minimum Power .2 HP

Quantity Provided 2

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

Table III

Full travel positioning Accuracy in X, Y, Z Tested Under JIS Standard

.000040 inches

Full travel positioning Accuracy in X, Y, Z Tested Under the ISO/VDI Standards*

.00009850 inches

Full travel positioning Repeatability in X, Y, Z tested under JIS Standard

.000040 inches

Full travel positioning Repeatability in X, Y, Z tested under ISO/VDI Standard*

.000090 inches

Spindle Axis Perpendicular to Table Surface .00020 inches Parallelism of Table Surface With Table Motion

.00020

Table Surface Square to Cross Beam Motion .00025 inches Spindle Runout .000080 inches Spindle Perpendicularity to Table Surface All Travels

.00020 inches

Worktable Flatness Tolerance .00025 inches

* Machines to be tested under JIS OR VDI 3441; not required to test under both.

Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the machine (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal.

Tooling and/or Required Accessories. Tooling in accordance with Table V shall be provided with the machine. All tooling below shall have interface type HSK A40. Coolant through tools or piping options shall not be applied to any of the below tooling.

Table IV

Description Order Number Quantity

Haimer Hardened Blank Adapter RA40.0096.0407 2 Haimer Short Shrink Fit 1/2” Chuck A40.140.1/2Z 6 Haimer Short Shrink Fit 3/8” Chuck A40.140.3/8Z 6 Haimer Short Shrink Fit 16mm Chuck A40.140.16 6 Haimer ZG130 Shrink Fit Chuck A40.144.16 6 Haimer ER 16 Ultra Short Power Collet Chuck A40.020.16.3 6 Haimer ER 16 Short Power Collet Chuck A40.025.16.3 3 Haimer ER 16 Power Collet Locknut 83.914.16 9 High Precision ER 16 1/8” Collet 81.163.1/8z 6 High Precision ER 16 3/16” Collet 81.163.3/16z 6

High Precision ER 16 1/4” Collet 81.163.1/4z 6 High Precision ER 16 5/16” Collet 81.163.5/16z 6 High Precision ER 16 3/8” Collet 81.163.3/8z 6 Haimer ER 25 Ultra Short Power Collet Chuck A40.025.25.3 3 Haimer ER 25 Short Power Collet Chuck A40.020.25.3 3 Haimer ER 25 Power Collet Locknut 83.914.25 3 High Precision ER 25 1/4” Collet 81.253.1/4z 3 High Precision ER 25 3/8” Collet 81.253.3/8z 3 High Precision ER 25 1/2” Collet 81.253.1/2z 3 Haimer Balancing Screw Kit 80.203.00 3 Haimer Torque Wrench 84.600.00 3 Haimer Torque ER 16 Wrench Insert 84.610.16 3 Haimer Torque ER 25 Wrench Insert 84.610.25 3

Tooling Cabinet. All tooling in Table III shall be accessible in a contractor provided tool cabinet. The tool cabinet shall have a minimum dimension of 26 inches length, 20 inches width and 42 inches height. The tooling cabinet shall contain a minimum of 4 pull out drawers that are lockable. At a minimum, 1 “one” of the pull out drawers shall be seven 7 inches in height. A tool cabinet shall be provided with each machine totaling a quantity of 3 cabinets.

Single Point Diamond Dresser Unit. At a minimum, a single point diamond dresser unit shall be supplied with the dressing and truing station defined in 3.7.4 as a part of the options of tooling provided in the machine. This single point diamond dresser unit shall be comprised of a diamond point dresser that is mounted in a base that can be fixed to the t-table surface via magnetic mount, T slot nut, or equivalent. This base shall allow the single point diamond to rotate from 0 degrees parallel with the table to 90 degrees away from table. The base shall be modular from the table and the single point diamond dresser shall be removable from the base for replacement and maintenance. The shank of the diamond point dresser shall include a taper that terminates at the diamond. This taper shall have a maximum of 10 degrees.

Dressing and Truing Station. The machine shall incorporate a means to dress and true grinding wheels in the spindle through a sub-routine. This grinding truing station can exist as a standalone-mounted unit(s) that the spindle can always travel to or it can be attached to the worktable that the machine can find based on controller input. All components of grinding/truing station shall take up the minimal amount of table space possible. If dressing and truing tooling is mounted to table, components must be behind the spindle and cross-rail of the machine and not interfere with the dust collection system during operation. For all electrically driven dressing tools a cable management system shall be incorporated that allows the dressing tools to move with the table and handle the quick changing distances during grinding operations. The dressing tools and units shall be of modular type for ease of removal and maintenance.

The machine tool manufacture can choose to supply a profile dresser, single point diamond dresser, rotary dresser, any other dresser tooling types, or a combination of different types that would accomplish the below requirements. When entering a dressing cycle the machine shall retract the quill to its minimum Z axis position to prevent a crash and return to this retracted Z position at the conclusion of the dressing cycle. The dressing cycle sub-routine shall memorize the position

FRCE requirements for dressing wheel shapes:

a) Means to grind and true grinding wheels with dimensions up to 2 inches in height and 6 inches diameter. With maximum radius fillet of .188 inches.

b) Ability to dress a wheel with a bottom radius of 0.012 of an inch.

c) Interpolation of Z and U axis for tapered dressing.

d) Undercut dressing of grinding wheel.

Auditory Device. Grinding machine shall be equipped with one (1) audio listening device. The device shall be external and serve the purpose of operator monitoring during the grinding operations. All support equipment for this device shall be supplied including but not limited to headphones. This device shall include a visual cue to accompany the audio.

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:

a) Points of Lubricant Application

b) Servicing Interval

c) Type of Lubricant

d) Viscosity

e) Military or Federal Specification for Each Lubricant (If available)

f) 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.

a) Nomenclature

b) Manufacturer’s Name

c) Manufacturer’s Model Designation

d) Manufacturer’s Serial Number

e) Power Input (Volts, Total Amps, Phase, Frequency)

f) Contract Number

g) 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. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

Technical Data. Three (3) hard copies and two (2) electronic copy(s) of technical data shall be provided with the machine. Each electronic copy shall be provided on a read-only optical disc. All copies of technical data shall be legible and written in the English language. Technical Data shall include the following

a. All engineering drawings shall be in accordance with ASME Y14.100. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine, consumables and expendables information (such as oils, fluids, grease, filters…), and recommended spare parts list.

b. Factory service and operator manuals for the type and model of the machine being purchased.

c. Diagnostic procedures for isolating and correcting faults. Procedures shall be included in the service manuals for recalibrating and performing operational checks to ensure proper operation of any replaced parts, as required.

d. Preventative and predictive maintenance tasks, including oil and vibration analysis, and show recommended intervals of tasks.

e. Software manuals and registration keys/codes shall be provided, along with original software installation disks.

f. The Contractor shall provide the Government a copy of all test results completed in section 4.7 of this specification.

Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

Control of Hazardous Energy (Lockout/Tagout) Procedures. A written procedure for isolation of all energy sources on all equipment provided under this contract, in accordance with 29 CFR 1910.147, shall be provided by the contractor and included in the technical manuals. The draft procedures shall be submitted in Microsoft Word compatible format thirty (30) calendar days ACA for Government review and approval.

Instrument and Calibration Procedures. Calibration procedures and/or tooling requiring operator verification or recalibration as part of a production run or on a daily or periodic basis shall be provided to the Government. The contractor shall provide a list of these items at the time of proposal. All items shall have a certificate of calibration traceable to the National Institute of Standards and Technology (NIST). The contractor shall submit draft procedures thirty (30) calendar days ACA for Government review and approval.

Acceptance Test Plan (ATP). The Contractor shall adhere to the Acceptance Test Plan (ATP) outlined in section 4.7. The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. The Manufacture’s standard testing procedures shall be included in the ATP. The ATP shall include any procedures necessary for compliance with Sections 4.4 and 4.5 that are not covered by the Manufacturer’s standard testing procedures. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The approved ATP shall become part of the contract.

Equipment Drawings. The Contractors proposal shall be provided with dimensioned equipment drawings in both a .PDF file and CAD file compatible with AutoCAD 2015 edition. The dimensioned CAD file shall be drawn to actual size and show footprint and any manufacturer’s special foundation requirements of new equipment to include ancillary pieces, utility connection points, access doors and required maintenance clearance dimensions. The CAD file shall show side and elevation views.

Installation. Contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel required for unloading, rigging, installation, anchoring, connecting machine to utilities, and leveling the machine in place. The Contractor shall provide the necessary anchor bolts, leveling screws and related hardware to secure machine components to a foundation. Contractor shall also be responsible for the Installation Responsibilities sheet. Contractor shall be responsible for reading, understanding, and complying with Government facility requirements and information in Attachments A, B, and C.

Field Supervisor. The Contractor shall provide a full-time field supervisor to direct installation and testing of the supplies from start of installation to final acceptance.

The field supervisor shall be capable of reading, writing, and conversing fluently in the English language. The field supervisor shall have full authority to implement field decisions expeditiously. No work shall be accomplished when the field supervisor is not in the immediate work area. The field supervisor shall be identified to the receiving activity prior to start of installation. The field supervisor shall be responsible for coordinating with the receiving activity for any security clearances for all contractor personnel expected to perform on-site work. The receiving activity Government Point of Contact shall be notified of any change in personnel performing this duty.

Installation Plan. The Contractor shall be responsible for providing an Installation Plan in accordance with Attachment C, Paragraph 3.1.7. The Installation Plan shall contain detailed information regarding all installation work. The initial Installation Plan shall be delivered to the Government within 90 calendar days After Contract Award (ACA) for review and approval.

Lead and Asbestos Testing. The Contractor shall be responsible for conducting an onsite survey for Lead Based Paint (LBP) and Asbestos Containing Material (ACM) in accordance with Attachment C, Paragraph 3.2.1. The onsite survey shall be completed within 30 calendar days ACA; coordinate with the Contracting Officer.

Compressed Air Connection. The Contractor shall be responsible for design and installation of new compressed air piping and associated components in accordance with Attachment C, Paragraph 3.2.2 (See Attachment D for pipe size and source location). The existing compressed air pressure available at the Government facility fluctuates between 83 to 93 psi. The contractor shall assume that all compressed air qualities to be of the lowest quality that is useable as compressed air. The Contractor shall make provisions to filter, dry, humidify, lubricate, amplify, and regulate the Government supplied compressed air to meet the Original Equipment Manufacturer (OEM) compressed air requirements and recommendations.

Existing Equipment and Utilities Removal. The contractor shall be responsible for removing replaced equipment and utilities in accordance with Attachment C, Paragraph

3.2.3. The existing machines to be removed are vertical grinding and\jig grinding machines, 3 machines total, located in Building 133 (See Attachment D for detailed equipment and utilities information).