FY20 Tool Cutter Grinder Specification.docx

Attachment E – Environmental Protection Requirements Specification for New Tool and Cutter Grinder

Spec. # 3-20-3415

Manufacturing Engineering Work Group Watervliet Arsenal Watervliet, New York 12189 11/25/2019

Department of the Army

TACOM

Table of Contents

Scope:

Abbreviated Description:

The machine tool covered by this specification shall be a heavy duty tool and cutter grinder with no less than twelve (12) individual axes of motion, with no less than five (5) axes under simultaneous CNC control. There shall be synchronous linear motors for the linear axes and synchronous torque motors for the rotational axes with all linear axes equipped with direct position transducers.

Applicable Standards and Publications:

All work performed and procedures followed in association with this project shall meet or exceed all applicable and current OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

Clarification:

If there are any ambiguities or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description prior to submitting an offer, such ambiguities or discrepancies shall be reported to the contracting officer by the contractor before the date scheduled for close of bidding/receipt of proposal. Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could been foreseen had such reasonable examinations been made, may be denied.

Requirements:

All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from their standard practice or configuration, the arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

General Requirements:

1.1 This equipment shall be a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer. Equipment incorporating new or unproven technology is subject to rejection at the discretion of the contracting officer.

Design and Engineering:

The machine shall be designed and engineered in accordance with latest standards recognized or adopted by the Association for Manufacturing Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use.

Materials:

Materials incorporated in the construction of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability.

Construction:

All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

Alignment Retention:

Nonintegral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the Squareness and/or parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of accidental dislocation.

Slideway Design and Construction:

1.1.1 All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Please state in your proposal details of the way system being offered.

a.) Integral cast iron ways shall be hardened to a value between RC 50 and RC 54. This hardness value shall reach a depth of .100 inch or more.

b.) Hardened and ground steel ways for mating with Turcite, Rulon or other such low friction, forgiving materials shall be hardened to a value between RC 55 and RC 62. Actual hardness values within the hardened and ground steel ways shall not vary more than 5 RC points throughout the measured area.

c.) Hardened and ground steel ways, for use with antifriction roller bearings, shall be hardened to a value between RC 62 and RC 65. This hardness value shall reach a depth of 1/8 inch or more. Slideway systems other than the three (3) referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

Replaceable Ways:

If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

Way Wipers:

All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall also be easily removable and replaceable.

Workmanship:

Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology. Shims that do not appear on the engineering drawings shall not be incorporated in the machine. Spacers that do appear on the engineering drawings are permissible.

Maintainability:

All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for replacement or adjustment as applicable. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

Interchangeability:

All parts bearing the same part number shall be functionally interchangeable.

Electrical Safety Devices:

The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plugin circuit breakers or currentlimiting fuses are not acceptable.

Motors:

All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. All motors shall be rated for continuous duty. Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with thermal overload protection. Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC. Motor starters shall provide drop-out protection. This means that in the event of power loss, the equipment shall be re-energized only by deliberate action of the operator. Manual or mechanical motor starters are not acceptable. All motors shall be housed in enclosures of the appropriate NEMA type for class and severity of service. All AC unidirectional motor housing shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 hp or greater shall be equipped with a “soft-start” mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 hp or greater shall be tested per IEEE Standard 112-Method B and must meet Premium Efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 9IEC 60034-30:2008. All motors are to be permanently lubricated and sealed.

Motor I.D. Plates:

Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

Operator Control Voltage:

All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

Utility Outlet:

The machine shall be provided with an operational 120volt singlephase, 20-ampere dualreceptacle 3wire utility outlet. This outlet shall be protected by a groundfault interrupter and shall be externally mounted on the operator control panel and easily accessible. A “noise" suppression device shall be provided.

Safety and Environmental Requirements:

The contractor shall review the environmental requirements documented in Attachment E and comply as applicable.

Protection of Machine Operator:

Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent state, federal, local laws and regulations.

Protection of the Machine:

The machine shall be fully equipped with the devices necessary to prevent selfdamage in the event of malfunction and/or ordinary operator negligence insofar as practical.

Noise Levels:

Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a properly calibrated sound level meter set for "A" weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the proper operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

Ozone Depleting Substances:

1.1.1.1 Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozonedepleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. This machine shall utilize new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: OzoneDepletionPotential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC11, CFC12 and CFC 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

Asbestos and Mercury Free Certification:

All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

Material Safety Data Sheets:

The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of the submission of their proposal.

Lead-Free and Chromium-Free Paint Certification:

All paints and primers applied to the system shall be certified as lead free and chromiumfree. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery.

PCB-Free Certification:

To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection (see section 3.4), these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and its equipment shall be certified as PCBfree prior to being shipped.

Lockout/Tagout Procedures:

The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

Identification Plate:

A corrosionresistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and full load amps) Government Contract Number Date of Manufacture

Data Plates:

All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plan, bold face lettering. Lettering shall be permanent and have a contrasting background.

Utility Connections:

Equipment supplied to the Watervliet Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc. This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc. Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

Utility Connection Labor:

Watervliet Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

Utility Requirements:

Electrical:

The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC to the fused or breaker type disconnect switch. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional. OFFEROR IS TO STATE REQUIRED POWER/ELECTRICAL REQUIREMENTS FOR OFFERED MACHINE (VOLTAGE, FULL LOAD AMPS, KVA, ETC.). See Attachment C and complete.

Pneumatics/Air:

If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary accessories, fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 85 psi and if higher or lower pressure is needed at the machine or a different air flow rate is needed, the machine shall be fully equipped with the devices needed to modify the supply pressure and volume. The machine shall also be equipped with devices (ie. air dryer) to remove the ABOVE normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig.

Electrical Conversion Equipment/Transformers:

If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be furnished with the machine by the contractor. All transformers must meet NEMA TP 1-2002 energy efficiency requirements. Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description.

Air Booster Unit:

If the machine offered requires more than 85 psi at a particular volume then an air booster unit shall be provided with the machine. If necessary, an accumulator tank shall be provided with the booster. Please state in your proposal what the machine requirements will be and if a booster and tank will be required. Installation shall be provided by the contractor. If the use of an air booster is not possible and an air compressor is required, the contractor must state this in their proposal and provide justification detailing CFM, psi, application, and duration of air usage.

Air Dryers/Filtration:

If the offeror determines that on machine air dryers are required to maintain appropriate moisture levels the industrial air dryers are to be of the latest technology that will result in the most energy efficient design such as advanced heat exchangers, use of heat sink reservoir to allow on/off cycling, reduce pressure drop by use of multi-pass flow patterns, and alternative configurations such as desiccant media. Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35° F pressure dew point, minimum, from air entering the equipment at 110° F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor. All designs are to be supplied by manufacturers participating in the CAGI Refrigerated Dryer Performance Verification Program and have been tested and rated in accordance with CAGI ADF 100. Power for the refrigerated air dryer unit shall be 110 V AC and shall be wired and powered through the machine electrics. Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS HSE and Ingersoll-Rand D31NC models.

Lubrication:

The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon Inc. Gearboxes or transmission cases shall be lubricated by the wetsump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Systems of the foregoing types are considered automatic systems and they shall be equipped to be fail safe to the maximum extent possible. Any sensors or other devices used to detect the presence (or absence) of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods (e.g. Grease fittings, oil cups etc.) are permissible for lubrication points not practically served by automatic systems. For nonrecirculating automatic systems (such as slideway lubrication), the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems (such as pressure spray), easily cleanable or replaceable filtration devices shall be provided. Wetsump type systems shall be equipped with means to confirm proper oil level. Sight gages, if used, shall be of the external standing tube type rather than the flushmounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

Lubrication Plate:

A lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

Lubricants, Hydraulic Fluids, Oils and Coolants:

Watervliet Arsenal established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor is requested to choose the required lubricants, hydraulic fluids, oils and coolants from Attachment “A”, enclosed or where designated (*see note) approved industry/commercial equivalents. If a substitute is required, the contractor shall provide, at time of machine delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

Hydraulic System:

Hydraulic systems provided shall be sized and powered for the intended application and shall conform to industry standards. The systems shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120° F in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure as well as under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, antisurge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

Painting:

All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromiumfree and leadfree. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semigloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

Machine Hold Down and Leveling:

The machine base shall be provided with sufficient and properly located holes for positive holddown when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended holddown and leveling hardware.

Note: All hold down and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

Gears:

All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

Handwheels:

Where power feed and/or rapid traverse of a machine component is provided or specified, associated handwheels or cranks, if any, shall not rotate when power feed or rapid traverse is engaged.

Technical Data:

All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

The contractor shall provide full documentation in the form of (as-built) drawings and manuals. Drawings shall not be generic. Drawings/schematics shall be provided in the quantities indicated below. A “hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2009, shall be of one-to-one scale, shall be dimensioned in English units, and shall not utilize the color yellow. “On-line” technical data will not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided.

Machine and Equipment Floor Plan:

Machine and equipment floor plan AutoCAD drawing shall contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power, air, water, etc.) required to operate the machine. The top view AutoCAD drawing shall depict the machine, pallet system with setup station, foundations, all ancillary equipment, and all necessary clearance requirements for normal use and maintenance (door openings, panel access, etc.). This data shall be furnished with offeror’s proposal (One hardcopy and one AutoCAD electronic copy)

Note: Watervliet Arsenal's standard 8”-10” monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires specificallyshaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc. Important: See instruction par. 6.4.

Catalog of Standard Tooling and Accessories:

Shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e. machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (Two hardcopies) Non-Standard (Special) Tooling and Accessories:

To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. (One hardcopy and one AutoCAD electronic copy) Installation Instructions and Drawings:

Instructions containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished 60 days prior to scheduled delivery of the machine. (One hardcopy and one AutoCAD electronic copy) Lubrication Diagram and Instruction:

To be delivered to the technical POC at time of machine delivery. (One hardcopy and one AutoCAD electronic copy) Operating Instructions:

These instructions shall be in provided in separate manuals from other technical data provided. To be delivered upon machine delivery. (Four hardcopies and one electronic copy) Maintenance and Troubleshooting Instructions:

To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly drawings. To be delivered at time of machine delivery. (Two hard copies and two electronic copies) Electronic and Hydraulic Schematics:

To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery. (One hardcopy and one electronic copy) Note: If, during installation and testing, the actual electrical and/or hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "AsBuilt" schematics shall be a condition of final acceptance.

Repair Parts Catalog:

This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and original equipment manufacturers part numbers and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be delivered at time of machine delivery. (Two hardcopies and one electronic copy) Program Manuals:

Where a CNC machine is offered or specified, programming manuals shall be supplied. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented and usable on the system offered or specified. To be delivered at time of machine delivery. (One hardcopy and one electronic copy) Software Documentation:

The offeror shall provide documentation of all system software and/or ladder logic developed to control and interface with the control/drives with the machine tool. To be delivered 30 days after delivery of the machine. (One hardcopy and one electronic copy) One copy of the system memory backup (S-Ram) shall be provided on compact flash drive at startup of machine.

Training Required:

The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal" and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". If specialized formal “off-site” training is available specify on offer availability and price as an option. The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Note: For all types of training, the associated technical data (see 3.1.24) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training.

Repair/Replacement Parts and Service:

1.1.2 The offeror shall provide parts and/or service for the contracted equipment within 72 hrs of notification of a problem. The offeror further agrees, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and be sufficient in detail to permit successful acquisition of the parts and associated repair service. The offeror shall supply a list of recommended spare machine parts as an option with the offer.

Special Tools:

If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

Control of Cutting Fluids:

If the machine is equipped with a coolant system, the contractor shall insure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine or leaking to the floor when producing workpieces of a size within the machine's normal working range. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leakproof metallic or nonmetallic liner.

Site Conditions:

The machine covered by this specification will be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65° F to 95° F and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4° F per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying whatever is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

Chip Removal:

If applicable an automatic belt type chip removal unit shall be provided to convey chips of any material from the machine to an external container without manual aid. The unit shall be reversible to facilitate clearing of blockages. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The unit shall operate successfully in a variety of machining environments including drycutting, machining with cutting oils and machining with waterextendable oils. Automatic is defined as providing a return of cutting fluids to the machine's coolant tank which shall be separate from the conveyer. The chip removal unit shall be engineered for the machine so that, when fully installed in accordance with instructions, all points subject to periodic maintenance and lubrication shall be easily accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself.

Machine Installation, Startup, and Testing:

Work to be performed at the Arsenal:

Site Designation:

Upon receipt of the required installation and foundation drawings (see 3.1.24), Watervliet Arsenal will designate an installation site and outline a general machine location on the shop floor.

Utilities:

Once the machine is installed, positioned and rough leveled by the contractor or their designated rigging crew Watervliet personnel will run utilities (power and air) to first points of connection on the machine. Watervliet must be provided with sufficient time to accomplish these connections. Sufficient time may be up to 3 working days depending on Watervliet personnel availability. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon their arrival and continue under their guidance.

Note: If installation instructions, electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.24), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

Work to be performed by the Contractor:

1.1.1 This project is classified as a turn-key with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Contractor personnel shall adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields, to wear safety shoes, and to refrain from wearing loose clothing (i.e. “hoodies”) and jewelry while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine.

Site Preparation:

Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall layout the machine. Please note that the majority of the Watervliet Arsenal’s shop floor is covered with 2.5” thick wood block. The contractor is responsible for the removal of wood block flooring and existing concrete preparation. Contractor shall also be responsible for securing wood block flooring and install any leveling pads necessary for installation.

Rigging : Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services should be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Only propane powered forklifts are permitted and forklifts must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses. The contractor shall ensure they bring all equipment/material necessary for the rigging of the machine. If necessary, the Watervliet Arsenal can provide the contractor with information for local rigging companies.

Installation:

Once the machine is positioned and rough leveled by the contractor WVA personnel will run utilities to the machine. Watervliet must be provided with sufficient time to accomplish these connections. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 & 4 and perform the required on-site training. The contractor and the service personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing their own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenal furnished equipment.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

Machine Specific Requirements:

Machine Tool Description:

The machine tool covered by this specification shall be a heavy duty tool and cutter grinder with no less than twelve (12) individual axes of motion, with no less than five (5) axes under simultaneous cnc control. There shall be synchronous linear motors for the linear axes and synchronous torque motors for the rotational axes with all linear axes equipped with direct position transducers.

The machine shall have built in capability for automatic resharpening of end mills and other type milling cutters, either high speed steel or carbide, to include grinding the flute (flute polishing), grind the end teeth including gash and relief (primary, secondary, tertiary), and grind the outside diameter, primary, secondary and tertiary including corner radii. The foregoing shall be accomplished in a single setup without removing tool from the machine and without manual manipulation of any involved axis.

Required Characteristics:

Machine Envelope:

The machine and all ancillary equipment are anticipated to be placed in an area where building columns are 18’ apart and on second floor. Building height restrictions may be as low as 11’. The floorplan submitted as required by paragraph 3.1.24(b) will be used to evaluate whether the machine and its equipment will fit in the anticipated installation site.

Size Characteristics:

Maximum travels:

Maximum travel speeds:

Rotational Axes:

Work head (A-axis):

Accuracy:

a.) Radial run-out and axial run-out of the workpiece spindle of the A axis

a. Radial Run-out 0.002mm

b. Axial Run-out 0.002mm b.) Radial run-out and axial run-out of the grinding spindle

a. Radial Run-out 0.004mm

b. Axial Run-out 0.004mm c.) Radial run-out of workpiece spindle

a. 0.01mm at 100mm distance

b. 0.02mm at 300mm distance d.) Parallelism of the A axis to the X axis

a. 0. 01mm along 100mm distance

b. 0. 02mm along 300mm distance e.) Parallelism of the A axis to the X3 axis

a. 0.006mm along 100mm distance

b. 0.010mm along 300mm distance f.) Parallelism table of the X3 slide to the X axis and the Z axis

a. 0.01mm along 100mm length in X direction

b. 0.05mm along 100mm length in Z direction g.) Parallelism of stop angle of X3 slide to X3 axis

a. 0.006mm along 100mm length h.) Parallelism of stop angle of X4 slide to X4 axis

a. 0.006mm along 100mm length i.) Perpendicularity of the A axis to the Y axis

a. 0.01mm along 100mm length

b. 0.02mm along 200mm length Required Features/Options/Accessories:

The machine shall be fully designed, configured, and installed with the following features, options, and accessories in addition to the base machine design:

Operating Characteristics:

1.1.1.1 The machine shall be delivered fully equipped and ready to perform, as a minimum, the following required functions in a single setup with all involved axes under simultaneous CNC control:

a.) Grind the flute from a pre-fluted blank (flute polish) to include right and left hand helix.

b.) Grind the end teeth including gash and relief, primary, secondary and tertiary.

c.) Grind outside diameter to include primary, secondary and tertiary.

d.) Apply corner radii including primary, secondary and tertiary.

e.) Grind a ball nose endmill.

Spindle Drive Characteristics:

The machine to be provided in accordance with this specification shall be so arranged as to provide not less than 25% of the specified horsepower during any of the sharpening/grinding cycles within the machines capability. In addition, an illustration (chart) of the horsepower/ spindle rpm characteristics of the grinding spindle drive to be provided shall be included in the offerors proposal.

Wheel dress:

The machine shall be provided with automatic wheel dressing capability to include dressing roll and dressing software, compatible with all types of abrasive wheels within the machine’s offered capacity as provided by the machine tool builder.

Coolant System:

The machine shall be equipped with a complete high volume coolant system designed for use with industrial coolant. The coolant system shall be complete including all necessary pumps, piping, valves, motors, and a reservoir with a minimum capacity of 180 gallons of coolant. The coolant system shall have inbuilt capacity to provide a minimum of 21gpm of high velocity coolant to the tool being ground. Start/stop of the coolant flow shall be under cnc control. In addition to cnc control, a provision for manual actuation, as well as a means to control the rate of flow, of the coolant shall be provided. All components shall be floor mounted, easily accessible for cleaning and flushing and shall not require a special foundation or pit for installation. Screens or other suitable devices to prevent contamination of the coolant with foreign debris shall also be provided. The coolant system shall also be provided a means to generate a feed hold condition if insufficient coolant or a loss of required coolant pressure occurs. A warning light or a message displayed on the control shall be included. If machine needs a filtration system it shall convey chip/swarf from the machine to an external container without manual aid. Controls shall include Manual/Auto, Fwd/Rev and Stop. There shall be controls located at the conveyor as well as at the operator’s station. The unit shall operate successfully with watersoluble coolant. Automatic means shall be provided to return cutting fluids from machine to the filtration coolant tank. The filtration unit shall be engineered for the machine so that when fully installed in accord with OEM instructions all points subject to periodic maintenance and lubrication shall be externally accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself.

Axes and Motor Cooling:

If any axes or motors are to be cooled than the manufacturer shall supply a suitable device to be used to maintain correct operating temperatures and pressure. All operating conditions must be able to be monitored on operator control panel.

Refrigerated Heat Exchanger:

A refrigerated coolant chiller or heat exchange system shall be provided. The system shall have sufficient coolant capacity to depress the grinding coolant temperature to 75 degrees F +/- 5 degrees or to 10 degrees F less than ambient temperature, whichever is greater. Maximum ambient range at the Watervliet Arsenal is 55 degrees F in winter and 100 degrees F in summer. The system shall have ample capacity to process and supply sufficient coolant to permit operation of the machine at full capacity. The coolant chiller shall be independently operated and not interlocked to machine operation.

Wheel change system:

1.1.2.1 A 12 station wheel changer shall be provided with the system, where dismounting and mounting of a wheel from the machine shall not alter the operating characteristics or balance of the wheel.

Lead checking system:

A system capable of determining the helix angle of any type of milling cutter or end mill shall be provided.

Automatic measuring of linear axis X, Y, and Z reference points/Grinding spindle:

The machine reference points of the axes shall be automatically and precisely measured by means of electrical contact. This measuring method shall be a fully automated process optimizing accuracy and repeatability. Measurement shall start automatically and runs independently by means of a program similar in function/capability as Helitronic Tool Studio. The tool shall be provided with all Tool Grippers, Test Bars and Setting Discs required for this feature.

Software efficiency options:

A system with the following efficiency options shall be provided. These options shall be of the Helitronic Tool Studio or equal alternative:

a.) Feedrate Optimizer: provides options for feed control and for monitoring the grinding wheel and machine load.

b.) Tool Balancer: Analyze and balance out if necessary, center-cutting tools with an odd number of flutes or special tools.

c.) Integrated Measuring System: Outside diameter, rake angle and core diameter can be measured using the probe ball without having to unclamp the tool.

d.) Adaptive Control: Possible overloading of grinding wheels is excluded.

Automatic Fire Extinguisher:

Inclusion of CO2 bottle required no halon.

Mist Extraction System:

The machine shall be provided with a 1000 CFM, 95% efficient mist extractor system. The system shall continually collect coolant and machining/cutting mist from inside the machine enclosure, separate it at the mist collector, discharge clean air above and drain the liquid back into the coolant reservoir. The mist collector shall be power through the machine electronics. The contractor shall be fully responsible for interfacing the mist collector unit with the machine including any necessary duct work.

Other Requirements:

a.) Circular sliding door with automatic door lock b.) Low coolant detection c.) LED workspace lighting d.) Explosion lid with emergency stop Required Tooling:

The following tooling is in addition to any tooling which may be referenced elsewhere in this specification. All tooling is required to be delivered with the machine.

1.1.1.2 Basic Equipment:

The following tooling shall be delivered with the machine.

1. Tool gripper for clamping of tools with ISO taper SK50 ANSI

1. Test bar ISO 50 for measuring of machine reference points

1. Setting disc HSK 50 for measuring of machine reference points Clamping and Measuring Equipment:

The following tooling shall be…