FY21 New Rotary Grinder Specification 01-21-3415.docx

Equip Engr Spec # 01-21-3415 Date: 29 September 2020

New 48” Vertical Rotary Surface Grinder

Table of Contents

1. Scope

1.1 Abbreviated Description 2

2. Applicable Standards and Publications 2

3. Requirements

4. Quality Assurance Provisions

5. Preservation, Packaging and Delivery Instructions 19

6. Instructions for Preparing Technical Offers 20 1.

Scope:

1.1 Abbreviated Description. This specification defines the requirements for a new Heavy Duty Vertical Spindle, 48” Rotary Table Surface Grinder. With a Complete filtration system, of the type paper and magnetic drum and whatever equipment is needed for a complete operating machine to meet the needs of the Watervliet Arsenal (WVA).

2. Applicable Standards and Publications. All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal, 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.

3. Requirements. All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his 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.

3.1 General Requirements.

3.1.1 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. The machine shall be designed for use without the need for a special foundation see paragraph 3.1.17a.

3.1.2 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.

3.1.3 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.

3.1.3.1 Construction of Major Components. All major machine components such as beds, saddles, columns, etc. are castings either of iron or semisteel, or shall be constructed as mild steel weldments. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be thermally stress relieved to preclude spontaneous distortion. All hollow base castings or weldments shall be filled with vibration absorbent polymer.

3.1.3.2 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.

3.1.4 Slideway Design and Construction. 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 RC 50 to RC 54 to 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 within the range of RC 55 to RC 62. Actual hardness within this range shall not very more than 5 RC points.

C. Hardened and ground steel ways for use with antifriction roller bearings shall be to a hardness of RC 62 to RC 65 to 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.

3.1.4.1 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.

3.1.4.2 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. Everything associated with the ways and the table movement shall be protected from grinding dust.

3.1.5 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.

3.1.5.1 Shimming. Shims that do not appear on the engineering drawings shall not be incorporated in the machine.

3.1.5.2 Spacing. Spacers that do appear on the engineering drawings are permissible.

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

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

3.1.8 Applicable Power Source. The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. No internal or external transformers will be acceptable to convert to lower supply voltage.

3.1.8.1 General Electrical Characteristics. The electrical system shall conform, in quality, safety and performance, to all industry electrical standards equal to or better than that of the National Fire Protection Association (NFPA 70) and (NFPA 79).

3.1.8.2 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.

3.1.8.3 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 equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service. Each motor shall bear an identification plate containing, as a minimum, the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency and frame or mounting. All AC unidirectional motor housings 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 of the high efficiency type as determined by the testing procedures described in IEEE Standard 112, Section b.

Note: All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

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

3.1.8.5 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 and easily accessible. A “noise" suppression device shall be provided.

3.1.9 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment D and comply as applicable.

3.1.9.1 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. The machine manufacturer will provide WVA with platforms and guarding to provide adequate access and operator protection as defined in OSHA 29 CFR PART 1910, as it pertains to machine safety.

3.1.9.2 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.

3.1.9.3 Noise Levels. The government's preference is to achieve noise levels not in excess of 80 dba and shall be accomplished at no additional expense to the Government. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities (see 3.4.1.2), and shall be measured at any or various times during this test at the discretion of the Technical POC or other appointed representatives. 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.

3.1.9.4 Ozone Depleting Substances. 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. All substances or systems, that are approved for use by the Environmental Protection Agency (EPA) 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.

3.1.9.5 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.

3.1.9.6 LeadFree and ChromiumFree 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.

3.1.9.7 PCBFree 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.

3.1.9.8 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.

3.1.10 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 total amps) Government Contract Number Date of Manufacture

3.1.11 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.

3.1.11.1 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.

3.1.11.2 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.

3.1.12 Hydraulic System. Hydraulic systems provided shall be sized and powered for the intended application and shall conform industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible sight gages to indicate fluid level. An appropriately sized refrigeration system shall be provided to ensure the hydraulic fluid does not exceed 120 degrees f in temperature. The hydraulic system shall be protected against overpressure as well as underpressure. 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. Pressure gages shall be liquid filled.

3.1.13 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.

3.1.14 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 holddown and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

3.1.15 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.

3.1.16 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.

3.1.17 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.

a. Machine foundation: Typical floor thickness at Watervliet is 8”-10”. A special foundation is NOT ACCEPTABLE, a special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specifically shaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc.

The soil (sub-straight) is assumed to be medium dense gravel or medium dense gravel and sand with a minimum bearing capacity of 4,000 PSF.

b. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in AutoCAD shall be provided on a CD. This plan shall contain the dimensioned bolt-hole pattern of the holddown bolts for the machines. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power, air, water, etc.) required to operate the machine. This data shall be furnished 30 after receipt of contract WITH ATTACHMENT C. One reproducible hardcopy and one electronic copy on CD in AutoCAD. SEE ATTACHMENT C

c. Installation Instructions and Drawings 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 reproducible hardcopy and two electronic copies on CD in AutoCAD Release 2007 or later.

d. Lubrication Diagram or Instruction. To be delivered at time of machine delivery. Two reproducible hardcopy and two electronic copies on CD in AutoCAD Release 2007 or later.

e. Operating/Operator Instructions. These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery. Four Hard copies minimum and two electronic copies CD.

f. Maintenance and Troubleshooting Instructions and Mechanical Assembly drawings for all machine systems. To be delivered at time of machine delivery. Titled Maintenance Drawings and Troubleshooting Instructions. Two reproducible hardcopies and two electronic copies on CD in AutoCAD 2007 or later of the machines mechanical assembly drawings.

g. Electrical and hydraulic schematics to be furnished at time of machine delivery. To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. Two reproducible hardcopy and two electronic copies on CD in AutoCAD Release 2007 or later. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

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.

h. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification 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 furnished not later than 30 days prior to delivery of the machine. Two reproducible hardcopies and two electronic copies.

i. Programming 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. These manuals shall be delivered at machine delivery. One Fanuc CD-ROM Manual and 1 Operation and Fanuc Handbooks.

j. Software Documentation. The offeror shall provide copies of all system software and/or ladder logic developed to control and to interface the new control/drives with the existing machine tool. Two copies on CD, two hard copies. To be delivered to the technical POC no later 30 days after final acceptance of the machine.

Note: All technical data can be put on one CD and a copy be made for the second CD.

3.1.18 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 at an authorized control system training site as determined and arranged for by the contractor". 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:

Hydraulic maintenance (if applicable)

Note: For all types of training, the associated technical data (see 3.1.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A training schedule showing the hours of training for each person under their assigned category, shall be sent in with proposals for review.

3.1.19 Repair/Replacement Parts and Service. The offeror shall also agree to provide parts and/or service for the contracted equipment within 72 hrs of notification of a problem. Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify Watervliet Arsenal’s POC within two business days and shall provide a delivery schedule to be approved by Watervliet Arsenal’s POC. 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.

Note: The offeror shall supply a list of recommended spare machine parts as an option with the offer.

3.1.20 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 80 to 85 psi (unknown volume) and if higher or lower pressure or a specific volume is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 80 psi supply pressure. The machine shall also be equipped with devices 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 80 psig.

3.1.21 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.

3.1.22 Control of Cutting Fluids. The machine and coolant system provided shall be designed 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.

3.1.23 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 degrees F. To 95 degrees F. and relative humidity will range from 20% or less to 100%. On any given day, the temperature in the machine shop may change as much as 4 degrees 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.

3.1.24 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine/control/drive systems wherever it is needed to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable.

3.1.25 Chip/Swarf Removal and Filtration/Coolant Tank. An automatic chip/swarf removal unit shall be of type paper and magnetic drum, to be supplied with the rotary grinder such as Barns model MPE-150 or Heavy Duty equal with the following upgrades.

· Rare earth drum magnet upgraded from standard equipment.

· 5 horsepower sump/ pumpback system, Gusher Trash pump designed for pumping dirty coolant with solids. The pump shall be high speed and have a blade at the inlet that will break up the clumps of swarf without issue.

· Media re-winder to collect and separate the dirty paper from the swarf prior to entering the sludge pan.

· Roll away sludge pan capable to be lifted with a fork truck.

· 110 gallons per minute coolant delivery to grinding wheel at 30 psi.

· 500 gallon coolant capacity minimum.

The filtration system 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.

3.1.26 Machine Installation, Startup and Testing.

3.1.26.1 Work to be Performed by the Arsenal. This project is classified as a turnkey with the contractor being responsible for all-work associated with the installation unless otherwise stated. Upon receipt of the required installation floor plan Watervliet Arsenal will clear the intended installation site prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities to first points of connection. 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 his arrival and continue under his guidance.

Note: If installation instructions and electrical are not delivered at or before the times specified (see 3.1.17), 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.

3.1.26.2 Work to be Performed by the Contractor. This project is classified as a turnkey with the contractor being responsible for all-work associated with the installation. The Contractor shall be solely responsible for costs associated with skidding and shipment, rigging and installation at WVA. The contractor is responsible for the removal of wood block flooring and existing concrete preparation. Grouting for machine hold downs shall be the contractor’s responsibility regardless of foundation type. The contractor shall also provide competent Englishspeaking service personnel to install the machine, rough and finish level the machine, startup, and conduct the acceptance tests specified in section 4. The contractor 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 his 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 Arsenalfurnished equipment.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide a bill of lading and address label or a return shipping label from carrier and coordinate with the Arsenal POC.

3.2 MachineSpecific Requirements.

3.2.1 Machine Tool Description. This specification defines the requirements for a new Heavy Duty Vertical Spindle, 48” Rotary Table Surface Grinder. Complete with filtration system, paper and magnetic drum and other equipment/accessories required to make a complete system specified herein shall meet or exceed the following characteristics.

The machine shall be used by the arsenal for components used in the manufacture of cannons. The materials to be ground could be 4340 alloy steel which has been hardened to Rc38-42 and high nickel strength steels as well as other type steel components and materials including non-ferrous.

3.2.2 Required Characteristics.

A. Grinding wheel diameter ……………………………..26” B. Magnetic chuck diameter ……………………………..48” C. Swing inside wheel guard ……………………………..56” D. Vertical range…………………………………………..36” E. Maximum load on chuck………………………………3000 LBS. or more F. Grinding wheel horsepower……………………………75 HP G. Down federate IPM……………………………………. .0001”to .100” H. Chuck rotation speed………………………………….. 6 to 24 RPM I. Coolant requirement……………………………………500 gallons minimum at 110 gallons/minute

3.2.3 Other Required Characteristics.

3.2.3.1 Magnetic Chuck. The chuck shall be capable of securely holding the work piece on the chuck face under maximum metal removal conditions in accordance with manufacture’s loading and blocking procedures. The poles of the magnetic chuck shall be no more than 1 inch apart over the entire face of the chuck so that small parts as well as large parts can be held securely during grinding operation. A variable holding type electromagnetic chuck control, including demagnetizer for eliminating residual magnetism from work piece suitable for this type of machine such as a Neutrofier ll or equal.

3.2.3.2 Remote Hand Held Operator’s Pendant. A remote operator’s pendant shall be provided. The machine shall be provided with a remote operator’s pendant with the following minimum functions. Communication with WVA operators will be necessary to determine functions desired. Preferred Hand held pendent Fanuc HMOP P/N A02B-0259-C221#A a.) Inch/Metric Incremental Jog b.) Feed Override c.) Jog d.) Spdl. Start/Stop e.) Cycle Start f.) Feed Hold g.) Machine Stop h.) Master Stop i.) Remote On/Off j.) 2-line LCD Display k.) Manual Pulse Generator

3.2.3.3 Hydraulic System Chiller. If needed to maintain acceptable hydraulic oil temperatures and accuracies the machine shall be provided with an appropriately sized hydraulic chiller system. See par. 3.1.12.

3.2.3.4 Spindle Square-ness With Chuck. At any given time regardless of wear that may have taken place in the bearings and slides, the alignment must be easily adjustable back to new OEM alignment specification. The alignment type shall be a three point column support where as the spindle column contacts the base at three widely spaced points which provides for quick and accurate adjustments of the grinding spindle relative to the magnetic chuck. Three heavy bushings are threaded into the column with calibrated washers to facilitate adjustment. Large hold-down bolts threaded into the base assure rigidity and provide single unit construction of the head, column and base to resist deflection under heavy grinding pressures. This system is what was used on Blanchard Rotary Grinders in the past.

3.2.3.5 Platform. Shall be provided with machine for the operator to stand on for loading and unloading the table. Platform shall be the type that runs the entire side of the machine, complete with railings and stairs. Platform shall be wide enough to have full movement around the work piece to prep for grinding and a work surface big enough for a small print.

3.2.4 Alignments and Accuracies.

· Magnetic chuck flat in all directions

· Surface of magnetic chuck parallel with its transverse movement…………………………. .002” Total

· Tapper of wheel spindle true running…………………. .0002” TIR

· Wheel spindle axial runout……………………………. .0002” TIR

· Wheel spindle square with magnetic chuck…………… .001”/12”

· Vertical adjustment of wheel spindle housing square with magnetic chuck in all planes…………….. .001”/12”

3.2.4.1 Positioning Accuracy and Repeatability.

· Positioning…………………………………………… .00025”

· Repeatability………………………………………… .00012”

3.3 Machine Control System. The desired control system provided as part of this project is Fanuc Power mate or equal.

3.3.1 Operator Control Panel. Fanuc Power Mate vertical power down feed system utilizing an AC Servo Drive motor with an absolute position encoder feedback system that does not require home or over-travel switches. Feed may be “continuous” at a pre-set rate or the system may be set to use a “burst” technique to provide the traditional, impulse feed. Coarse feed rates for roughing and fine feedrates for finishing shall be available in either the “continuous” or the “impulse” modes. Coarse feed rate from .001 to .100 inches per minute. Fine feed rates from .0001 to .010 inches per minute. To include coarse to fine change over to points .000 to .010 inches above the zero point and Inch to metric switching. Feed range .000 to 9.999 inches or .000 to 99.99 millimeters. The operator panel will include the Fanuc Power Mate control with a 7.2 inch monochrome LCD display. The magnetic chuck controls and the machine operator switches are also mounted on the panel. Complete with Analog load meter.

3.3.2 Enclosures. If enclosures are provided, they shall be NEMA12 rated. In addition:

a.) If required, given shop environmental conditions as detailed in par. 3.1.23, new control system enclosures for electronic circuitry shall be air conditioned and air filtered to maintain constant temperature, to reduce humidity and to prevent contamination of control boards and other critical system components. Air conditioning units shall not utilize Ozone Depleting substances.

3.3.3 Interconnecting Wiring. All wiring shall comply with accepted Joint Industry Code (JIC), National Machine Tool Builders Association (NMTBA), and National Fire Protection Association (NFPA) Standards.

3.3.4 Control/Operating System Software and Documentation. Two hardcopies two electronic copies on CD of the touchscreen software if applies, ladder logic, manufacturer’s system software for the control, interface software, etc. and all pertinent documentation are to be provided prior to final acceptance. If the control provided is equipped with a flash card reader then a flash card loaded with the final version back up of the Fanuc system software (Static RAM or S RAM) shall be provided with the final documentation and 1 extra flash card.

3.3.5 Control Functions and Capacities. Also, prior to the development of system software for this machine it shall be required that the contractor actively communicates with Watervliet machine operators, programmers and maintenance personnel to determine control functionality. This communication will be best achieved on-site at Watervliet. Also, please provide with your proposal a complete list of control options available for the control system being offered. Include a brief description of the options. Indicate which ones you are offering as part of your control.

3.3.6 Diagnostics Capabilities. The CNC shall be equipped with diagnostic capabilities covering the control itself, the interface and the machine tool. As a minimum, diagnostic capability shall include the display of a message or other meaningful indicator to identify any fault that causes the machine to be inoperable. This includes electrical/electronic faults and also any mechanical faults that result in operation of a safety interlock.

3.4 Requirements for Demonstration of Conformance.

3.4.1 Certification, Drawings and Tests Required. The contractor shall demonstrate both the machine’s conformance to all requirements elsewhere specified in section 3 of this specification. The contractor shall also, as a minimum, provide the following certification and perform the following specific tests:

3.4.2 Certification of Completeness. The contractor shall provide written certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements.

3.4.3 Test of Conformance to Specified Performance Characteristics. The machine shall be dry cycled at least 30 minutes, during which time the machine shall be tested for conformance to specified performance characteristics, including but not limited to, feeds, speeds and manual as well as automatic cycling.

3.4.4 Test of Conformance to Specified Alignments and Accuracies. The machine shall be operated under CNC control and laser tested with three bi-directional positioning accuracy and repeatability runs. Positioning accuracy and repeatability runs shall be tested at intervals specified by Watervliet machine inspectors. Before correction bi-directional readings will be supplied along with the corrected. The machine shall be tested for conformance to the accuracies specified in paragraph 3.2.4.

3.4.5 Test of Conformance to Specified Horsepower Characteristics. At the discretion of the WVA POC the machine may be tested for power and rigidity. The vendor shall provide a proposed test part of their choosing for this test. The test shall pull full load spindle horsepower for at least three minutes. The workpiece finish and machine rigidity will be evaluated.

3.4.6 Test of Conformance to Specified Performance on Workpieces. Paragraph outlines the types of accuracies which the machine shall be capable of producing on actual workpieces. The machine shall be tested to determine its capability to rough and finish grinds both top and bottom surfaces of 8 test blocks. Four placed approximately 6 inches in from the outer periphery of the magnetic chuck, spaced equally apart. Also 4 blocks placed approximately 6 inches from inner circle of the magnetic chuck, spaced equally apart. The machine shall remove from the blocks, by rough grinding a total of ¼ cubic inches per minute of metal per rated spindle motor horsepower. The test blocks shall then be finished ground to a 32 RA micro-inches. Finished blocks shall be parallel top and bottom and of the same thickness, within .0002” per foot of their separation on the chuck. The method used to obtain designated requirements shall be at the supplier’s option, with the approval of the Arsenal POC, standard production methods for a time study work piece is the prefer method. The suggested workpiece shall sufficiently demonstrate the capabilities and features of the machine. Workpieces shall be 4340 alloy steel pre-heat treated to Rc 38-42.

3.4.7 Provision of Materials and Equipment for Preliminary and Final Acceptance Testing.

3.4.7.1 Material for Workpieces. All materials necessary to produce the workpieces required in paragraphs 3.4.6 shall be furnished by the contractor.

3.4.7.2 Tooling. Tooling for all testing shall be provided by the contractor.

3.4.7.3 Cutting Fluids. Any cutting fluids necessary to perform the tests specified in paragraphs 3.4 shall be furnished by the contractor during preliminary acceptance testing and by Watervliet for the final acceptance.

3.4.7.4 Hydraulic Fluids and Lubricants. All hydraulic fluids and lubricants necessary to perform any of the required tests shall be furnished by the contractor during preliminary acceptance testing and by Watervliet for the final acceptance.

3.4.7.5 Testing and Measuring Equipment. All testing and measuring equipment (laser equipment included) needed to perform any of the required tests and measure the results shall be furnished by the contractor and shall be properly calibrated to standards traceable to the National Institute of Standards and Technology (NIST).

4 Quality Assurance Provisions.

4.1 Responsibility for Inspection. The contractor shall be responsible for performing all certifications and tests required in paragraph 3.4 and shall provide such materials, supplies and equipment as are specified in paragraph 3.4.

4.2 Preliminary Acceptance Inspection. Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in paragraph 3.4. However, prior to officially scheduling the preliminary acceptance inspection the contractor shall perform preliminary machine geometry alignments, laser accuracy tests and cut a test part. When these tests are completed successfully, the contractor shall provide no less than 14 calendar days notice to the Arsenal Contracting Officer that the machine is ready for the preliminary acceptance inspection. This notification shall also include for review the test results of all preliminary tests performed. If acceptable, the Arsenal representatives will schedule an inspection and the contractor shall await the arrival of the Arsenal representatives before starting the official inspection for which all testing will be repeated.

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection.

4.3.1 Examination for Completeness. The contractor shall furnish the Arsenal's representatives with a certification of completeness (see par. 3.4.2). The Arsenal's representatives will reserve the right to examine the machine to ascertain the presence of all specified features, equipment, markings and safety devices.

4.3.2 Examination of Performance Characteristics. During the test of conformance to specified performance characteristics (see par. 3.4); the Arsenal's representatives will observe the machine and its equipment for proper operation. Also during this test, the Arsenal's representatives may perform independent measurements of sound levels for conformance to par. 3.1.9.2.

4.3.3 Examination of Alignments and Accuracies. During the test of conformance to specified alignments and accuracies (see par.