HEDMS Product Description.pdf

PURCHASE

DESCRIPTION

for

Horizontal Electrical Discharge Machining System

(HEDMS)

for the

809th SCIENCE & ENGINEERING LABORATORY

(809 MXSS/MXDTAC)

Hill AFB, UT

07 Dec 2022

1. SCOPE:

1.1. This purchase description (PD) covers detailed specifications and performance requirements for a Horizontal Electrical Discharge Machining System for 809 MXSS/MXDTAC at Hill AFB, Utah. From this point on, the Horizontal Electrical Discharge Machining System will be referred to as HEDMS throughout this PD. To acquire a HEDMS to enable precise removal of additively manufactured metal parts from the surface of build plates.

2. OVERVIEW:

2.1. Acquisition of a HEDMS will drastically reduce the amount of sacrificial material required at the build interface. The HEDMS will provide excellent geometric accuracy and minimal loss of workpiece material. The HEDMS will allow faster cutting than a standard wire electrical discharge machining system while reducing part contamination and damage. The HEDMS will be used to support additively manufactured metal components for use on weapons systems such as A-10, C-130, C-17, F-16, F-35, KC-135, T-38, Ground and Shop Support Equipment and Structures, Vehicles, Missile components, etc.

3. SYSTEM DESIGN:

3.1. ENGLISH: All documents and software submitted by contractor to USAF contracting office must be in American English. All documents and software provided with HEDMS must be in American English.

3.2. The HEDMS shall be new and one of the manufacturer's current production models, which, on the date of the solicitation, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. The HEDMS shall be an off the shelf design meant for a production level metal additive manufacturing environment. Products such as a prototype unit, pre-production model, a repaired unit or an experimental unit do not qualify. The system shall include all components, parts and features necessary to meet the requirements specified herein and be complete and ready for use.

3.3. The HEDMS shall meet the following minimum requirements:

3.3.1. Must have a highly rigid table that allows for mounting a variety of metallic build plates (surface additively manufactured metal parts are built on).

3.3.2. Must accommodate build plates up to 20in x 20in with 16-inch-tall part.

3.3.3. Must handle a build plate with part affixed weighing 1,000 pounds.

3.3.4. Must allow an operator to securely mount a build plate with part affixed right-side up on the table in the flat horizontal position.

3.3.5. Must automatically fully invert the horizontal table with build plate mounted upside-down prior to cutting part/workpiece.

3.3.6. Part(s) must be suspended, hanging down vertically, prior to cutting with horizontal wire, to allow part(s) to fall away by gravity downward for safe capture in a collection basket type device.

3.3.7. Must include a stainless-steel part collection basket capable of holding 1,000 pounds or more. Allows use of optional internal separators.

3.3.8. Must utilize a flooded dielectric bath with a tank capacity of 230 gallons.

Dielectric fluid conductivity levels of about 2,000 micro-siemens per centimeter.

3.3.9. Must have a chiller to control the dielectric fluid temperature.

3.3.10. Must use a 0.008-inch diameter molybdenum wire. Kerf loss of < 0.02in.

3.3.11. Must utilize a double spool wire system allowing wire to travel both forward and reverse with wire speeds of 20 meters per second, reusing the wire back and forth.

3.3.12. Must include a device that enables high speed loading and unloading of wire at speeds of 15 meters per second.

3.3.13. Must have machining speeds up to 9.4 in2/minute with +0.004 in. accuracy.

3.3.14. Must allow travel in the Y axis 25.5 inches and Z axis 7.8 inches.

3.3.15. Must use a bipolar pulse type power generator.

3.3.16. Must use a mist extraction system to prevent smoke and mist from exiting system.

3.3.17. Must have a high-capacity filtering system with capacity equivalent to 4 standard filters.

3.3.18. Must use a type 2 surge protection device to prevent against power surges.

3.3.19. Must use a 12 KVA, 3 phase, isolation transformer to prevent load disturbances.

4. OTHER DELIVERABLES:

4.1. Optional items or accessories that shall be included with HEDMS:

4.1.1. Two full spools of Molybdenum wire (0.008 in)

4.1.2. One complete spare set of wire guides

4.1.3. Loading/Unloading tool, see section 3.3.12

4.1.4. Reinforced collection basket, see section 3.3.7.

4.1.5. Work area light

4.1.6. Mist extraction system, see section 3.3.15

4.1.7. Extended filtration, see section 3.3.16

4.1.8. Adapter plate(s) to accommodate two 250mm x 250mm build plates

4.1.9. User/Operators manual-English

4.1.10. Dielectric Fluid in sufficient amount to fill machine at least three times.

4.2. WARRANTY: The successful bidder (contractor) shall provide a minimum one-year warranty which warrants all products provided under this contract, under normal use, to be free from defects in materials and workmanship and that the HEDMS will perform its design function for a period of no less than one (1) year. Warranty period to start from date of final acceptance. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be repaired by the contactor at no additional cost to the government. The contractor shall provide, free of charge, software updates and/or system upgrades that are released during the warranty period. Warranty shall include the cost(s) of parts, shipping, labor, and any travel related expenses. Warranty repairs which present a safety hazard are to be repaired within 7 business days of notice of failure. Non-safety related warranty repairs are to be repaired within 15 business days of failure notice.

5. AFTER CONTRACT AWARD:

5.1. The contractor shall deliver the HEDMS within 100 days. The contractor shall be responsible for the crating and shipment of HEDMS to its final destination IAW standard commercial practice. Contractor shall make all arrangements necessary, and cover all costs to deliver HEDMS and all related equipment, supplies, materials, fabrications, etc. to the job site at Hill Air Force Base, Utah. Contractor shall coordinate delivery and off-loading with the government representative (GR) from 809 MXSS/MXDTAC. The contractor shall supply and deliver operations/maintenance manuals upon delivery of the HEDMS or sooner.

Failure to meet all requirements outlined in this PD shall be grounds for rejection.

5.2. Installation:

5.2.1. At no additional cost, the contractor shall provide on-site service for the uncrating, installation and setup of HEDMS. Contractor’s representative shall inspect HEDMS to ensure that all included pieces/parts/optional items are present and accounted for. In addition, they shall fully install HEDMS and demonstrate that it is fully functional prior to final acceptance by government representative.

5.2.2. All labor, food, travel and accommodation expenses for on-site installation by the contractor’s representative(s) shall be included.

5.3. Training:

5.3.1. Immediately following installation, and at no additional cost, the vendor shall provide HEDMS training. A qualified, factory trained on HEDMS, specialist(s) must provide training for 4 or more operators, for at least three 8-hour days, on-site at Hill AFB, Utah.

Training, at a minimum, shall include:

5.3.1.1. HEDMS System Introduction

5.3.1.2. Start Up procedures

5.3.1.3. Complete setup of wire drive, guides, dielectric fluid, basket, etc.

5.3.1.4. Manipulation and use of fixturing/mounting of build plates

5.3.1.5. Software – complete operation of all functions and controller

5.3.1.6. Hardware– complete operation of all functions

5.3.1.7. Cover all capabilities/features/functions

5.3.1.8. Shut Down procedures

5.3.1.9. System Care & Detailed Maintenance

5.3.2. All labor, food, travel and accommodation expenses for the applications specialist(s) to make on-site visit shall be included.

**Attention**

All line items for this purchase order shall be shipped to the following address:

7278 4th Street BLDG 100 Bay D Hill AFB, UT 84056

UIC: FF50T0

Attn: Aaron Erickson

4.2. WARRANTY: The successful bidder (contractor) shall provide a minimum one-year warranty which warrants all products provided under this contract, under normal use, to be free from defects in materials and workmanship and that the HEDMS will perfo...