Multi Tasking 5-Axis Mill Turning Centers-SOW_5-1-2024.pdf

MULTI-TASKING 5-AXIS MILL TURNING CENTERS - 1333ND24QNB130215

STATEMENT OF WORK

TITLE: Multi-Tasking 5-Axis Mill Turning Center equipment purchase, installation, and training

OFFICE REQUESTING SERVICE: Fabrication Technology Group

I. BACKGROUND INFORMATION

The Fabrication Technology Office (FTO) provides a wide range of engineering, fabrication, and technical services to support the creation of unique measurement instruments and scientific apparatus needed by NIST scientists and research staff. The group provides the mission critical engineering and manufacturing expertise and equipment needed to produce specialized parts and subassemblies for a variety of one-of-a-kind instruments conceived by NIST scientists and engineers. A cadre of highly skilled engineers, instrument makers, and engineering technicians provide this core capability. Beyond fabricating parts and equipment, group staff members work collaboratively with NIST research staff providing research support, technical consulting, and testing services. The group specializes in single job/prototype work and short production runs of unique mechanical components. The group also provides mechanical engineering design, optics and glass fabrication, and overall technical solutions for the fabrication and assembly of electromechanical devices.

To meet mission requirements, the FTO needs to procure two new multi-tasking 5-axis mill turning centers. The purchase of these multi-tasking 5-axis mill turning centers is necessary to permit precise, high-quality manufacturing, and IT sustainability with regards to C1 and C2-axis positioning of 0.0001° contouring, B Axis rotation of .0001-degree, bar working capacity measuring +2.5 inches, HSK-A63 (T63) tool holding, main and secondary A2-6 spindle nose, 32 HP milling spindle speed including training, rigging and installation. The upgrade will also enable the efficient use of NIST’s new integrated shop layout.

II. SPECIFICATIONS

The Contractor shall provide two Multi-Tasking 5-Axis Mill Turning Centers for fabrication, modification and prototyping of one-of-a-kind instruments and components to be used by NIST, Gaithersburg, MD.

The required equipment will allow for full 5 axis machining with C1 and C2-Axis positioning of 0.0001-degree, B Axis rotation of .0001-degree, bar working capacity measuring +2.5 inches, HSK-A63 (T63) tool holding, main and secondary A2-6 spindle nose, and a minimum of 32 HP milling spindle speed. Training, rigging and installation shall also be provided by the contractor.

Two machining centers comprised of the following (2x each of the below) Item 1: 1 ea Multi-Tasking Center

• Main Spindle bore diameter 76MM (2.99")

• Main spindle motor 22KW (30HP)

• Main spindle speed 5,000 RPM

• Main spindle - C1-Axis positioning 0.0001-degree contouring

• Main spindle A2-6 Collet Nose

• Second spindle motor 18.5KW (25HP)

• Second spindle speed 5,000 RPM 1

• Second spindle C2-Axis positioning 0.0001 degree

• Second spindle A2-6 Collet Nose

• Mill-spindle speed 20,000 RPM / (OIL & AIR LUBRICATION)

• B-Axis 0.0001-degree contouring

• Conversational and G code programming

• Electrical control box UL standard (480V) with internal transformer

Item 2: 1 ea Tool Changers - Magazines / Stockers (HSK) and accessories

• 74 Tool HSK-63A magazine

• Tooling package credit not to exceed $50,000

• Turret work stopper (for boring bar holder)

• Multi and flash tooling system

• Number display magazine panel

• Front tool set-up unit

Item 3: 1 ea Work Holding and accessories

• Automatic chuck jaws open/close on main and second spindle

• Chuck open/close confirmation on main and second spindle

• Programmable chuck pressure system on main and second spindles

• Double foot switch- Chuck open/Close on main and second spindles

Item 4: 1 ea CNC Control

• Microsoft Windows 10 based Control

• 19" Color LCD touch screen, dual monitor

• McAfee embedded control

• Windows based software for machining center

• Program size: minimum of 32 MB

• 3-D coordinate conversation

• G00 Slope constant

• Cylindrical & polar coordinate

• Direct entry of drawings dimensions

• Synchronous tapping (milling spindle)

• Main spindle and mill spindle simultaneous rotation

• Inch/metric conversion

• SD memory I/F(1-port) + USB I/F(1-port)

• LAN port

• USB I/F (1-port)

• Safety shield (Automatic and manual operation)

• AI thermal shield

• Program in process restart function

• Auto tool changer and recovery

• V-Axis control function

• Relocation device

• Windows 10 operating system for machine control

Item 5: 1 ea CNC Control - Software

• Overload detection system

• Auto pecking cycle with load detection

• Smooth engraving function

• Re-threading function

• Thread start point compensation

• Mill turning

• Work setting error compensation

• 5-axis machining package

• Tool radius compensation/5-axis

• Second spindle simultaneous 5-axis software

• Tool cutting point control

• Tool length comp in tool axis direction

• Tool data converter

• Set and inspect kit

Item 6: 1 ea Probing

• Tool eye (automatic)

• Absolute positioning system (linear axis)

• X, Y, Z Pitch error compensation input

• Coolers for ball screw (X, Y, Z-axis)

Item 7: 1 ea Spindles - Milling

• Smooth AI Spindle

• Mill-spindle speed 20,000 RPM – HSK-A63 / 24KW (oil and air lubrication)

Item 8: 1 ea Work Holding - Main and Second Spindle Hydraulic 3-Jaw Chuck Packages

• Schunk THW3 225/66 A2-6 Quick change chuck + Kitagawa S-1875 OPEN CYLINDER (main spindle) (for 2.99" bore)

• Schunk THW3 225/66 A2-6 Quick change chuck + Kitagawa Y-1530RE Closed cylinder (second spindle)

Item 9: 1 ea Automation

• Automatic parts catcher

Item 10: 1 ea Chip and Coolant Management

• Complete coolant system

• Coolant through milling head

• Simultaneous discharge

• Shower coolant on main and second spindle

• Preparation only for chip conveyor side discharge (hinge or concept)

• Chuck air blast on second spindle

• 200 PSI Through mill spindle coolant/flood coolant

Item 11: 1 ea Chip and Coolant Management - Chip Conveyor/ Air

• Chip conveyor side discharge

• Turret air blast (flood coolant nozzle)

• Mist collector with filtration

Item 12: 1 ea Probing – Training/Part Measurement

• Renishaw RMP600QE radio work measuring system-complete package

• Renishaw additional on-site standard training for part

• Probe with calibration tool

• Reference sphere and magnet stand

Item 13: 1 ea Spindles - Second Turning Spindle

• C2-axis 0.0001-degree contouring with C-axis (C1-C2 synchronous)

Item 14: 1 ea Miscellaneous

• Full coverage chip and coolant guard (completely enclosed cabinet)

• Square signal tower with three light colors

• Work light

• Status light

• Adjusting tools

• Auto power on/off with warm up

• Operator door interlock with lock switch

• Hydraulic pressure with interlock

• Roller guides

• Power transformer for North American markets

Item 15: 1 ea Foundation Inspection / Runoff / Installation

• Foundation kit with anchor, bolts, and plates

• Test bar for HSK-63A

• Including rigging and installation

• Certified foundation drawing

Item 16: 2 ea Training

• Minimum 1 week program / maintenance training

• On site applications support

• Maintenance, and troubleshooting training for the instruments and controlling software

• Electronics manuals including electronic and hard copies

III. INSTALLATION/FOB DESTINATION

Installation of one machine with anchoring per flooring depth of 8” of concrete.

Installation of one machine with anchoring per flooring depth of 15” of concrete.

IV. WARRANTY

The Contractor shall provide, at a minimum, a two (2) year warranty for the equipment. The warranty shall cover all parts from defects, labor, and travel. The warranty shall commence upon successful completion of delivery, installation, training, and demonstration of all required specifications. Includes standard unlimited program training for 2 years upon acceptance from the government.

V. DELIVERY

Delivery will be to Building 304/155, NIST, Gaithersburg, Maryland. Normal duty hours are Monday through Friday, 8:00 a.m. to 5:00 p.m. Eastern Time, apart from Federal holidays.

VI. DELIVERABLES

Description Quantity Due Date Multi-Tasking Centers installed and functioning to specifications as outlined in Section II of this SOW and to manufacturer specifications.

Two 11 months after receipt of order

Electronic (.pdf) or paper copies of the operations and maintenance manual for the system covering proper operation, routine

One 11 months after receipt of order

Warranty – to cover each machine Two Upon acceptance from government

Minimum 10 days program / maintenance training. On site applications support.

two 10 training days nonconsecutively

Maintenance, and troubleshooting training for the instruments and controlling software.

one 10 training days nonconsecutively

$50,000 tooling credit one Upon acceptance from government

Electronics manuals: electronic and hard copies one Upon acceptance from government

Installation of one machine with anchoring per flooring depth of 8” of concrete one *11 months after receipt of order

Installation of one machine with anchoring per flooring depth of 15” of concrete one *11 months after receipt of order

* NIST would prefer an earlier delivery date than the 11-months after the receipt of order.

The maximum delivery date of the two (2) multi-tasking 5 axis mill turning centers is 11 months after receipt of order.

VII. ACCEPTANCE CRITERIA

After delivery at NIST, the Contracting Officer’s Representative (COR) will visually check to ensure that the correct items were shipped. After the Milling Systems are installed by the contractor, NIST will verify that the systems meet the technical requirements in Section 2 in the Statement of Requirements and the manufacturer’s specifications. The operation and maintenance manuals will be reviewed to verify that they describe procedures for operating and maintaining the milling systems. The service technician shall go over training schedules and maintenance requirements of the machines. The NIST COR will review deliverables and determine if these criteria are met.

VIII. TRAVEL

Travel to the NIST, Gaithersburg is required. All travel expenses shall be included in the firm fixed price of this contract.

IX. MINIMUM CONTRACTOR QUALIFICATIONS

The Contractor shall provide authorized service engineers to install the Multi-Tasking 5-Axis Mill Turning Centers.

X. GENERAL INFORMATION

This work does not involve confidential or proprietary data. The certification and accreditation requirements of Clause 1352.239-73 do not apply, and a security accreditation package is not required.

Safety: The Contractor employee shall be responsible for knowing and complying with all installation safety prevention regulations. Such regulations include, but are not limited to, general safety, fire prevention, and waste disposal.

Security: NIST is a restricted campus. An identification badge is required for access for entry into buildings and is shown to the armed Security Police when entering the campus.

Regular Business Hours. Regular business hours are Monday through Friday, 8:00 am to 5:00 pm Eastern Time.

Identification Badges: Contractor employees shall comply with NIST identification and access requirements. Each Contractor employee shall wear a visible identification badge provided by the NIST Security Office.

Vehicle Registration: All Contractor employees must register their vehicles with the NIST Security Office to gain access to the campus. A valid driver’s license, Government-furnished civilian ID, proof of insurance and current registration must be presented to the NIST Security Office, at which time a NIST vehicle pass will be issued. The pass shall be displayed on the vehicle in accordance with NIST Security Office instructions.