Ultrafine Wire EDM Specifications.pdf

SOLICITATION NO.: N00173-12-R-RV03

Attachment A: Specifications

Ultrafine Wire EDM Machine Critical Specifications

Scope Metallic circuits used for interaction with an electron beam to generate coherent electromagnetic radiation are proportional to the wavelength of operation. The higher the frequency, the smaller the structure. For devices operating at upper-millimeter and sub-millimeter wavelengths, non-conventional fabrication methods are required. In particular, methods that do not rely on material removal using mechanical forces. Electrical discharge machining (EDM) is the optimum method to meet these requirements. In order to produce structures that can operate up to the 500-700 GHz frequency regime, candidate EDM machines must be able to accommodate ultrafine wire with diameters less than or equal to 0.0008 inches.

1.0 CLIN 0001

AgieCharmilles Cut 1000 +F

1.0.1 The required system must be capable of cutting with both brass and tungsten wire.

1.0.2 The required system must be able to accommodate wire diameters ranging from a minimum of 0.0008 inches up to at least 0.008 inches.

1.0.3 The required system must have a minimum measurement resolution of not more than 1 × 10-7 meters (0.1 µm).

1.0.4 The required system must be able to use deionized water as the dielectric fluid and have a built-in system to monitor and maintain a stable water temperature of no more than 20±0.1°C

1.0.5 The required system must include a dual-wire threading system that can automatically switch between spools with two different diameter wires to provide a balance of fast cutting speed with larger wires and fine detail with smaller wires.

1.0.6 The required system must be capable of automatically threading wires into the feed system without requiring manual wire-guide changes. It must accommodate wire diameters of at least 0.008 inches down to a minimum diameter 0.0008 inches.

1.0.7 The required system must contain linear x-y motion control; the machine must include an additional rotary axis under full computer numerical control (CNC) with a hands-free pneumatically-actuated 3R chuck.

1.0.8 The required system must possess internal computer-aided manufacturing (CAM) software so that computer-aided design (CAD) models can be uploaded and converted to machine code suitable for running on the EDM.

2.0 CLIN 0002

User License for Vision 5 PC Cut

2.0.1 The required system must be capable of simulating the operation of the AgieCharmilles Cut 1000+F so that CNC code can be simulated independently of the EDM machine. It must operate on the Windows operating system.

2.0.2 The required system must contain additional software to verify CNC code independently of the EDM machine to be installed on a separate computer running the Microsoft Windows operating system.

3.0 CLIN 0003

Control Module for Additional Axis for Cut 1000

The required system must allow the interface between the additional axis JS R- 10100D-55 Stainless (CLIN 0006) and the Cut 1000+F (CLIN 0001).

4.0 CLIN 0004

Variant Pneumatic Interface for Pedal Operation (Foot Switch) The required system must allow for hands free operation of a clamping chuck.

5.0 CLIN 0005

Stacklamp Indicator The required system must show the status of the Cut 1000+F by means of color coded light.

6.0 CLIN 0006

Axis JS R-10100D-55 Stainless Steel The required system must include an additional axis that must allow for both turn and burn cutting and indexing. It must interface with the control module listed in CLIN 0003.

7.0 CLIN 0007

Variant A-Axis with System 3R Chuck SP 7359-RS The required system must include a chuck that has a pneumatically operated clamping mechanism. It must interface with the Axis JS R-10100D-55 Stainless (CLIN 0006)

8.0 CLIN 0008

Measuring Instrument DTMB 500 The required system must include a wire tension calibration tool capable of reading tension for wires in sizes of at least 0.0008”.

9.0 CLIN 0009

ResinMax Deionizing System The required system must be capable of maintaining the dielectric cutting water at DI levels required by the Cut 1000+F. It must include two 50 liter resin bottles.

10.0 CLIN 0010

WEDM Tooling Starter Kit The required system must contain a tooling kit that includes the following items:

SUBCLIN 0010AA 1 – Part number C860000 8mm clamping kit.

SUBCLIN 0010AB 1 – Part number: C666040 support.

SUBCLIN 0010AC 1 – Part number: 3R-293.33 multi-vise.

11.0 CLIN 0011

Custom 3R Tooling Package

The required system must contain a tooling package of the following items:

SUBCLIN 0011AA 1 – Table adapter kit (155mm clamping support, table adapter, +4mm support spacers, storage case).

SUBCLIN 0011AB 1 – Clamping bar (adjustable frame clamping component).

SUBCLIN 0011AC 1 – 0-70mm vise (horizontal clamping vise).

SUBCLIN 0011AD 1 – Side clamp (horizontal clamp allows both top and bottom clearance).

SUBCLIN 0011AE 1 – Double edge clamp (low profile clamp holds thin parts or stacks of thin parts vertically).

SUBCLIN 0011AF 1 – Clamping flange (used to clamp multiple square parts in a single setup and allow both top and bottom clearance).

12.0 CLIN 0012

Custom Consumable Package The required system must contain a consumables package of the following items:

SUBCLIN 0012AA 8 spools 0.02mm x 3000m Tungsten wire SUBCLIN 0012AB 2 spools 0.03mm x 3,000m Tungsten wire SUBCLIN 0012AC 6 spools 0.05mm x 5,000m Tungsten wire SUBCLIN 0012AD 3 spools 0.03mm x 5,000m SP wire SUBCLIN 0012AE 2 spools 0.05mm x 20,000m SP wire SUBCLIN 0012AF 5 spools 0.07mm x 20,000m SP wire

SUBCLIN 0012AG The required system must contain enough dielectric particulate filters to perform at least 4 changes.

13.0 CLIN 0013

Installation, Testing and Acceptance

The contractor shall deliver the electric discharge machine to NRL (building 208, room

143) no later than 168 days after contract award. Installation of the electric discharge machine shall be completed no later than 30 days after delivery. NRL shall provide the necessary facilities and utility hook-ups for proper installation and operation of the electric discharge machine. The contractor shall provide operational demonstration including functionality checks, machine calibration and test cuts. The electric discharge machine shall be ready for immediate use following installation and set-up. The contractor shall also provide the necessary hardware for testing. Acceptance shall occur after installation and testing is complete.

14.0 CLIN 0014

Training

The contractor shall provide at least 1 week of onsite system training for at least 4 persons at their training center in Chicago. Training shall occur no later than two months after installation and testing (CLIN 0013) is complete.

15.0 CLIN 0015

Warranty The contractor shall provide the standard commercial warranty offered to the general public, including labor and materials. The period of the warranty shall begin upon acceptance of CLINs 0001, 0002, 0003, 0004, 0005, 0006, 0007, 0008, 0009, 0010, 0011, 0012 and last a minimum of one year.

16.0 CLIN 0016

Documentation The contractor shall provide the following documentation at the time of installation.

16.0.1 All operation and maintenance manual(s) or equivalent.

16.0.2 One quick reference manual.

16.0.3 Software manuals for the software included with the system.

16.0.4 Drawings and schematics for full site preparation, operation, troubleshooting, servicing, and repair of the system and its components.