New Horizontal Cold Spray Hone Specification 06-21-3419 Rev A.docx

Scope of Work for New Horizontal Cold Spray Hone January 21, 2021 Watervliet Arsenal (WVA) Watervliet, New York 12189-4050

Scope of Work for New Horizontal Cold Spray Hone

Manufacturing Engineering Work Group Scope of Work No. 06-21-3419 January 28, 2021 Rev. A

Department of the Army

TACOM

1. Scope:

1.1 Abbreviated Description: This specification covers the requirements for a new horizontal honing machines for the machining of internal bores up to 8” diameter with a honing stroke of 26’. With the option to purchase a second machine. The machine or machines shall be built with the capability for using diamond or super abrasive honing stones (CBN) and 80 mesh silicon carbide, 3/8” x 3/8” x 6” brush assembly for cleaning and processing of tube bore diameters on high strength steel, and cold spray TANTALUM.

1.2 Required Submittal Schedule: The bidder/successful bidder will be required to submit the following items for approval or as machine documentation:

Para. Item Description Submission Requirement

3.1.9.5 Asbestos & Mercury Free Certification Proposal

3.1.9.6 Material Safety Data Sheets 30 days after Contract Award

3.1.8.8 PCB-Free Certification Prior to shipment of new equipment

3.2.5.1 Hone Tool Body Design Prior to Fabrication

3.3.5 Control Functions and Capacities Proposal

3.4.1.5 Workpiece Performance Test Proposal

6.1 Attachment C Proposal

Note: The contractor can combine into one binder appropriately sectioned the information required in paragraph 3.1.17

2. Applicable Standards and Publications: Various standards and other publications are referenced in section 3 of this specification. Where they are referenced or required, they are meant to indicate an acceptable level of quality, safety or performance. Offerors may choose to adhere to standards other than those specified, provided that the substitute represents a level of quality, safety or performance equal to or better than the one specified. Any substitutions must be clearly disclosed and explained in the offerors statement of compliance (see 6.2). Any standards adhered to in complying with this specification shall be the latest issues in effect on the date of the submission of bids or technical proposals and offerors are responsible for obtaining copies of the most current revisions.

2.1 The Following Standards and Other Publications of the Following Organizations Are Referenced Within this Specification:

F. INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS STANDARD 112, SECTION B.

G. TITLE 29, CODE OF FEDERAL REGULATIONS, PART 1910,

SUBPART 0.

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. Section 6, "instructions to offerors", contains more detailed information regarding offered alternatives.

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.

3.1.2 Materials: Materials incorporated in the construction of new parts for 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, for the new 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. Distortion and deflection at maximum loads shall be limited to a degree consistent with retention of alignments and tolerances, and the machine shall recover from distortions and deflections at no load. 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 components such as beds, saddles, columns, shall be castings either of iron or semi-steel, 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.

3.1.3.2 Alignment Retention: Non-integral machine components, including columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry, shall utilize pins, keys, square shoulders or other such positive means of retaining alignment and regaining it in the event of accidental dislocation. Offers of machines whose retention of alignment depends solely upon bolt tension and/or adhesives will be unacceptable.

3.1.4 Slideway Design and Construction 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.

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.

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. Equivalent slideway systems other than the three (3) referred to above may be offered. 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. In such cases, way protection is still required and a suitable alternative to covers shall be proposed for review and acceptance.

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.

3.1.5 Workmanship: Workmanship throughout the machine and its equipment shall be of good quality and meet industry standards.

3.1.5.1 Shimming: A shim is herein defined as an unplanned insert whose presence, dimension and shape do not appear on the engineering drawings and which cannot, therefore, be reproduced from those drawings. Shims, as defined above, shall not be incorporated in the machine.

3.1.5.2 Spacing: A spacer is herein defined as a planned insert whose presence dimension and shape does appear on the engineering drawings. Spacers, as defined, in this paragraph, are permissible.

3.1.5.3 Other Unacceptable Repair Measures: Welding, brazing, soldering and other such techniques shall be used only where called for in the machine’s design. They shall not be used to repair machine components defective in material or in machining accuracy.

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

3.1.8.1 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.

3.1.8.2 Electrical Safety Devices and Limit Switches: The machine and its equipment shall be protected with circuit breaker and limit switches where applicable.

3.1.8.2.1 Circuit Breakers: 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 volts, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plug-in circuit breakers or current limiting fuses are not acceptable.

3.1.8.3 Conversion Equipment: If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment WILL NOT BE ALLOWED. Machine must be designed to meet WVA power source see paragraph 3.1.8.1.

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.

3.1.8.5 Operator Control Voltage: All electrical controls meant for use by the operator of the machine shall carry AC maximum. Class “A” ground fault interrupt protection shall be provided.

3.1.8.6 Utility Outlet: The machine shall be provided with a dual-receptacle 3-wire utility outlet fully wired and equipped to deliver 120-voly single phase AC power at up to 20 amperes, based upon a 480-volt 3-phase input. This outlet shall be protected by a ground-fault interrupter and shall be externally mounted and easily accessible. If the machine specified or offered is numerically controlled, an electric “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 Title 29, Code of Federal Regulations, Part 1910, Subpart O, Subpart J and NFPA 79 for noise levels (see 3.1.9.3).

3.1.9.2 Protection of the Machine: The machine shall be fully equipped with the devices necessary to prevent self damage in the event of malfunction and/or ordinary operator negligence insofar as practical. Such devices include, but are not limited to, limit switches, positive end stops, overload protection devices, lubrication failsafe.

3.1.9.3 Noise Levels: The government's preference is to achieve noise levels not in excess of 80 dBA. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities. Noise levels in the vicinity of the machine, even if not meeting the desired 80 dBA, 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. "Vicinity of the Machine" is further defined as an imaginary line completely surrounding the machine at a distance not exceeding one meter from the nearest point on the machine. The maximum noise level limit shall apply at the operator's console, even if the console lies inside the one meter envelope. Techniques such as sound level averaging or exposure time weighting shall not be used in meeting this requirement. 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 1 ozone depleting substance within the government specification or standards set forth in the contract. The restricted class 1 CFC's and Halons currently used as refrigerants, solvents, lubricants, drying agents, propellants and firefighting agents are listed in Attachment B. All shall be replaced by new substances or systems that are approved for use by the Environmental Protection Agency (EPA). They shall be functionally equivalent to the CFC's, Halons, Carbon Tetrachloride and Methyl Chloroform being replaced. The acceptable substitutes shall have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data Sheets (MSDS) shall be submitted for approval to the Watervliet Arsenal technical POC 30-days after a contract award. (See Attachment #B for list of Class I Ozone Depleting Substances.)

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. If an asbestos material or mercury must be utilized, a statement of justification must be submitted and approved prior to construction. An asbestos material is any material containing more than one percent by weight of asbestos.

3.1.9.6 Material Safety Data Sheets: The offeror shall provide all Material Safety Data Sheets to the Watervliet Arsenal at the time of the proposal submission.

3.1.9.7 Lead-free and Chromium-free Paint Certification: All paints and primers applied to the machine tool shall be certified as being lead and chromium free. 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 at the time of proposal submission.

3.1.9.8 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 Biphenyls (PCB’s). The machine and its equipment shall be certified as PCBfree prior to being shipped. PCB free is defined as a level of contamination which is undetectable using EPA approved methodologies.

3.1.9.9 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, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.10 Identification Plate: A corrosion resistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the machine's original nameplate. This plate shall bear the information called for as follows, with space at the bottom for one additional line of information to be applied by the Government.

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 a series progressive distribution system such as manufactured by Trabon Inc. Gearboxes or transmission cases shall be lubricated by the wet sump 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 non-recirculating automatic systems, 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. Wet sump 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 flush mounted 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 justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

Note: The contractor shall be responsible for providing all lubricants, hydraulic fluids, oils and coolants necessary to complete all factory testing.

3.1.12 Hydraulic System: When a hydraulic system of any type is provided or specified, it shall be appropriately sized and powered for the intended application and shall conform to industry standards. The system 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, anti-surge 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.

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 chromium-free and lead-free. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semi-gloss", and selected by the Government, from a list of standard colors supplied by the offeror. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow, warning signs, tags or emblems will be affixed to respective areas of the machine in accordance appropriate safety standards.

3.1.14 Machine Hold Down and Leveling: The machine base shall be provided with sufficient and properly located holes for positive hold-down when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended hold-down and leveling hardware. The hold-down bolts themselves shall be long enough to permit insertion of a series of government furnished two-inch thick blocks between the machine base and the floor surface. Each block is approximately 6" wide by 8" long and is placed at leveling and/or hold-down sites in the machine's base.

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

3.1.15 Gears: All gears used in this machine shall meet or exceed the industry standards recommended 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 and delivery dates below. 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, as indicated below, in hardcopy and in AutoCAD 2007 or newer on CD. Please note any AutoCAD drawings provided shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. “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 shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

Note: All major components, shown in mechanical, electrical, electronic or pneumatic drawings submitted, shall have identifying numbers referenced to the repair part list/spreadsheet, required per paragraph 3.1.17 (j).

a. Foundation Drawings, Standard or Special: Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award or at least 210 days prior to scheduled delivery of the machine. All drawings shall be dimensioned in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

If a special foundation (see note) is required and the vendor/contractor refuses to provide the detailed drawings required then this shall be grounds for disqualification from further consideration in the machine tool procurement. Vendor proposals submitted shall be clear in their response to this requirement.

Important: See instruction par. 6.5

Foundation Drawings details shall include at least:

1) At least one drawing shall depict an over-lay top view of the machine foundation outline, machine general arrangement drawing (including all ancillary equipment) and the anchor bolt hole pattern.

2) The foundation drawings shall include 100% complete foundation details necessary for Watervliet Arsenal to directly hand over to a General Contractor for construction. This detail shall include, but not be limited to, complete foundation dimensions, rebar locations, rebar size, rebar pattern, concrete PSI requirements, and load bearing specs.

b. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in AutoCAD shall be provided on a CD. This plan shall depict the complete machine space envelope including all ancillary equipment and 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 including the full load amperage requirements, air, water.) required to operate the machine. This data shall be furnished as soon as possible after contract award or within 30 calendar days. One reproducible hardcopy and one electronic copy on CD in AutoCAD shall be provided.

c. Catalog of Standard Tooling and Accessories: A catalog of standard tooling and accessories shall be furnished 60 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 hard copies at factory testing)

d. Nonstandard (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. Dimensional information shall be in the English system or may be dual inch/metric in cases where the metric system is the system customarily employed by the contractor. (Two reproducible copies at factory testing, if applicable)

e. Installation Instructions and Drawings: Shall 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 as soon as possible after contract award or at least 210 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD.

f. Lubrication Diagram or Instructions: To be delivered at time of machine delivery. (One reproducible hard copy and one electronic copy on CD at factory testing)

g. Operating Instructions: New operating instructions/manuals shall be provided outlining the new procedures. Operating instructions specifically directed to the machine operator are to be provided in separate manuals from all other technical data. These operator instructions are to clearly describe the functions of all operator panel pushbuttons and screen softkeys. To be delivered to the technical POC at the start of system testing. (Four hard copies and 2 electronic copies at factory testing)

h. Maintenance and Troubleshooting Instructions and Manuals: Maintenance and Troubleshooting manuals for all machine systems. This material shall include assembly drawings. To be delivered to the technical POC at the start of system testing. (Two hard copies and 2 electronic copies at factory testing)

i. Electrical Schematics: Electrical schematics are to be furnished. To be considered acceptable, these schematics must clearly portray all final control and drive system modifications or other changes made as part of this project and how they tie to their respective main systems. Final as-built drawings are to be furnished to the technical POC, not later than 30 days after final system test acceptance. (Two hard copies and 2 electronic copies at factory testing)

Note: If, during installation and testing, the actual systems are configured differently than depicted on the schematics, receipt of the revised "as-built" schematics shall be a condition of final acceptance.

j. Repair Parts List/Spreadsheet: The contractor shall provide in Excel Spreadsheet format spreadsheet shall encompass every major replaceable part or sub-assembly altered or added as part of this retrofit/rebuild. The repair parts spreadsheet shall include illustrations which clearly locate parts within larger subassemblies. To be furnished not later than 30 days prior to delivery of the machine. Every part listed shall have the following data associated to it:

· Contractor Part Number

· Part Description

· Drawing Number

· Part, original Manufacturer Part Number (where Applicable)

· Company Contact Number for part replacement.

The spreadsheet shall allow data to be sorted by any of the above-mentioned parameters. The version of EXCEL to be used is 2013 and shall be on CD. This CD shall be reviewed by the Contracting Officer’s Technical Representative at the contractor’s factory test. (CD)

l. Programming Manuals: Programming manuals shall be provided. 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 to the technical POC at the start of the retrofit/rebuild. (At factory testing in CD format)

m. Software Documentation: The offeror shall provide two copies of all system software and/or ladder logic developed to control and interface with the new control/drives provided. A final revision of the software shall be furnished to the technical POC not later than 30 days after final acceptance of the rebuild/retrofit or at such time when all software revisions have been completed. (Two hard copies and 2 electronic copies at factory testing)

3.1.18 Machine Installation, Startup and Testing: Watervliet Arsenal personnel will not be required to assist the contractor other than to provide material handling assistance associated with this machine.

3.1.18.1 Work to be performed by the Arsenal: Upon receipt of the required installation and foundation drawings (see 3.1.17), the Watervliet Arsenal will prepare 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, foundation drawings and electrical and hydraulic schematics 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.

3.1.18.2 Work to be performed by the Contractor: This project shall be a turn-key operation with the contractor being fully responsible for all work, and providing all personnel and equipment necessary to perform the required scope of work. If a special foundation is not required 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 provide competent English-speaking service personnel to install the machine, rough and finish level the machine place the machine in operation and conduct the acceptance tests specified in section 4. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, 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 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 non-availability of Arsenal personnel or Arsenal-furnished equipment.

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.

3.1.19 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:

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.

3.1.20 Repair/Replacement Parts and Service: The offeror shall also agree to provide parts and 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. In the event of a national emergency the U.S. Government reserves the right to obtain the data and use it to support operation of the machine tool(s) purchased under this contract.

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

3.1.21 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 PSI and if higher or lower pressure 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 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. An external compressor is not acceptable.

3.1.22 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.

3.1.23 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 leak proof metallic or nonmetallic liner.

Note: Coolant containment design depends on the workpiece. The contractor shall coordinate with the Watervliet Arsenal for developing a means of coolant insertion into the bore of the workpiece and coolant collection upon exiting the workpiece.

3.1.24 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 60 degrees F. to 95 degrees 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 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.

3.1.26 Elapsed Time Meter: The machine shall be fitted with a meter to measure operating time of the spindle drive. The time totalizing meter shall be of the nonresetting type and shall have a range of 0 to 99,999 hours in increments of 1 hour. 1-hour being the least significant digit. Upon reaching the maximum accumulative hours the meter readout shall automatically revert to zero and continue to totalize time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the equipment. The meter shall be located as to be readily visible but not subject to abuse relative to the operating environment of the equipment. Time meters resident in the numerical control unit are unacceptable.

3.2 Detailed Requirements:

3.2.1 Machine Tool Description: The machine tool this purchase specification refers to is a PLC-controlled, single spindle, heavy-duty, horizontal bed honing machine. This machine tool will be used to hone the bores of gun tubes.

3.2.2 Required Characteristics:

3.2.2.1 Machine Tool Size Characteristics:

Characteristics Value

Stroke Length Variable 0 – 26’

Honing tool sizes 155mm and 120mm

Outside diameter of tubes to be honed 6 inches to 13.5 inches

Work piece weight capacity 5000 lbs.

Work piece length 20’

Work piece centerline height above the floor No less than 36˝ to no more than 48˝

3.2.2.2 Machine Tool Performance Characteristics:

Characteristics Value

Honing Head Drive Motor 40 HP or more continuous (Infinitely Variable)

RECIPROCATION POWER 30 HP or more continuous

Honing spindle speed range 30 rpm or less to 400 rpm or more

Rate of honing head reciprocation 1 linear ft. per minute or less to 70 linear ft. per minute or more

Honing head reversal points .040˝ from set position

Stock Removal Rate 65 in3/ Hour

Coolant Delivery 0 to 100 gallons/minute or more infinitely variable

3.2.2.3 No-Load Alignments and Accuracies:

Characteristics Value

Honing spindle, axial or face runout .001˝ maximum T.I.R.

Note: The contractor shall submit, in their proposal, the method of testing for each parameter required by this paragraph and what equipment they will use at their factory to perform those tests.

3.2.2.4 Required Accuracy of Workpieces:

Characteristics Allowable Tolerances

Out of roundness of the bore measured 0.0005˝ or less over total hone depth At 5 random locations

Overall taper of the workpiece bore Not to exceed 0.001˝

Surface finish of workpiece bore 16 Micro-inch or finer steel Finish Tantalum 3 micro-inch or finer

3.2.3 Other Required Characteristics:

3.2.3.1 Honing Spindle. The honing spindle shall be adaptable so as to accept the full complement of hone tool bodies and drive shafts supplied to enable the honing of diameters specified in paragraph 3.2.2.1 and shall be arranged so as the machine tool operator can interface with minimal effort the components necessary for the selected job. The honing spindle speed range shall remain adjustable in a step-less manner for the range specified in paragraph 3.2.2.2 and shall be selectable for clockwise or counter-clockwise rotation from the operator’s control station.

3.2.3.2 Drive Shaft and Tool Supports: The drive shafts shall be alloy steel, bored and of suitable diameter and wall thickness to be compatible with the bores of the cylinders to be honed and the stock removal rate required. The drive shafts shall be a maximum of two piece construction, straight within five thousandths (.005˝) of an inch or less in any two foot length and within ten thousandths (.010˝) maximum overall.