Specifications.pdf

A. The contractor shall provide all resources (except as may be expressly stated in the contract as furnished by the government) necessary to furnish the items below in accordance with the description/specification/work statement in Section C.

B. One (1) each Electrical Discharge Machine

C.1 The Electrical Discharge Machine (EDM) shall be furnished in accordance with the following:

A. Shall be a wire-cutting EDM and capable of both submerged and non-submerged cutting, and of using various wire diameters ranging in size from a minimum of no more than 0.008 inch to a maximum of at least 0.012 inch.

B. Shall be capable of handling non-submerged or submerged work pieces of at least 24.000 inches in length, 38.000 inches in width, and 14.500 inches in height.

C. Shall be capable of 4–axis continuous path operation with the U and V axes movement independent and simultaneous with the X and Y-axes movement.

The Z-axis is a positioning axis. The axes travel shall be as follows:

1. X-axis travel shall be at least 21.000 inches

2. Y-axis travel shall be at least 12.000 inches

3. Z-axis travel shall be at least 14.500 inches

4. U-axis travel shall be at least 21.000 inches

5. V-axis travel shall be at least 12.000 inches

D. Shall be capable of cutting tapers of at least 45 degrees in 14.500-inch thick material throughout the maximum X-Y-axes travels.

E. Shall be capable of linear cutting speeds of at least 36.000 square inches per hour in 2.000 inch thick 15-5 PH stainless steel heat treated to H-1150

(Rockwell C scale (Rc) 38-40).

F. Shall be capable of X and Y-axes rapid jog feed rates of at least 100.000 inches per minute.

G. Shall have X, Y, and Z axes positioning accuracy’s through full range of movements of +/- 0.0003 inches and X, Y, U, and V axes repeatability of +/-

0.0003 inches.

H. Shall have Z-axis positioning accuracy of +/- 0.0005 and repeatability of

+/- 0.0005.

I. The level of the bath in the work tank shall be able to be set manually along with the Z-axis allowing for submersion of varying work piece height while keeping the U and V axes clear of the bath.

J. Shall be capable of automatically threading various wire diameters from a minimum of no more than 0.008 inches to a maximum of no less than 0.012 inches. This operation shall be through a start hole of no more than 0.040 inches diameter through a work piece height of at least 14.500 inches.

K. Shall utilize coaxial flushing when both submerged and non-submerged at a working pressure of at least 150 pounds per square inch (psi) to ensure rapid removal of ash residue and minimize wire breakage. The flushing pressure and/or flow parameters shall automatically adjust to change in flushing conditions.

L. Shall be capable of producing surface finishes of at least 14 micro inches

RMS in 2.000 inch thick 15-5 PH stainless steel heat treated to H 1150 (Rc

38-40) using no more than 2 skim cuts.

M. Shall have a work tank enabling the complete submersion in dielectric fluid of a work piece that is at least 24.000 inches in length, 38.000 inches in width,

14.500 inches in height, and the clamping devices used to secure the work piece to the table. The work tank shall have a drop door to facilitate work piece set-up.

N. Shall be equipped with a dielectric fluid supply unit as follows:

1. Shall use de-ionized water as the dielectric fluid.

2. Shall have a dielectric reservoir holding at least the dielectric required to completely submerge the work piece that is at least 24.000 inches in length, 38.000 inches in width, 14.500 inches in height, and the clamping devices used to secure the work piece to the table in the work tank.

3. Shall have a water de-ionizer providing filtered de-ionized dielectric fluid for the operation of the machine.

4. Shall utilize a dual filtration system allowing filters to be switched so the used filter cartridge can be changed while the machine is in operation.

5. Shall include a heat exchanger to maintain thermal stability of the machine.

6. Shall be capable of filling and draining the work tank in less than 2 minutes.

O. Shall include a dielectric chiller unit having a tank capacity of at least 10 gallons and the capability to maintain the dielectric fluid temperature constant with the ambient temperature while the machine is in operation and the work piece submerged or non-submerged.

P. Shall be capable of operating on 460-volt, 60-hertz, 3-phase power available at the site.

Q. Shall be capable of utilizing all Mecatool clamping devices and adapters.

R. Shall be equipped with a Computer Numerical Control (CNC) system as follows:

1. Shall be a Pentium based software programmable 32-bit multi-tasking microcomputer type which is capable of receiving data through a CD-

ROM Drive, RJ45 Ethernet port, USB device, and manually by the operator via a keyboard. The CNC system shall accept and translate the program data into positioning and feed command signals and initiate the programmed auxiliary and controlling the required wire cutting parameters.

2. Shall be a 4-axis programmable automatic control system with continuous path 4-axis (X, Y, U, and V) operation having linear and circular interpolation. Shall have independent U and V axis programming enabling the machining of a work piece with dissimilar shapes on the top and bottom surfaces, and positioning the Z-axis.

3. Shall have axis drives which accept the translated signals and move the EDM slides to the programmed position with the control selecting and monitoring wire feed rate, axis feed rate, path of axis movements, and sequence and timing of operations. All drives shall be immediately responsive to control commands (no delay in positioning) and function within the tolerances as stated in sentences “D” through

“N”. The control shall ensure that machine functions occur in the proper sequence that the CNC program calls for and shall initiate protective action should a faulty condition occur.

4. The CNC unit shall be capable of monitoring wire deflection and automatically applying positioning corrections while the machine is cutting, enabling contour accuracy during maximum cutting speed.

5. Shall be capable of monitoring the amount of flushing and automatically correct the flow as cutting conditions change the amount of flow as compared to the programmed flow.

6. Shall include, but not be limited to the following features:

a) Shall have at least a 32-bit Pentium based processor

b) Shall be capable of concurrent programming

c) Shall have at least a 20 gigabyte hard drive for mass data storage of programs and cutting technology for loading/downloading

d) Shall have at least one USB port for loading/downloading of programs

e) Shall have at least 128MB non-volatile RAM memory

f) Shall accept inputs from an RJ45 Ethernet port, manually via keyboard, CD ROM drive, USB device, or from internal computer assisted graphic programming software

g) Shall accept both incremental and absolute commands

h) Shall be capable of operating an auxiliary rotary axis

i) Shall incorporate at least a 12-inch graphics CRT (Cathode

Ray Tube) or Color Liquid Crystal display monitor including the following displays;

1) Shall graphically display contour of programmed path and curve positioning during cutting

2) Shall display all operational and stored generator, flushing, and curve settings

3) Shall display burn stability, efficiency, and linear speed

4) Shall display error messages and diagnostic indicators

5) Shall display status of active cut process

6) Shall display maintenance procedures, recommended tasks, and intervals

j) Shall include an ISO (International Standards) edition for

MDI (Manual Data Input) commands

k) Shall include at least the following functions:

1) Inch/metric display

2) Program rotation (0 degree – 360 degree)

3) Scaling (.001-99.999)

4) Mirror imaging

5) Programmable electronic limits

6) Single Block operation

7) Wire diameter compensation

8) Automatic wire squaring

9) Automatic edge and center finding while either submerged or non-submerged

10) High speed graphics check of program data

11) Programmable generator settings

12) Programmable flushing setting, including mode, pressure, and conductivity

13) Programmable wire settings including type, tension, and speed

14) Manually set bath height to correspond with Z height and work piece height

15) Automatic job recovery after a power failure

16) Automatic start point return

17) Automatic halt point return

18) Backlash compensation

19) Pitch error compensation

20) Automatic broken wire reset and rethread

21) Inch/metric conversion

l) Shall be equipped with a remote control hand box to facilitate job set-up and machine operations and shall include provisions for the manual control of:

1) Axes traverse (X, Y, U, V, Z)

2) Axes zero reset

3) Return to “home” position

4) Halt point return

5) Wire threading and cutting operation

6) Wire squaring, edge, and center finding

7) Cycle start/stop and “E” (emergency) stop

8) Manual eroding

m) Shall have Axis (X, Y, U, V) resolution of no more than

0.00004 inches

n) Shall be capable of accepting command units from a minimum of no more than 0.00005 inches to a maximum of no less than 999.99999 inches.

S. Shall have the following machine fabrication:

1. Shall be a box-type casting or castings reinforced with heavy, strategically arranged ribs, stress relieved and otherwise constructed to support the various moving parts and any load within the rated capacity of the machine.

2. Shall be equipped with a worktable or mounting beam surface in a rectangular configuration with threaded holes used for clamping the work piece(s) and is compatible with Mecatool clamping devices and adapters. The worktable or beam surface shall be machined flat and parallel to the X and Y-axes within +/-0.0003 inches and is zero line aligned. The worktable shall be capable of supporting a work piece weight of 2000 pounds non-submerged and 1400 pounds submerged and fabricated allowing the wire and lower wire guide support to pass through the range of their travel without interference. Provisions shall be made around the table to collect and return dielectric fluid to reservoir/filter.

3. Shall have a “C” frame construction that utilizes oversized ball screws and linear guide ways.

4. Shall be fabricated such that X and Y axes motion is provided by table and/or wire guide column motion. Both the machine bed and wire guide column shall be machined to accept way bearings of a precise fit to the respective ways. Way bearings shall be replaceable and made of a material with low friction characteristics that will not cause wear to the ways, sticking, or over-shooting and will not cause excessive load on the feed motors and drive components. Adjustable gibs, guides, or bearing shall be provided to maintain and adjust alignment of the axes to the ways and prevent the units from lifting from their ways under normal operating loads, without causing excessive loading of the feed drive motors. Way covers shall be provided

5. Shall be fabricated such that all machine slide motions be provided with a means of overtravel protection to prevent damage to the machine power feed and rapid traverse mechanisms in the event the machine is inadvertently fed or rapidly traversed into an overtravel switch. The X and Y axes slide motions shall be driven by independent infinitely variable, direct current (DC) or alternating current (AC) servo units incorporating rotary encoders for closed loop feedback to the CNC control, and coupled to precision anti-friction recirculating ball screw and nut assemblies. Contour tolerances shall be +/-0.0003 inches. All motors shall be rated for continuous duty and have permanently lubricated and sealed ball or roller bearings.

6. Shall have all operating controls necessary for manual and programmed operation of the machine mounted for convenient operator access and shall be clearly identified to facilitate use. All parts subject to wear, breakage, and distortion shall be accessible for adjustment, replacement and repair.

7. Shall accept, process, and display in either the U.S. Customary system of units (US) or in dual US and International system of units (SI). US or US/SI units shall be used to graduate measuring and indicating devices such as scales, depth stops, carriage stops, dial indicators, pressure gauges, temperature indicators, and other similar devices.

8. Shall be equipped with covers, guards, and other safety devices for all parts of the machine that present safety hazards which do not interfere with the operation of the machine. The covers shall be removable to facilitate inspection, maintenance, and repair of the parts.

9. Shall be provided with a means to ensure adequate lubrication for all moving parts. Each lubricant reservoir shall be identified by type of lubricant and shall have means for determining fluid level. All oil lubrication holes, grease fittings, and oil reservoirs shall be accessible for service.

10. Shall be fabricated such that all rotating dials and/or hand wheels used to position the machine axes, shall be graduated in increments no larger than 0.001 inch. Dial and hand wheel diameters shall be permanently and legibly engraved or etched on a non-glare background with graduations that can be read from the operator’s normal position.

11. Shall have all words on plates, panels and charts in the English language. Characters shall be engraved, etched, embossed, or stamped in bold face on a contrasting background.

T. Shall be furnished so as to include at least the following equipment;

1. Upper and lower wire guides for the following wire sizes:

a) 0.008 inch

b) 0.010 inch

c) 0.012 inch

2. One complete set of spare fuses

3. Remote operator’s controller hand box

4. Ion exchange cartridge(s)

5. Ion exchange resin

6. Filters

7. Alignment Centering Device

8. Four Sided Table or Rail Zero Line Table

9. Indicator with arm

10. System software

11. Wire EDM Tension Meter

12. A spinning unit with variable speed of 0 to 1500 rpms. Spinning unit must also be submersible for wire EDM applications. Spinning unit must also have a digital control for speed selection and IO for external speed control and automatic start/stop

U. The Contractor shall furnish with delivery of the machine two- (2) sets of operation, CNC programming, and maintenance manuals. The contractor shall also furnish all software information required to operate/program the machine’s CNC control.

V. The Contractor shall furnish, within thirty (30) days after date of contract award, sufficient information to allow the Government to prepare the site.

The Government will bring the electrical and air service to within ten (10) feet of the installed EDM.

W. The contractor shall install the EDM in building 1225, room 106, 7 Langley

Blvd., NASA Langley Research Center, Hampton, VA. 23681.

X. The Contractor shall, immediately after installation, demonstrate that the

EDM is in accordance with the above specifications and perform the attached performance test. The contractor shall also guarantee the equipment will perform at this level of acceptance for a period of not less that 12 months from the completed installation date.

AA. The Contractor shall provide all operators training and instruction materials at the NASA site for at least two NASA employees. Training is to be conducted by a qualified representative from the Contractor. The training period shall be for a minimum period of 4 working days. The Contractor shall also furnish advanced operator training at the NASA site for at least two

NASA employees. This advanced training shall be a minimum of 4 working days and offered within 30 days of the machine’s acceptance.

BB. Shall include the Taper Expert Option 0.0250mm (0.010”).

CC. Shall come equipped with a Chromium Hardened Table.

DD. Shall come with a Wire EDM Tension Meter.

EE. Shall include 45 degree Taper Kit.

FF. Shall include the Turn-WHILE-Burn for FI640CCS.

GG. Shall include a second year machine warranty.

HH. Shall include One Visit Per Year – Preventive Maintenance W / Parts – Wire.