Purchase Specification 5 May 2020.pdf

DEPARTMENT OF THE AIR FORCE

HILL AIR FORCE BASE, UTAH

PURCHASE DESCRIPTION/SPECIFICATION FOR A

CNC 3-Axis Milling Machine for Fabrication of Critical Aircraft Components

5 May 2020

PURCHASE DESCRIPTION FOR A CNC-MILLING MACHINE

1.0 SCOPE.

1.1 Scope. This specification describes the minimum requirements for a computer numerically controlled (CNC) milling machine designed for cutting out flat sheet metal blanks in titanium, stainless steel and aluminum using vacuum hold down with spoiler sheets and flood coolant.

2.0 APPLICABLE DOCUMENTS.

2.1 General. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government Documents.

2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

STANDARDS – FEDERAL

FED-STD-H28A: Screw Thread Standards for Federal Service (1994 Ed.)

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards (2016 Ed.)

OSHA 40 CFR 82: Protection of Stratospheric Ozone (2012)

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

DEPARTMENT OF DEFENSE

U.S. AIR FORCE

AFOSH 91-501: Air Force Consolidated Occupational Safety Standard

(Application for copies should be addressed http://www.af.mil/shared/media/epubs/AFOSHSTD91-501.pdf ) http://www.af.mil/shared/media/epubs/AFOSHSTD91-501.pdf

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property (2012 Ed.) Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg.

262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://assist.daps.dla.mil/quicksearch)

2.2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

Hill AFB Instr. 91-302: Control of Hazardous Energy (Lockout/Tagout)

(Applications for these documents should be addressed to the contracting officer)

2.3 Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

2.3.1 Specifications, Standards, and Handbooks.

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components (2010 Ed.)

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.)

ISO 10791-2: Geometric tests for machines with vertical spindle or universal heads with vertical primary rotary axis (vertical Z-axis) (2001 Ed.)

ISO 10791-4: Accuracy and repeatability of positioning of linear and rotary axes (1998 Ed.)

ISO 10791-6: Accuracy of speeds and interpolations (2014 Ed.)

ISO 10791-7: Accuracy of finished test pieces (2014 Ed.)

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland) https://assist.daps.dla.mil/quicksearch

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 Volts Maximum) (2014 Ed.)

NEMA ICS 1: Industrial Control and Systems General Requirements (2015 Rev.)

NEMA ICS 6: Industrial Control and Systems: Enclosures (2011 Rev.)

NEMA MG 1: Motors and Generators (2016 Ed.)

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code (2017 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2015 Ed.)

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE EIA-267-C: Axis and Motion Nomenclature for Numerically Controlled Machines (2015 Ed.)

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale, PA 15096)

American Society of Mechanical Engineers (ASME)

ASME B5.54 Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers. (2005 Ed.)

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org )

2.4 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

http://www.asme.org/

3.1 Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the US Customary inch/pound system. It is permissible to include metric system graduations.

3.1.2 Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).Gauges and instrumentation shall be designed for calibration.

3.1.3 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910 and AFOSH 91-501.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.23. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.3.2 Chip Guarding. Permanent chip and coolant barriers shall surround the working area but shall not impede visibility, automatic tool change, or loading and removal of materials and finished parts.

3.1.4 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 80 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 80 dB requirements.

3.1.5 Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture with the exception of fluorescent lighting where required.

3.1.6 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

3.1.7 Ozone depleting substances. Class I ozone depleting substances in accordance with section 602(a) of the Clean Air Act Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of Stratospheric Ozone, shall not be contained within or used in manufacture of this item.

3.1.8 Lead. Lead and materials containing lead shall not be used on or in the machine with the exception to radiation cladding and lead solder in circuits.

3.1.9 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

3.1.10 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.11 Lubrication. Means shall be provided to ensure adequate lubrication (oil, grease, coolant, etc.) for all moving parts. All mechanisms requiring lubrication including gears, slide ways, and bearings (except sealed-for-life type) shall be lubricated automatically by a central pressurized lubrication system. The contractor shall provide all Safety Data Sheets (SDS) for all oils or lubricants required for machine operation. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required and the operator/mechanic shall refill the lubrication reservoirs according to machine manuals. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.12 Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

3.2 Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.2.1 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

3.2.2 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.3 Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein.

3.2.4 Gears. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.2.5 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.6 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.7 Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

3.2.8 Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.2.9 Components. The machine shall consist of not less than the following components:

3.2.9.1 Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

3.2.9.2 Gantry. A 3 axis moving gantry shall provide axes movement. Sensors shall provide feedback on the condition of the spindle components and performance for predictive maintenance.

3.2.9.3 Table. The stationary table shall comply with Table I and shall be designed as a vacuum hold down grid for use with a permeable waterproof spoiler board that can maintain vacuum on the parts despite liquid coolant presence.

3.2.9.4 Coolant System. The machine shall be designed and equipped for flood, mist, and air coolant in conjunction with vacuum hold down. It shall be equipped with all liquid and vacuum pumps, filters, nozzles, holding tanks, separators necessary to form a complete coolant delivery and recovery system. The machine shall be designed to use QualiChem Xtreme-Cut 250C as the coolant. The system shall include two (2) hand wash-down hoses located at opposite ends of the workspace. A means shall be provided to separate metallic and non-metallic debris from the coolant. The system shall be supplied with a coolant separator to remove coolant from the vacuum stream.

3.2.9.5 Tool Changer. The machine shall have a tool magazine and tool change mechanism capable of holding no less than 15 CAT 40 tool holders and changing them under computer control, including a Renishaw TS-27R contact tool setter. It shall also be capable of expansion to accommodate additional holders in the event of a system upgrade at a later date.

3.2.9.6 Programming The contractor shall provide the following software for use in writing tool path programs for use with the system. The software package shall come with two (2) licenses for off line programming and is in addition to the software that operates the milling machine.

a. Router-CIM Automation Suite 2017

b. A post processor to generate machine code from the AutoNest tool path.

c. AutoNest for Router-CIM

d. AutoCAD CAM Companion

e. Two workstations to do the programming, a server, and communication lines for connecting to the machine shall be provided by the Air Force and will meet the specifications provided by the vendor for support of the software and for communications with the milling machine.

3.2.9.7 Chip Conveyors. The machine shall be equipped with twin conveyors or augers to facilitate chip removal

3.2.10 Axes. All axes of the machine shall be actuated through a closed loop, high-gain electrical servo mechanism. Infinitely variable feed drives shall be provided for all axes. Axes shall be machined to accept bearings of a precise fit to their respective ways.

Axis nomenclature shall be in accordance with SAE EIA-267-C.

3.2.11 Hydraulic System. Hydraulic systems and all their components shall conform to ISO 4413. The systems shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.2.12 Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.2.13 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be provided by the Air Force within 10’ of the machine with means of lockout in the off position only in accordance with Hill AFB Instruction 91-302, Control of Hazardous Energy (Lockout/Tagout). The vendor shall be responsible to attach to that point and to control that source until it is accepted as complete by the Air Force.

3.2.13.1 Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA ICS 250 type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79.

3.2.13.2 Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

3.2.13.3 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.2.14 Controller Features. The machine controller shall consist of a Fanuc 32i-MB CNC Control incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be both synchronous and independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, linear interpolation, circular interpolation, programmable interface, part program edit, buffer edit capability, part program storage, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits.

3.2.14.1 Software Access. Access to the system software shall be restricted by password with a minimum of two (2) categories of access such as Administration, Operators, Programmers, and Maintenance with access to various read-write functions appropriate for those individuals. Complete access to all machine programming and software customization shall be given to the machine programmers to accommodate variations in components, new workload, and process optimization.

3.2.15 Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG 1. Each motor shall have an identification plate in accordance with paragraph 3.7.2 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.2.16 Camera. A camera shall be mounted to provide a real time tool view of the activity of the cutting tool. Sufficient lighting shall be provided mounted on the machining head for camera operation. The camera view screen shall be located at the operator’s work station.

3.2.17 Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.2.18 Hour Meter. The machine shall be equipped with a non-resetting type, hour meter to display accumulated operating time of the spindle drive motor, mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, or run time of the servo motor(s) shall be considered to meet this requirement.

3.2.19 Rigid Tapping. The machine shall be equipped for rigid tapping under servo control.

3.2.20

3.3 Size and Capacity. The size and capacity of the machine shall be not less than the values specified in Table I.

Table I: Size and Capacity Item US Customary

Vacuum Pump Power 40 HP Table Dimensions 72 x 144 inches X-axis travel 150 inches Y-axis travel 75 inches Z-axis travel 24 inches Spindle Power (ASME B5.54 pp 9.5.8) 29 HP Spindle Speed (infinitely variable) 6,000 RPM Tool Holder CAT 40 Feed Rate & Rapid Traverse Rate X and Y Axes 0-2,000 IPM Feed Rate & Rapid Traverse Rate Z Axis 0-700 IPM

3.4 Alignment and Accuracy. The tolerances of the machine shall meet the requirements of ISO 10791-2, -4, -6, and -7 as described in 4.7.3 except as noted in Table II which takes precedence.

Table II Alignment and Accuracy.

ISO 10791-2 US Customary

4.1:Straightness X-axis over 150” range in XY and XZ 0.003” 4.1:Straightness Y-axis over 75” range in XY and YZ 0.002” 4.1:Straightness Z-axis over 27.5” range in XZ and YZ 0.0015” 4.3:Squareness between Z and X 0.0013”/ft. / 0.002”total 4.3:Squareness between Z and Y 0.0013”/ft. / 0.002”total 4.3:Squareness between Y and X 0.0008”/ft. / 0.003”total 4.4:Run-out of spindle a) at the spindle nose, b) 12” from nose a)0.0004” b)0.0008” 4.4:Parallelism of spindle and Z a) in YZ, b) in ZX 0.0019”/ft.

4.4 Squareness between spindle and the X axis 0.0008”/ft.

4.4 Squareness between spindle and the Y axis 0.0008”/ft.

4.5 Flatness of the table in the XY plane ±0.0016”

ISO 10791-4 Positioning Linear Axes X axis Y axis Z axis Unidirectional accuracy of positioning A↑ and A↓

±0.001”

±0.001”

±0.0005”

Unidirectional repeatability of positioning R↑ and R↓

±0.0006” ±0.0006” ±0.0003”

Reversal value B <0.0005” <0.0005” <0.0005” ISO 10791-6 Circularity @17 inches/minute @97 inches/minute

5.4 Ball-Bar 150 mm bar bi-directional, table upper right quadrant

0.0025” 0.0025”

5.4 Ball-Bar 150 mm bar bi-directional, table center

0.0025” 0.0025”

5.4 Ball-Bar 150 mm bar bi-directional, lower left quadrant

0.0025” 0.0025”

Note: BB analysis shall indicate that no single characteristic contributes significantly more circularity error than the others.

ASME B5.54 Spindle Idle Run Loss Test

9.4 After 4 cuts, each increasing the % of power on the amp meter, final full torque @ 90% power 26 Hp. metal removal rate

ISO 10791-7 Cutting Test 320 mm Circle Diamond Square Tolerance

Central Hole

a) Cylindricity 0.0006 inch

b) Squareness between the hole axis and basis A 0.00026 inch

Square

a) Straightness of side B 0.0006 inch

a) Straightness of side F 0.0006 inch

a) Straightness of side G 0.0006 inch

a) Straightness of side H 0.0006 inch

b) Perpendicularity of side F to basis B 0.0015 inch

b) Perpendicularity of side H to basis B 0.0015 inch

c) Parallelism of the opposite side G to basis B 0.0015 inch

Diamond

a) Straightness of side K 0.0009 inch

a) Straightness of side L 0.0009 inch

a) Straightness of side M 0.0009 inch

a) Straightness of side N 0.0009 inch

b) Angularity of 30º angle of side K to basis B 48 seconds

b) Angularity of 60º angle of side L to basis B 48 seconds

b) Angularity of 30º angle of side M to basis B 48 seconds

b) Angularity of 60º angle of side N to basis B 48 seconds

Circle

a) Circularity of P 0.0025 inch

b) Concentricity of the external circle P and the internal bored hole C 0.001 inch

Sloping Face

a) Straightness of the left 93º angle face J 0.0006 inch

b) Accuracy of the left 93º angle face J to basis B 48 seconds

c) Straightness of the bottom 3º angle face I 0.0006 inch

d) Accuracy of the bottom 3º angle face I 48 seconds

Bored Holes

a) Position of the D1 hole with respect to internal bored hole C 0.002 inch

a) Position of the D2 hole with respect to internal bored hole C 0.002 inch

a) Position of the D3 hole with respect to internal bored hole C 0.002 inch

a) Position of the D4 hole with respect to internal bored hole C 0.002 inch

b) Concentricity of hole E1 to hole D1 0.0012 inch

b) Concentricity of hole E2 to hole D2 0.0012 inch

b) Concentricity of hole E3 to hole D3 0.0012 inch

b) Concentricity of hole E4 to hole D4 0.0012 inch

3.5 Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the machine (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal.

3.5.1 CAT 40 Tool Holders. The contractor shall include a tool package consisting of the following tool holders to be delivered with the machine:

Mfg. & Part Number Quantity Sandvik Coromant AA3B14-40 40 105 CAT40 ER40 collet holders w/knobs 24 Sandvik Coromant A393.15-40 ER40 collets ¼” 4 Sandvik Coromant A393.15-40 ER40 collets 3/8” 4 Sandvik Coromant A393.15-40 ER40 collets ½” 4 Sandvik Coromant A393.15-40 ER40 collets 5/8” 4 Sandvik Coromant A393.15-40 ER40 collets ¾” 4 Sandvik Coromant A393.15-40 ER40 collets 1” 4

3.6 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.6.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

Points of Lubricant Application Servicing Interval Type of Lubricant Viscosity Military or Federal Specification for Each Lubricant (If available) Size and Type of Each Lubricant Filter

3.6.2 Nameplate. A nameplate shall be permanently and securely attached to each machine and major subcomponents. The primary nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's Name Manufacturer's Model Designation Manufacturer's Serial Number Power Input (Volts, Total Amps, Phase, Frequency) Contract Number Date of Manufacture

3.6.3 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.6.2 Nameplate.

3.7 Technical Data. The contractor shall supply and deliver with the machine one (1) electronic and one (1) printed hard copy of all “as built” standard manuals containing all necessary electrical wiring diagrams, hydraulic schematic diagrams, operator's manuals, parts lists, recommended spare parts list, preventive maintenance instructions, part programming manuals and drawings of machine components and all other instructions for operation and maintenance of the machine and its peripheral equipment. All electrical diagrams shall contain average electronic characteristic waveform and voltage readings at pre-selected points throughout the system. All copies of technical data shall be legible and written in the American English language.

3.7.1 Safety Data Sheets. The contractor shall identify all chemicals and hazardous materials, including but not limited to oils, greases, metalworking fluid, coolant, and refrigerants, required to make the equipment operational. The contractor shall submit this list for approval by the Government within thirty (30) calendar days after contract award (ACA). The Government will respond within thirty (30) calendar days. All chemicals and hazardous materials required for testing at the contractors facility shall be supplied by the contractor and shall remain the property of the contractor. The contractor shall deliver the equipment free of chemicals and hazardous materials. All chemicals and hazardous materials, or equivalent, required to test and run the equipment at Hill AFB will be supplied by Hill AFB.

3.7.2 Preliminary Installation Drawings. Preliminary Installation Drawings shall be provided with the initial proposal for review. Contractor shall submit installation drawings which include physical dimensions of the system, supporting equipment, and accessories with required placement dimensions in relation to the main machine components and in relation to the features of the area of the building, as well as all foundation drawings so the Government can estimate the feasibility and cost of modifications to the installation site.

Contractor drawings shall include all utility requirements (i.e. electrical, air, etc.). Electrical requirements provided by contractor shall include voltage, current, phase, and frequency, full load amps, and any other information applicable to connecting the machine. Minimum compressed air requirements provided by contractor shall include pressure, flow, and any other information applicable to connecting the machine. The Government shall review and return the preliminary drawings to the contractor with comments and/or approval at the time of contract award. If revisions are required, the contractor has ten (10) calendar days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

3.7.3 Final Installation Drawings. Final drawings shall bear a complete title block with a permanent drawing number, signature, date, and an original stamp.

3.7.4 Integrated Master Schedule. The contractor shall provide an Integrated Master Schedule (IMS) with estimated completion dates for all major events (e.g. design, manufacture, test, demolition, installation, etc.) necessary to deliver a completely functional system. The IMS shall be in contractor format and two hard copies shall be delivered with the contractor’s formal proposal.

3.7.5 Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan. The plan shall include a detailed description of all installation work, a detailed site layout, general equipment specifications (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions, including detailed information concerning any equipment that applies a load to a facility structure, wall, or roof. The site preparation plan shall be submitted within sixty (60) calendar days after contract award for review and comments.

The Government shall respond to the contractor within fifteen (15) calendar days. The contractor shall have ten (10) calendar days to officially respond in writing to the comments.

All Government comments shall be reviewed and answered by the contractor in an acceptable manner before any work begins.

3.8 Installation. The contractor shall be responsible for the complete installation of the machine and two licenses of drafting, nesting, and post processing software. The contractor shall provide all qualified personnel, tools, hardware, equipment, services, materials, and material handling equipment to complete the installation including, but not limited to the following: shipping, off-load and load trucks; deliver new equipment/materials to the designated install site, rigging, install the equipment and perform start-up and testing to ensure that the complete machine is fully operational. The Contractor shall also be responsible for establishing communications between the programming stations and the machine and installing and setting up all software. The premises shall be kept neat and clean, satisfactory to the Government. The envelope of the machine shall include all equipment, machinery, controls, guards, and complete operator footprint. Contractor shall also be responsible for his portion of the attached “Installation Responsibilities” sheet.

3.9 Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is an American citizen of good standing and repute and proficient in the English language and qualified to teach the operation, programming, and maintenance of the machine, shall be provided for specialized training to familiarize Government personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The course shall utilize as-built drawings and manuals provided under this contract and shall include hands-on training.

All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government. The training shall be as follows.

3.9.1 Machine Operator Training. Training shall be provided for up to five (5) machine operators. Training shall be performed at the Government facility and shall not be less than five (5) consecutive eight (8) hour workdays, between 7:00 am and 3:30 pm excluding any federal holidays.

3.9.2 Maintenance Training. Training shall be provided for up to five (5) maintenance personnel. Training shall be performed at the Government facility and shall not be less than five (5) consecutive eight (8) hour workdays, between 7:00 am and 3:30 pm excluding any federal holidays.

3.9.3 Programmer Training. Training shall be provided for up to five (5) programming personnel. Training shall be performed at the Government facility and shall not be less than five (5) consecutive eight (8) hour workdays, between 7:00 am and 3:30 pm excluding any federal holidays.

4.0 QUALITY ASSURANCE.

4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Contract quality assurance inspection (Origin) (see 4.4).

b. Final Inspection/Acceptance test (Destination) (see 4.5).

4.3 Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 70°±15º F.

4.4 Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. The system and all peripheral equipment added to the system shall be fully assembled and perform all functions in accordance with this specification. Quality conformance inspection shall consist of the examination in 4.6 and all tests in 4.7. The machine shall pass the examination, all tests, and contract quality assurance inspection to be acceptable for shipment.

4.5 Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed at destination on the system to ensure conformance with this purchase description. The acceptance test shall be performed only after the system is installed and fully assembled at its final location. The acceptance test shall consist of the examination in

4.6 and all tests in 4.7. The machine shall pass the examination and all tests to be accepted.

4.6 Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment and workmanship to determine compliance with the requirements of this specification.

4.7 Tests. All programs, instruments, and tools required to perform and evaluate the tests shall be furnished by the contractor and shall be calibrated in accordance with the attached (QAP) Quality Assurance Provision. The materials for testing at the factory shall be provided by the manufacturer of the equipment. Materials for testing at the Government facility shall be provided by the Government.

4.7.1 Operational Test. The machine shall be operated at no load through all cycles for not less than four (4) hours. During the operational test, the operation of all controls, motors, adjusting mechanisms, vacuum, coolant, and other accessories shall be verified and recorded. If any function of the machine fails under this testing, the test shall be restarted when the fault is documented and repaired and will not be considered passing until it completes a full four (4) hour test without fault or error. During operational testing the control functions and machine response to commands for motions and auxiliary functions shall be checked. The machine shall be run in each mode of operation (Manual and Automatic) to test the machine’s response to command data. After the operational test is complete, over-travel limits (programmed stops and hard stops), emergency stop devices, safety zone performance, and accessories shall be verified. The safety limit stops shall be checked by attempting to exceed the limits of travel.

4.7.2 Programming Test. The software for programming the machine shall be tested after installation to assure that there are no hardware, installation, or communication errors with the software or industrial network and that the post processor successfully programs all functions of the machine. This test shall include processing the program used for the operational test of automatic operation specified in 4.7.1, the Circle-Diamond-Square (CDS) cutting test specified in 4.7.3.e, and nesting for the vacuum test in 4.7.3.f.

4.7.3 Performance Test. Performance testing shall be performed at the factory and after installation at the destination. Reported test results need only reflect the “as left” condition with any software compensation noted it the test report. Tests shall be performed and shall meet these standards as follows:

a. Geometric tests per Table II. Methods of measurement are detailed in ISO 10731-2.

b. Testing positioning of linear axes per Table II. Methods of measurement are detailed in ISO 10791-4 Section 4.

c. Circular Interpolation testing per ISO 10791-6 drawing K4 at the center of the table, lower-left corner, and upper-right corner with a 150 mm bar with the feed rates and tolerances specified there. This test shall be conducted using a Renishaw QC20-W calibrated bar and shall be performed as a volumetric test, incorporating X, Y, and Z axes, in accordance with Renishaw operating instructions. The raw electronic file generated shall be provided to the government with the machine. Fine tuning of the machine shall be performed using the diagnostic results built into the Ball-Bar software before the cutting tests.

d. A Spindle Idle Run Loss Test shall be performed to verify spindle power output per ASME B5.54 pp 9.5.8 using aluminum. The Spindle Idle Run Loss Test shall only be required at origin.

e. A Circle-Diamond-Square cut test shall be performed in accordance with ISO 10791-7 drawing M1_320 in the XY plane. The finished test piece shall be measured on a CMM. Measurement results shall conform to the tolerances specified in Table II. Other cutting tests described in ISO 10791-7 are not required.

f. A cutting test demonstrating the efficacy of the vacuum hold down system shall be run at the factory using 0.04” AISI 304 stainless steel sheet and spoiler board as recommended by the contractor for this application. A sample of shapes shall be processed using the supplied CAD/CAM software and arranged to optimize placement on the sheet by the nesting software function. The sheet shall be held in place only by the vacuum system. A set of corner holes shall be milled before cutting parts and another set afterward to verify that the sheet did not move during milling.

This test need not be repeated at the time of installation.

g. The equipment shall be tested for compliance with paragraph 3.1.4. “Audible Noise Level.”

INSTALLATION RESPONSIBILITIES

The Government shall:

1. Provide a machine foundation in accordance with the Manufacturer’s design requirements and utilities required for operation within 10 feet of the foundation.

2. Provide water soluble cutting fluid at destination in accordance with the manufacture instructions.

3. Provide the aluminum blank for CDS performance testing at Government facility.

4. Provide a classroom/computers for training at Government facility.

5. Provide computers and network for programming at Government facility. This shall include the basic operating software for the computers and server as specified by the contractor.

The Contractor shall:

1. Provide labor and material handling equipment for off-loading and placing item on foundation.

2. Provide and install anchor bolts and nuts and any adhesive or grout required.

3. Assemble, set, and rough level the machine on its foundation.

4. Level and align machine.

5. Connect machine to the provided utilities hook-up.

6. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests except the CMM at the Government facility for verifying Circle Diamond Square test.

7. Charge all systems with fluids in accordance with manufacturer's instructions except water soluble coolant which will be provided by the Government.

8. Provide aluminum and stainless steel material for test cutting at Contractor's facility.

9. Provide instructor and training materials for users, programmers, and maintenance.

10. Provide software and installation for programming and nesting at Government facility. This shall include all licensing for two simultaneous users of the software.

DEPARTMENT OF THE AIR FORCE