PWS - Cincinnati 5-Axis.docx
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- Cincinnati 5 Axis Mill Maintenance and Calibration Federal contract opportunity
- Solicitation number
- FA8224-20-R-AXIS
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| File | Type | Posted |
|---|---|---|
| Combined Synopsis Solicitation - Cincinnati 5 Axis.docx | DOCX document | |
| CDRL A002 Accident-Incident.pdf | ||
| Wage Determination - Cincinnati.pdf | ||
| CDRL A003 Calibration Certificate.pdf | ||
| CDRL A004 Works Certificate.pdf | ||
| CDRL A001 Safety.pdf |
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Performance-Based Work Statement (PWS)
Cincinnati Milacron 5-Axis Honeycomb Profiler
U.S AIR FORCE
309th Maintenance Wing, Maintenance Support Group (MSXG), Commodities Maintenance Group (CMXG), Hill AFB, Utah
5/1/2020 Cincinnati Milacron 5-Axis Honeycomb Profiler i
TABLE OF CONTENTS
| 1 | DESCRIPTION OF SERVICES | 1 |
| 2 | BASIC SERVICES | 1 |
| 2.1 | Alignment | 1 |
| 2.2 | Documentation | 1 |
| 2.3 | Scan | 1 |
| 2.4 | Calibration | 1 |
| 2.5 | Telephone/Email Support | 2 |
| 2.6 | Repairs | 2 |
| 2.7 | Parts | 3 |
| 2.8 | Functional Testing | 3 |
| 3 | SERVICES SUMMARY | 3 |
| 4 | GENERAL INFORMATION | 4 |
| 4.1 | Base Access | 4 |
| 4.2 | Hours of Operation | 4 |
| 4.3 | Records | 4 |
| 4.4 | Environmental Controls | 5 |
| 4.5 | Foreign Object Damage (FOD) and Tool Control | 5 |
| 4.6 | Security Requirements | 5 |
| 4.7 | Safety Requirements | 6 |
| 5 | MANPOWER REPORTING | 6 |
| 5.1 | Special Qualifications | 6 |
| 6 | PUBLICATIONS | 7 |
| 7 | TRAVEL REQUIREMENTS | 7 |
| APPENDIX A – ACRONYMNS & ABBREVIATIONS LIST | 8 | |
| APPENDIX B – ESTIMATED WORKLOAD DATA | 9 | |
| APPENDIX C – SAFETY, FIRE PROTECTION & HEALTH SPECIFICATION INDUSTRIAL SAFETY REQUIREMENTS | 10 | |
| APPENDIX D – EVALUATION & VOLUMETRIC REQUIREMENTS | 16 | |
| APPENDIX E – LOCATION OF CINCINNATI MILACRON 5-AXIS | 19 |
DESCRIPTION OF SERVICES
This performance work statement (PWS) identifies requirements of the 309 MXSG at Hill AFB for a service contract to maintain Cincinnati Milacron computer numerical control (CNC) 5-Axis gantry mill machine. The services shall consist of annual volumetric compensation (calibration), authorized repairs, and functional tests. The contractor shall provide personnel, support equipment, and documentation necessary to repair, test, and volumetrically compensate the equipment, as identified in this PWS including lasers such as API XD Laser or a Renishaw XD Laser and to be approved by 309 CMXG Engineering Lead (EL).
BASIC SERVICES
Perform all procedures with current compensation tables turned off. Perform as found scan (laser tracker is allowable for this step only). Perform Alignment as described in 2.1.
Alignment The Cincinnati in building 238 will be physically aligned according to the Original Equipment manufacturer (OEM) specifications.
Documentation Provide a copy of the work certificate complete with data for each machine, documenting that the equipment has been inspected and meets the requirements in the Cincinnati Work Certificate (Appendix A) at each measurement point, within fifteen (15) calendar days. Three complete CD-ROM copies of the data shall be provided in PDF format. (CDRL A004) (DI-RELI-80322) Scan The contractor shall scan the machines using API XD Laser or a Renishaw XD. Using information obtained from the scan the contractor shall create and input new compensation tables as described in 2.3.
Calibration The contractor shall perform annual inspection on the Cincinnati machine listed in Appendix B. The volumetric adjustments shall be performed in accordance with (IAW) Appendix D, "Evaluation and Volumetric Adjustment Requirements for Cincinnati Milacron 5-Axis gantry mill CNC Machine in Building 238.” Providing Calibration Certificates within 5 calendar days. (CDRL A003) (DI-QCIC-80798C) Compensation Tables: The contractor shall create compensation table(s) for each axis as necessary to meet Government specifications.
The contractor shall coordinate specific dates of initial volumetric compensation through the EL. The contractor shall perform subsequent volumetric adjustment at 12-month intervals following the initial calibrations.
Telephone/Email Support The Contractor shall provide telephone and email support to Government personnel to assist with troubleshooting, engineering and maintenance functions. During normal duty hours, the contractor shall respond within two (2) hours to the EL. After normal duty hours the contractor shall respond within the first two (2) hours of the next business day.
Repairs Repair Task Order (TO). The contractor shall provide an updated itemized cost estimate at the TO level for repairs to include labor hours, travel, and required parts/ materials as well as estimated repair time within one (1) business day of evaluation and sent to the CO, COR and EL. The contractor shall determine the time frame for the cost estimate and provide a schedule of repairs which will be agreed upon at the TO level by the CO. The contractor shall coordinate with and receive approval from CO in conjunction with the COR, prior to any repairs being made. The contractor shall complete repairs as agreed upon with the CO and IAW the OEM Manual.
The contractor shall complete all repairs within two (2) business days dependent upon parts availability after prior approval has been given by the CO and coordinated by the COR and EL.
For each service/repair call made, the contractor shall document the work accomplished in a logbook that will be kept by the EL. As a minimum, the contractor shall document the following information:
a. Date and time the call was made by the EL
b. Check-in and check-out times
c. Services performed (e.g. general, volumetric compensation)
d. Components repaired and/or replaced
e. Names of all technicians performing the service
f. Agreed upon repair completion times
g. Other remarks needed to document the services
h. Government Representative functional test sign-off
i. Names and dates of personnel being trained General Repairs: If repairs are unable to be made via telephone/email the contractor shall be on-site to evaluate the machine for needed repairs within three (3) business days of being notified by the EL. The EL will obtain approval from the CO and COR prior to ordering repairs.
Emergency Repairs: If machine is inoperable, and repairs are unable to be made via telephone/email, the contractor shall be on-site to evaluate the machine for needed repairs within one (1) business day of being notified by the EL. The EL will immediately notify the COR of the emergency repair requirement and keep them apprised of the costs.
Parts Parts Task Order. The contractor shall provide all repair parts at the TO level. The contractor shall coordinate parts and delivery costs/methods for CO approval. Once contractor has approval from CO, the contractor shall coordinate for parts and delivery with the COR and EL. The contractor shall use technical data specified parts. If technical data specified parts are not available, the contractor shall request prior approval from the EL and CO on proposed replacement parts from other sources. The contractor shall not update technical orders.
Functional Testing Whenever the contractor finishes repairs or maintenance on equipment, the contractor shall contact the EL to coordinate a functional test. Proper operation of software/hardware, controls, motors, adjusting mechanisms, and other accessories shall be verified during the functional test. A qualified Government operator will run the functional test IAW Technical Orders and commercial manual. Government acceptance will not occur until functional test has been successfully executed and accepted and logged by the EL.
The contractor shall replace parts and materials with new commercial off the shelf (COTS) parts and materials if available or to OEM standards.
SERVICES SUMMARY
| Performance Objective |
| PWS Para |
| Performance Threshold |
Performance Threshold
| Contractor shall perform Volumetric Compensation on the Cincinnati Milacron 5-Axis gantry mill machine |
| 2.4.2 |
| 12-month intervals following the initial calibrations and IAW Appendix D (allowed one) |
| The contractor shall be on-site to evaluate the machine within three (3) business days |
| 2.6.3 |
| 80% of the time |
| The contractor shall provide telephone and email support |
| 2.5 |
| Normal Business Hours: Within two (2) hours |
After Normal Duty Hours: Within the first two (2) hours of the next business day
| The contractor shall document all work accomplished in a logbook that will be kept by the EL. |
| 2.6.2 |
| 100% Compliance |
| CDRL |
| PWS |
Para
| Title |
| Delivery Date |
| A001 |
| 4.7.1 & Appendix C |
| Contractor’s Safety Plan |
| No later than (NLT) 15 Calendar Days after award of contract and updates as required. |
| A002 |
| 4.7.2 & Appendix C |
| Accident/Incident |
| Provide notification in written or email format within 3 calendar days. Provide any information not available at the time of initial notification, NLT 20 calendar days unless extended by the ACO. |
| A003 |
| 2.4 & Appendix D |
| Calibration |
| Provide Calibration Certificates within 5 calendar days of completion. |
| A004 |
| 2.2 |
| Works Certificate |
| Provide a copy of Works Certificate within 15 calendar days of completion. |
GENERAL INFORMATION
Base Access The EL will be responsible and ensure that the contractor is given clearance at the South Gate Visitors Center either by escorting the individual(s) or by computer clearance. The clearance process will be based on the security requirements at that time.
Hours of Operation Normal Hours of Operation. The contractor shall perform the services required under this contract during the following: Monday - Friday, from 0600-1630 MST/MDT, except Federal Holidays and any other days deemed appropriate by the Government.
Records The contractor shall be responsible for creating, maintaining, and disposing of only those Government-required records that are specifically cited in this PWS or required by the provisions of a mandatory directive listed in Appendix D, Applicable Publications and Forms. If requested by the Government, the contractor shall provide the original record or a reproducible copy of any such record within five working days of receipt of the request.
Environmental Controls The contractor shall ensure their employees are made aware that the performance of these services will occur in industrial areas. The industrial complex at Hill AFB has the potential to expose workers to hazardous materials, which may include, but is not limited to inhalation of Hexavalent Chrome, Chemlease 41, Sealants, Calibration Gases as well as contact with Methylene Dianiline, Isocyanates. While the contractor shall not perform duties in a regulated area (where exposures are expected to exceed the permissible exposure limits set by 29 CFR1910.10), there may be contact hazards with these materials. The contractor shall ensure proper protective measures and training is taken to ensure contracted employees are protected from hazards.
Compliance with Laws and Regulations: The contractor shall be knowledgeable of and comply with applicable Interstate, Federal, State and Local laws, regulations and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor shall comply as such laws come into effect.
Foreign Object Damage (FOD) and Tool Control The contractor shall follow the applicable guidance in chapters/paragraphs/sections of AFI 21-101 and HQ AFMC, Hill AFB, and 309MXW supplements to the AFI 21-101 concerning base tool (chapter 10 section B), and Foreign Object Damage (FOD) control policies (chapter 14, and sub paragraphs designated as 41), daily. Cloth rags are considered tools and will follow the same regulations and procedures as tools.
If tools, and/or equipment are lost, the contractor shall report the loss to the EL/COR no later than two hours after discovery. If tools are lost or not accounted for, then the contractor shall implement the lost tool procedures of AFMC supplement to AFI 21-101, chapter 10, section B.
Contractors performing functions in industrial areas on the center shall have a method for controlling and accounting for all tools used. All contractors working on the center shall inventory their tools at the beginning and end of each shift and at the end of each task to check for any lost or missing tools.
Security Requirements Security Requirements: The Contractor shall be responsible for safeguarding and shall account for all Government property provided for Contractor use. At the close of each work period, Government facilities, property, and materials shall be secured.
Safety Requirements Safety Requirements: The contractor shall implement a safety program that ensures protection of Government personnel and property.
The contractor shall establish a Safety Plan and checklist IAW Appendix C. The contractor shall submit the Safety Plan with the contract proposal. (CDRL A001) (DI-SAFT-82080) In the event of an accident/mishap, the contractor shall take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence. A written or email copy of the mishap / incident notification shall be sent within three calendar days to the COR, who will forward it to OOALC/SE. (CDRL A002) (DI-SAFT-81563)
MANPOWER REPORTING
The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.
Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October* of each calendar year. Contractors may direct questions to the CMRA help desk.
*Reporting Period: Contractors are required to input data by 31 October of each year.
Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.
User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for government personnel and contractors are available at the Army CMRA link at http://www.ecmra.mil.
Special Qualifications The contractor shall assign employees who possess the knowledge of, trouble shooting, general maintenance, calibrating and repair of the Siemens 840D controller.
PUBLICATIONS
Compliance with publications, regulations and operating instructions provided by the Government is required when they pertain to the procedures for materials expediting herein and where the contractor is authorized by the performance-based statement of work to accomplish the work specified in the publication, regulation or operating instructions. The publications prescribe USAF policies, use of materials, procedures and processes applicable to the work requirements. The contractor is required to acquire and work on the latest version of the publication.
TRAVEL REQUIREMENTS
Any All travel required shall be performed IAW FAR 31.205-46. The contractor is responsible for making all necessary travel arrangements for their personnel, including air travel, car rental, lodging and subsistence. Travel is restricted to round trip coach airfare tickets, economy class car rental, and per diem rates not to exceed FTR rates for the TDY location. Contractor shall also provide applicable expenditure documentation, IAW FAR 31.205-46, to the contracting officer for approval prior to travel. Receipts for contractor travel will be provided to the COR for validation. Government will approve all travel by the contractor for this contract effort in advance.
APPENDIX A – ACRONYMNS & ABBREVIATIONS LIST
Acronym/Abbreviation Definition
AFB Air Force Base
AFMC Air Force Material Command
CFR Code Federal Regulation
CNC Computer Numerical Control
COTS Commercial Off-the-Shelf
DOD Department of Defense
FAR Federal Acquisition Regulation
GR Government Representative
IAW In Accordance With
OEM Original Equipment Manufacturer
OJF On-the-Job Familiarization
OSHA Occupational Safety and Health Act
PWS Performance-Based Work Statement
USAF United States Air Force
APPENDIX B – ESTIMATED WORKLOAD DATA
| ITEM |
| NAME |
| PREVENTATIVE MAINTENANCE NUMBER |
| ESTIMATED QUANTITY |
| 1 |
| Cincinnati Milacron 5-Axis Honeycomb Profiler Mill |
with Siemens 840D Controller
| 009464 |
| 1 |
APPENDIX C – SAFETY, FIRE PROTECTION & HEALTH SPECIFICATION INDUSTRIAL SAFETY REQUIREMENTS
OGDEN AIR LOGISTICS COMPLEX
UNITED STATES AIR FORCE
HILL AIR FORCE BASE, UTAH 84056
Cincinnati Milacron 5-Axis Honeycomb Profiler Bldg 238
16 Apr 20
OO-ALC/SE
TH200407
SECTION I - GENERAL REQUIREMENTS
A. Safety Program Requirements.
The contractor will implement a safety program plan that ensures protection of Government personnel and property. As part of the Contractor Safety and Health Program, the contractor shall assign in their plan, by name and phone number, a person who will be the primary point of contact for safety and health issues for the on-site operation. The program will consist of, as a minimum:
1. Mishap reporting, as defined in paragraph B1 below.
2. A Safety Plan that addresses, as a minimum, the subjects listed in Section II –Specific Requirements, and will be used during the performance of the work described in the contract. The Safety Plan will be accepted by OO-ALC/SE (Safety Office) prior to commencement of any work described in this contract.
3. Routine and recurring surveillance to ensure the safety requirements of this contract are enforced.
4. Competent personnel to provide surveillance of the Safety Plan.
5. Identification of segregated work site locations for operations that cannot be co-mingled with general industrial operations and the process for ACO approval of operations and changes at these specific sites.
6. All contractor personnel shall be trained and qualified to perform their duties safely.
7. The contractor shall include a clause in all subcontracts requiring the subcontractors to comply with the safety provisions of this contract, as applicable.
B. Mishap Notification
1. The contractor shall notify OO-ALC/SE (801-586-6038) or the Hill AFB Command Post (801-777-3007) after normal duty hours, and the designated Government Representative (GR), i.e., the ACO, PCO, or DCMA COR (Contracting Officer's Representative) within one (1) hour of all mishaps or incidents at or exceeding $2,000 (material + labor) in damage to DOD property entrusted by this contract, even if the government is wholly or partially reimbursed. This notification requirement shall also include physiological mishaps/incidents. A written or email copy of the mishap/incident notification shall be sent within three calendar days to the GR, who will forward it to OO-ALC/SE. For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO.
Mishap notifications shall contain, as a minimum, the following information:
(a) Contract, Contract Number, Name and Title of Person(s) Reporting
(b) Date, Time and exact location of accident/incident
(c) Brief Narrative of accident/incident (Events leading to accident/incident)
(d) Cause of accident/incident, if known
(e) Estimated cost of accident/incident (material and labor to repair/replace)
(f) Nomenclature of equipment and personnel involved in accident/incident
(g) Corrective actions (taken or proposed)
(h) Other pertinent information
2. The contractor shall cooperate with any and all government mishap investigations. Additionally if requested by government personnel or designated government representative (GR), i.e., the ACO, PCO, or DCMA COR, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by safety investigators.
3. The contractor shall provide copies of contractor data related to mishaps, such as contractor analyses, test reports, summaries of investigations, etc. as necessary to support the government investigation.
4. The contractor shall support and comply with the safety investigation and reporting requirements of AFI 91-204, Chapters 1 – 5.
C. General Safety Requirements:
| The contractor is solely responsible for compliance with all federal, state and local laws, the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standards 29 CFR 1910 and 1926, as applicable, and the protection of their employees. Additionally, the contractor is responsible for the safety and health of all subcontractor employees. All documents required as a result of OSHA 29 CFR 1910 and 1926 regulations, (i.e. certifications, training, respiratory protection program, workplace hazard assessments), shall be made available to the COR upon request. |
| The contractor shall ensure assigned personnel are adequately trained and qualified for the task being performed. Brief all personnel on the hazards involved with operations and applicable precautions to be taken. Should unidentified hazards arise, cease operations until actions are taken to eliminate or mitigate hazards to safe levels. |
| Hazard Assessment. In accordance with 1910.132(d)(2), the contractor shall conduct a certified Hazard assessment on all work areas. A follow-on survey shall be conducted by the contractor when the workload or environment conditions change. If respirators are necessary to protect the health of the employee or whenever respirators are required by the contractor, the contractor employer shall establish and implement a written respiratory protection program according to 29CFR 1910.134. |
Contractor personnel must receive Explosive Safety Awareness Training if their duties require entry into the Explosive Clear Zone. This training will be provided by the OO-ALC Safety Office. Contact Eric Covington at 586-0168.
A Risk Assessment will be required prior to any work being accomplished, if munitions will remain in the facility.
Compliance with OSHA and other applicable laws and regulations for the protection of contractor employees is exclusively the obligation of the contractor. Note: The government shall assume no liability or responsibility for the contractor's compliance or non-compliance with such requirements. The contractor shall furnish to each of his/her employees a place of employment, which is free from recognized hazards. The contractor shall brief his/her employees on the safety requirements of this contract and on hazards associated with prescribed tasks. The contractor is responsible for compliance with OSHA Public Law and the resultant standards identified within. In addition, the contractor is required to flow down the safety requirements/specification to all subcontractors. This applies to Federal Acquisition Regulation (FAR) 12 commercial acquisitions as well. This contract shall in no way require persons to work in surroundings or under working conditions which are unsafe or dangerous to their health. The contractor must coordinate and perform work so as not to impact the safety of government employees or cause damage to government property. This requires providing personnel with protective equipment and associated safety equipment as may be necessary. The contractor must also protect personnel from hazards generated by the work. If the contractor employs BILINGUAL speaking employees, they must post bilingual signs and have written procedures for specific tasks in applicable languages.
SECTION II – SPECIFIC REQUIREMENTS
The contractor’s prepared Safety Plan shall:
· Demonstrate a management commitment to employee safety and health
· Identify applicable rules and regulations
· Identify the roles and responsibilities of Management, Supervisors, Employees and Safety Coordinator
· Identify work to be performed and location of expected operations
· Provide a description of safety program, safety monitoring responsibilities, organizational structure, and contact information for on-site personnel
· Include a work hazard analysis of the worksite and operations to be performed to include baseline hazard identification and required control measures
· Identify employee safety and health training requirements and the documentation process
· Include emergency response plans and procedures that relate to protection of government personnel and property
· Include hazard reporting procedures and identify individual(s) responsible for the correcting identified hazards
· Identify procedures for accident reporting and investigation
· Identify the process for tracking controlled hazards in contractors work area
The contractor shall ensure that each element identified below is adequately addressed in detail in the safety and health plan:
PEDESTRIAN CROSSWALKS: All contractor personnel are required to use the closest crosswalk, or traffic controlled intersection when crossing the road. Pedestrians must look both ways to ensure the coast is clear before stepping out into the crosswalk. Pedestrians DO NOT have the right of way unless they are already in the crosswalk. Contractor vehicle operators have the same responsibilities as pedestrians, to share the road and mutually observe and yield to pedestrians.
MOTOR VEHICLES: Contractor shall comply with the standards in: DoD Directive 5525.4, Enforcement of State Traffic Laws on DoD Installations", Nov 2, 1981, Para 3-4; DODI 6055.4, DoD Traffic Safety Program, 20 Jul 99; AFI 91-207, USAF Traffic Safety Program, 22 May 07; and AFI 91-207 AFMC SUP1, The US Air Force Traffic Safety Program, 1 Oct 07. Each applies to all persons at any time on an Air Force Installation and includes all leased, owned, or privatized property including housing areas. In addition: AFI 13-213, Airfield Management, 29 Jan 08, Paragraphs 1.3.6 and 4.4.2.1 applies to all contractors, sub-contractors, vendors, commercial delivery companies, and all other private business vehicles who operate anywhere on Hill Air Force Base, including the airfield (to include the industrial areas and any buildings or hangars located upon the airfield) in support of their mission.
HOUSEKEEPING: Housekeeping shall be conducted according to the requirements in OSHA Standard 29 CFR 1910.141. CLEAN AS YOU GO will be enforced.
The authorized Government Representative (OO-ALC Safety Office) shall accept/reject the contractor’s procedures within the Health and Safety Plan as meeting the intent of the below referenced standards, with the exception of Mishap Notification / Reporting Procedures, which are outlined in Section I, paragraph B of this Appendix C.
Element/Requirement Referenced Benchmark
Mishap Notification/Reporting Appendix C, Section I
Confined Space AFPAM91-203 para. 23.8
Hazardous Energy Control AFPAM91-203 para. 21.8
Facility Fire Protection NFPA 13, 70, & 72
NFPA 409/410
AFI 91-203 para. 6.2.9 through 6.2.15, and para. 22.5
Handling, Storage and use of Flammable/ NFPA 30, 33
| Hazardous Material Management | AFI 32-7086 HAFBSUP 1 |
| (If performance is on Hill AFB) |
| Storage and Materials Handling | DoDI 4140.62 |
| DoDI 4145.19-R-1 |
APPENDIX D – EVALUATION & VOLUMETRIC REQUIREMENTS
Scope:
The tasks identified in this document are required in accomplishing performance evaluations, calibrations, and alignment of the 5-axis gantry mill machine in building 238, using laser interferometer equipment and related test equipment. The machine evaluation tasks shall be accomplished in accordance with the basic and modified applicable portions of ANSI/ASME B5.54 as stated in the General Requirements. The calibration procedures shall comply with the requirements set forth in ANSI/NCSL Z540.3 and ISO/IEC 17025.
Applicable Specifications and Standards:
ANSI/ASME B5.54-2005 - Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers ANSI/NCSL Z540.3-2006- Requirements for the Calibration of Measuring and Test Equipment ISO/IEC 17025:2005 - General requirements for the competence of testing and calibration laboratories General Requirements:
Measure and plot the existing “As-Found” conditions of all axes individually. The measurements shall include basic requirements of ANSI/ASME B5.54. (Note: Certain non-standard and/or non-typical measurement applications may arise due to the configuration of a particular apparatus. In this case, some measurements may need to be modified, limited, or omitted. Document such cases during the machine evaluation process to justify deviating from standard measurement procedures.)
Adjust the control parameters as needed to improve the accuracy and repeatability of the machine, to the extent of the machine’s capability (subject to the machine’s control functions and the degree of the machine’s mechanical and electrical/electronic integrity). Control adjustments will include: positioning error compensation, sag or straightness compensation, backlash compensation, as well as other types of adjustments.
Document all “As-Found” and “As-Left” conditions.
Spindle Positioning Accuracy: Following all calibration adjustments, spindle position accuracy shall be within +.002 inch (volumetric positioning) for Cincinnati with respect to an ideal reference space, for any combination of axis positions of the five axis positions of the five axis of the machine.
Cincinnati Profiler Table Flatness: The Mounting table of the Cincinnati Profiler shall not deviate from an ideal horizontal plane by more than +.004 inch, when measured at locations adjacent to the leveling screw. In the event of a discrepancy in the accuracy requirements specified herein (including reference document), the more stringent requirement shall apply.
Individual Tasks:
Linear Axes Positional Calibration: Measure and adjust the linear displacement accuracy and repeatability for the X1, X2, Y, Z axes. Use five (5) set-up measurements, including X at mid Y travel. A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: Several measurement routines, Pitch error compensation, and Backlash compensation adjustments, will be needed in the control parameters before a final axis calibration is accomplished.) Set-up two lasers and optics for Dual axis laser measurements of the X1 and X2-axes simultaneously.
Rotary Axes Angular Displacement Calibration: Measure and adjust the angular displacement accuracy and repeatability for the 2-rotary axes. (2 set-up measurements are needed.) . A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: Several measurement routines, Pitch error compensation, and Backlash compensation adjustments, will be needed in the control parameters before a final axis calibration is accomplished.)
Angular Pitch Measurements: Measure the angular pitch for the X, Y, & Z axes. (Three set-ups will be needed.) A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: No adjustments will be made with these measurements.)
Angular Yaw Measurements: Measure the angular yaw for the X, Y, & Z axes. (Three set-ups will be needed). A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: No adjustments will be made with these measurements.)
Axial Straightness Calibration: Measure and adjust Axial Straightness for the X, Y, & Z axes. Two straightness error measurements set-ups shall be made for each axis, for a total of six set-ups. (Note: Several measurement routines and Sag/Straightness error adjustments may be needed in the control parameters before a final axis calibration is performed.) A minimum of three bi-directional measurements shall be performed for each final axes calibration.
Axial Squareness Measurements: Perform a squareness check for the XY, YZ & ZX planes. (Note: A telescoping ballbar or optical square can be used when performing these measurements). A total of six (6) measurements set-up will be needed. A minimum of three bi-directional measurement routines shall be performed for each plane. (Note: Normally no adjustments will be needed for this measurement, unless a crash of the machine has occurred, or the machine has otherwise been subjected to excessive loads. If needed adjustments are beyond the scope of a normal calibration, a repair work order request may be needed to resolve the squareness issues. Document each occurrence.)
Dynamic circular interpolation: Perform a dynamic circular interpolation, using a telescoping ballbar or equivalent device, in the XY-Plane, YZ-Plane and ZX-Plane. A minimum of three bi-directional measurement routines shall be performed for each plane. (Note: Two sets of tests will be needed over Cincinnati machine table/bed locations for the Cincinnati Milacron Profiler due to large table/bed areas. This means a total of six (6) set-up measurements will be needed.
Volumetric Laser Diagonal Measurements: Perform a volumetric laser diagonal measurement in each of the four quadrants (diagonals) of the rectangular workspace over the machine bed (four set-up measurements in total). A minimum of three bi-directional measurement routines shall be performed for each diagonal.
Table-Bed Level and Fatness: Measure and record the rise and fall of table-bed with respect to an ideal horizontal plane. Adjust the table bed level and flatness to within the machine’s accuracy capability. Repeat and record measurements as before, following final adjustments. Measurement locations shall be approximately evenly distributed over the table-bed, with a minimum number of locations as follows.
Cincinnati Milacron 5-axis Honeycomb Profiler: 36 locations (18 per table bed section)
Table-bed Position with Respect to Spindle Head: Measure and record the distance of the rise and fall of the table bed in relation to the spindle head in the x and y plane (with fixed Z-axis) at the various table-bed locations measured when adjusting the table-bed level and flatness. (Note: No adjustments will be made with these measurements.)
Documentation: (CDRL A003) (DI-QCIC-80798C) Provide a calibration certificate for the machine, documenting that the equipment has been inspected and meets the requirements of ANSI/ASME B5.54. Provide data plots and corresponding tables of the measurements made in the “As-Found” and “As-Left” conditions at each measurement point. Three complete CD-ROM copies of the data shall be provided in PDF format.
APPENDIX E – LOCATION OF CINCINNATI MILACRON 5-AXIS
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