RIPD E4000-23-1-01.pdf

ROCK ISLAND ARSENAL RIPD: E4000-23-1-01

PURCHASE DESCRIPTION DATE: XX-AUG-21

CNC JIG GRINDERS

1. GENERAL SYSTEM DESCRIPTION

The purpose of this project is to purchase two (2) CNC Jig Grinders. This equipment has an extremely high level of precision and will enhance the machining capacity at Rock Island Arsenal Joint Manufacturing and Technology Center.

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal.

Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.2 National Standards and Specifications

The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.2.1 Occupational Safety and Health Act of 1970 (OSHA).

2.2.2 American Society of Testing and Materials (ASTM).

2.2.3 American Society of Mechanical Engineers (ASME).

2.2.4 American National Standards Institute (ANSI).

2.2.5 National Electrical Manufacturers Association Standards (NEMA).

2.2.6 Electronic Industries Association (EIA).

2.2.7 Institute of Electrical and Electronics Engineers (IEEE).

2.2.8 American Code for Information Exchange (ASCII).

2.2.9 American Welding Society (AWS).

2.2.10 American Gear Manufacturers Association (AGMA).

2.2.11 National Fire Protection Association (NFPA).

2.2.11.1 NFPA-70 National Electrical Code

2.2.11.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.12 International Standards Organization (ISO).

3. DESIGN

3.1 Ownership

3.1.1 This equipment is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

3.2 General Design Standards

3.2.1 DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a 10-hp motor would not be acceptable.

3.2.2 UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English- US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.2.3 ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable):

Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine Weight. This information is necessary for compliance with the governments Unique Identification Program (UID).

3.2.4 DATA PLATES: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering.

Lettering shall be permanent and have a contrasting background.

3.2.5 ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID 2-D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

3.2.6 UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component http://dodprocurementtoolbox.com/site/uidregistry/ https://wawftraining.eb.mil/ and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.2.7 UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2.8 UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

3.2.8.1 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

3.2.8.2 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

3.2.8.3 Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. This is necessary to maintain IEPA compliance.

3.2.8.4 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

3.2.9 ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.2.10 CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.2.11 SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

3.2.12 DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

3.2.13 NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

3.2.14 COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.2.15 REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.2.16 CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.2.17 SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.2.18 FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.2.19 CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.2.20 PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.2.21 LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

3.2.21.1 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be English and the units shall be English standard (i.e. pints, quarts, and gallons)

3.2.21.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.2.21.2.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.2.21.2.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.2.21.2.3 All filters shall be either cleanable or replaceable.

3.2.21.2.4 All pumps shall be self-priming.

3.2.22 FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

3.2.22.1 Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

3.2.22.2 Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load.

3.2.23 COOLANT: The machine will be equipped with a coolant system and it shall be equipped with external flood coolant capabilities, as a minimum. Machines using cutting tools shall be equipped with both through the tool and external flood coolant capabilities. Coolant on/off shall be a machine control function.

3.2.23.1 The coolant systems shall include all necessary components necessary to provide completely functional systems, with sufficient capacity to give satisfactory service and provide adequate pressure and flow under normal operating conditions.

3.2.23.2 Coolant troughs and chip screens shall be provided around the machine table base to trap, direct, and return the coolant to the reservoir. An easily removable strainer shall be provided in the return line to the reservoir. "Easily removable" is defined as being removable after no more than 5-min of work by experienced personnel.

3.2.23.3 All machine coolant systems and their components shall provide drip-proof coolant delivery to the coolant point of discharge. In addition, the machine shall be designed and constructed to prevent coolant from escaping the confines of the machine or leaking to the floor when producing work-pieces of a size within the dimensions of the machine table.

3.2.24 MOTORS:

3.2.24.1 All motors shall be rated for continuous duty.

3.2.24.2 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

3.2.24.3 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.2.24.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.2.24.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.2.25 DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.2.26 HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.2.27 CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

3.2.28 FOUNDATION: The requirement for a separate foundation or floor alteration is not permissible. The system shall be capable of being installed on an existing concrete floor without modification to the system or the floor, except for installation of anchor bolts.

3.3 Safety, Security and Environmental

3.3.1 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

3.3.1.1 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

3.3.1.1.1 Access to RIA: Contractor and all subcontractor employees performing work at RIA shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The COR shall provide guidance to complete the Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

3.3.1.1.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti- Terrorism Training.

3.3.1.1.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

3.3.1.1.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or paced in a drop box at a RIA-JMTC access point.

3.3.1.2 Security Training: The contractor shall complete the following training:

3.3.1.2.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete.

The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.1.2.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

3.3.1.3 No Common Access Card (CAC) will be issued related to this project.

3.3.2 FEDERAL MARIJUANA LAWS REMAIN UNCHANGED: Note: Rock Island Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering Rock Island Arsenal.

3.3.3 REAL ID: Starting 03-May-2023 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

3.3.4 FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

3.3.5 INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

3.3.6 MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.7 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.3.8 SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.9 LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.10 TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.11 WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.12 ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

3.3.13 BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.14 EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

3.3.15 CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.3.16 OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.3.17 AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.4 Responsibilities

3.4.1 SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for this process.

3.4.2 SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system.

Examples would include, but are not limited to, buried sewer lines, standing water, and so forth.

The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

4. COMPONENT SPECIFICATION

The supplier shall furnish all equipment normally considered by him to be standard for his machine unless identified in this requirement to be of specific manufacture. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication.

4.1 Dimensions:

4.1.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 10-ft wide by 10-ft high, and shall not exceed 10-ft in length.

4.1.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 10,000lbs.

4.1.3 INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 10-ft long and 10-ft long, excluding the operator’s area. Maximum height shall not exceed 10-ft. Width is defined as front to back from the operator’s normal operating position.

4.2 Machine Base:

4.2.1 CONSTRUCTION: The base shall be heavily ribbed, close grained casting and shall form a rigid structure supporting the table and column. The base shall maintain the rigidity of the system over the life of the equipment.

4.2.2 ACCESS: The base shall provide access to components housed within for adjustment and servicing.

4.2.3 SUPPORT: The base and bed ways shall be such that the table and column are supported at any position within the machine’s rated travel.

4.2.4 HARDWARE: Means shall be provided for leveling and securing the base to the floor.

All necessary leveling wedges, bolts, nuts, and other hardware required for the installation shall be furnished by the manufacturer.

4.3 Machine Table:

4.3.1 POSITION DRIVE: The table shall provide X and Y-axes motion powered by motors driving precision, preloaded ball screws.

4.3.1.1 The end of the screw opposite the motor, or in the case of gear driven screws both ends, shall be anchored in preloaded, antifriction, ball and/or roller bearings, providing stiffness for servo response.

4.3.1.2 Position feed back shall have a linear resolution of 0.00001 in. or less.

4.3.2 WORK AREA: The machine table shall be at least 24 in. x 12 in.

4.3.3 WAY COVERS: All linear ways shall be properly protected from contamination by chips, coolant, and debris.

4.3.4 FIXTURE MOUNTING: The Jig Grinders shall have the manufacturer’s standard mounting plate. The rotary tables being provided shall include quickset mounting plates that allow for either rotary table to be mounted on either machine. The t-slots on the work surface shall be 3/8 in.

4.3.5 TABLE SUPPORT: Table and way configuration shall be such that the table cannot be lifted from its ways by machining forces.

4.3.6 ENCLOSURE: The work area perimeter shall be enclosed by chip and coolant shields.

A door shall be provided, allowing the operator access to the work area. This shall be interlocked to the machine controls to prevent operation with the doors open.

4.4 Column

4.4.1 FABRICATION: The column shall be a close grained casting forming a rigid structure supporting the spindle head. The column shall be stress-relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower cuts.

This shall be a box style construction only, to maintain rigidity of the system over the life of the equipment

4.4.2 VERTICAL DRIVES: Spindle head motion shall be powered by motors driving precision, preloaded ball screws.

4.4.2.1 The end of the screw opposite the motor, or in the case of gear driven screws at least one end, shall be anchored in preloaded, antifriction, ball and/or roller bearings, providing stiffness for servo response.

4.4.3 VERTICAL COVERS: The ball screw(s) providing Z-axis travel shall be covered both above and below the spindle head, in a manner affording protection from extraneous material.

4.5 Spindle Head:

4.5.1 TRAVEL: Z-axis travel shall be capable of being performed simultaneously with X-axis and Y-axis travel.

4.5.2 FABRICATION: The spindle head shall be a closed grained casting or steel fabrication, forming a rigid structure. The spindle head shall be stress relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower operations.

4.5.3 MOTION: The spindle head shall move vertically on the column ways for positioning and machining operations, providing the Z-axis motion. The spindle head shall be counterbalanced, relieving the ball screw of the spindle head weight. All spindle head and spindle functions shall be numerically controlled by the CNC control.

4.5.4 LOCATION: Position feed back shall have a linear resolution of 0.00001 in or less.

4.5.5 DRIVE: The spindle head shall be equipped with a variable speed motor rated to handle the range of spindle rotation and movement.

4.5.5.1 All spindle drive shafts shall be of steel or steel alloy, hardened to 58-62 Rockwell C, and ground. Spindle head shafts shall be mounted in precision ball and/or roller bearings.

4.5.6 SPEED RANGE: The spindle shall be variable speed up to a max RPM of 60,000

4.5.6.1 An additional spindle shall be provided that allows for capabilities of at least 90,000 RPM Quantity (1)

4.5.6.2 The spindle shall have a 0.0001 degree programmable resolution.

4.5.7 HARDNESS: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground.

4.5.8 DEAD ZONE: The end of the spindle nose shall reach within 9in. of the machine table face.

4.5.9 LUBRICATION: The machine shall be provided with a lubrication unit.

4.5.10 FREQUENCY CONVERTER: The spindle shall be provided with a frequency converter.

4.5.11 CLAMP RING: The spindle shall be supplied with a clamp ring.

4.5.12 TOOLING: The spindle shall be compatible with HSK E25 series tooling.

4.5.12.1 Sizes: The machine shall be supplied with at least six (6) collets. The collets should be of the following sizes: (2) 0.0125-inch, (2) 0.2500-inch, and (2) 0.3750-inch.

4.5.12.2 Extension: An arbor extension assembly of 100 mm shall be provided that is compatible with the HSK E25 tooling.

4.6 Tool Changer:

4.6.1 TYPE: The equipment shall include a rotary turret style tool changer.

4.6.2 NUMBER OF TOOLS: This system shall be capable of simultaneously holding (20) or more tools.

4.6.3 VIBRATION: The tool changer shall be solidly mounted with vibrations sufficiently dampened to ensure proper alignment with the spindle, and ability to change tools during cutting cycles without transferring vibrations into the machine tool or work-piece.

4.6.4 MACHINE MOUNTING: If the tool changer is mounted on the machine, the manufacturer shall provide means to allow safe access to the magazine and changing of tools.

4.6.5 INTERFACE: The tool changer system shall be capable of tool selection automatically by MDI and by command in the parts program.

4.7 Controls:

4.7.1 DRIVE MANUFACTURERS: Spindle drive motor and axis drive servo motors shall be designed and built by a single vendor. This shall include the motor controllers. Mixing of one controller brand with a different manufacturer of motor shall not be acceptable.

4.7.2 ENCODERS: Positioning shall be maintained by an absolute encoder on each axis of motion. This shall be designed such that in the event of a power loss, the system shall maintain position data sufficient to continue operation when power is restored without the need to re-zero (home) the machine.

4.7.3 DATA INPUT: The control shall be designed to operate from memory loaded from Ethernet connection, information downloaded from a host computer via serial port, and information loaded from Manual Data Input (MDI) using the keyboard.

4.7.4 CONSTRUCTION: The control shall utilize solid-state transistorized or integrated and modular construction. Plug-in circuit boards shall be coded to facilitate identification and location in the control and shall be arranged as convenient plug-in elements of quick disconnect modules with minimum connectors. Built-in test points, test procedures and instructions shall be provided for isolation and identification of defective components and circuitry. It shall be a Fanuc control

4.7.5 MEMORY: The control shall be provided with a minimum of 512K of usable part program storage.

4.7.6 POWER RECOVERY: The control shall recover from power outages. Upon power resumption, the control shall automatically reload/reboot the executive and bring itself back, by operator initiation, to a state where the operator can initiate part program load and restart.

4.7.7 MODES: Provision shall be made to allow operation in automatic, single block, Manual Data Input, and manual modes.

4.7.8 UNITS: Feed rates shall be programmable in both inch and metric systems.

4.7.9 BLOCK DELETE: A block delete and record delete feature shall be included in the control to allow specific routines to be bypassed.

4.7.10 JOG: The operator shall have the capability of jogging linear axes incrementally in steps of 0.0001in, 0.001in, and continuous. Metric jog shall be in increments of 0.01mm, 0.1mm and continuous.

4.7.11 ACCELERATION CONTROL: The control shall be capable of controlling acceleration and deceleration of axis feed rates and traverse moves, maximizing axes movement speeds, while reducing stress to the machine.

4.7.12 FEEDRATE MULTIPLIER: The control shall allow for incremental multiplication of the feedrate to enable capabilities for very fine manual adjustment. In no circumstance will the programmed feed rate be allowed to exceed the maximum feed rate of each axis.

4.7.13 OVER-LIMIT FUNCTIONS: The control shall allow limits to be set on feed rates for each tool in the magazine. If the limits are exceeded, the control shall perform preset options such as: feed-hold, feed-hold with spindle stop, or select new tool and proceed.

4.7.14 DWELL: The control shall be capable of accepting a programmed dwell. Dwell range shall be 0.0001 to 999,999 seconds.

4.7.15 OPERATOR VERIFICATION: The control shall be provided with a tool recovery method, which shall allow the operator to jog away from the work to check the tool during any machining move and return the tool to the correct position automatically.

4.7.16 BACKLASH COMPENSATION: The system shall include a control method of compensating for positioning backlash and axis error.

4.8 Ranges and Capacities:

4.8.1 AXES:

4.8.1.1 X-Axis Travel: Minimum of 19.6 in.

4.8.1.2 Y-Axis Travel: Minimum of 11.8 in.

4.8.1.3 W-Axis Travel: Minimum of 13.8 in.

4.8.1.4 Z-Axis Travel: Minimum of 5.5 in.

4.8.1.5 U-Axis Travel (Programmable): Minimum of 0.140 in.

4.8.1.5.1 U-Axis (Main Coarse Adjustment): 0.43 in. behind centerline of main spindle to

1.125 in beyond center.

4.8.1.6 Traverse: X, Y, W, Z axis: 0.00001 – 80in./min.

4.8.1.7 A & B Axis: The units shall be equipped with a rotary spin table rated for the environment that also allows the rotary table to tilt at any angle from 0-90 degrees. The rotary table shall have infinitely variable speeds from 10-100 RPM.

4.8.2 TABLE: Load capacity of the table shall be at least 660 lbs.

4.8.3 SPINDLE:

4.8.3.1 Spindle Speeds (Planetary mode): 1-300 rpm

4.8.3.2 Reciprocation Stroke Rate (1 in.): 0-190 cycles/min.

4.8.3.3 RPM Range: Minimum of at most 3,000 RPM up to maximum of at least 60,000

RPM

4.8.4 ACCURACY:

4.8.4.1 Positioning Accuracy:

4.8.4.1.1 X-Axis: Maximum total deviation over full travel 0.000080 in.

4.8.4.1.2 Y-Axis: Maximum total deviation over full travel 0.000080 in.

4.8.4.1.3 W-Axis: Maximum total deviation over full travel 0.000080 in.

4.8.4.1.4 Z-Axis: Maximum total deviation over full travel 0.000160 in.

4.8.4.2 Contouring Accuracy: Maximum total deviation 0.000120 in.

4.8.4.3 Geometric Squareness: 0.000080 in.

4.8.4.4 Geometric Alignment: 0.000080 in.

4.8.5 FEEDRATES:

4.8.5.1 X,Y,W, Z-axes: at least 0.00001- 80 in./ min

4.8.5.2 C-axis: at least 0.0000278 – 20 rpm

4.8.5.3 U-axis: at least 0.00001 – 0.47 in./min.

4.8.5.4 Z-axis (Reciprocation): 0.1 – 590 in./min.

4.8.6 TAPER ADJUSTMENT: The equipment shall have a taper adjustment of up to at least

1.5 degrees from centerline (3 degrees over full travel).

4.9 Additional Components and Features:

4.9.1 THROUGH SPINDLE COOLANT: The system shall include high pressure through spindle coolant.

4.9.2 CHIP REMOVAL: Means shall be provided for the removal of metal flakes/ chips that accumulate during the grinding process.

4.9.3 EARLY POWER FAILURE DETECTION: The system shall automatically detect power failure before the system is affected. It shall then react to prevent damage to the system, controls, tools, and fixtures. This may include, but is not limited to storing table position data to prevent the need to zero when power is restored, controlled stop and locking of the spindle to prevent dropping, etc.

4.9.4 LIGHTING: The system shall include high intensity lighting inside the work area to assist the operator in set-up and operation of the equipment.

4.9.5 PROCESS MONITOR/AUTOSIZE SENSOR: This feature shall dynamically measure and monitor the effective wheel diameter and automatically compensate the wheel edge to part edge for precise size finishing of holes and counters.

4.9.6 DRESSER ASSEMBLY: The system shall include a rotary wheel dresser assembly

4.9.7 DRESSING WHEEL: The dresser assembly shall come with a diamond dressing wheel (0.030 Radius)

4.9.8 PROBE: The machine shall be supplied with a high accuracy machine probe “Renishaw OMP400” or equivalent.

4.9.9 RISER: Any necessary step risers to accommodate tooling with the wheel dresser assembly shall be provided with the system.

4.9.10 SPIN TABLE: The machine shall be provided with a wet grinding compatible rotary spin table or equivalent means to rotate a part that shall be provided with a programmable controller. The diameter of the spin table top shall be at least 10 in. It shall have a TIR of at most 0.000005in with a max axial deviation of no more than 0.000020 in. As part of this CLIN, the vendor shall provide quantity (1) wet rotary air bearing table, however both machines shall be equipped with the framework and necessary hook-ups to operate with the table. This will allow the rotary table to move between the two machines as workload demands.

4.9.11 CHILLER: The machine shall be supplied with a coolant and chiller system.

4.9.12 VAPOR EXTRACTOR: The machine shall be supplied with a mist and vapor extractor.

4.9.13 FIRE SUPPRESSION: The machine shall be supplied with a fire suppression system.

4.9.14 SPARE PARTS KIT: The system shall be provided with the manufacturer’s standard spare parts kit. Quantity 1

4.9.15 TOOL KIT: The units shall be provided with any tools, fluids, lubricant, or sealant needed for the machines to be properly set up for operation.

4.9.16 MEASURING ACCESSORIES: All necessary measurement accessories shall be provide by the contractor, these may include but not be limited to: Clamp rings, dovetail clamps, additional holders etc.

5. CLIN 0002- REMANUFACTURED MOORE SPIN TABLE

5.1.1 RIA-JMTC currently utilizes a dry grinding only, rotary spin table on one of our Moore Jig Grinders. The contractor shall refurbish this rotary table or provide an equivalent rotary table/ means of rotating the part to be compliant with this portion of the RIPD.

6. CLIN 0003- WORKPIECE HOLDER FOR RIA SPECIFIED PART

6.1.1 The contractor shall provide a work-piece holding device to hold a bulk amount of a singular part. The Jig Grinder(s) shall use the probe to identify locations of the parts being held within the device and the Jig Grinder(s) shall be able to perform the grinding operation on all of the parts without the need for operator intervention. Part to be identified by RIA.

7. APPROVAL/SHIPPING

7.1 Test Standards and Specifications

7.1.1 OPERATIONAL TEST: Functions of the machine and the control unit shall be checked.

7.1.1.1 If the machine is equipped with a CNC control, upon completion of the warm-up and runoff checks, the machine shall be cycled continuously for a period of 8-hrs without a malfunction.

7.1.1.2 The runoff checks shall include operating the machine in each of its modes of operation to determine proper response of the machine to control commands. The cycle checks shall include spindle speed and feed-rate changes, independent and simultaneous operation of machine axis motions and diskette controlled auxiliary functions. Should a failure occur, the cycle shall be restarted after the correction and runoff for a full 8 hour period.

7.1.1.3 Adjustments during the test may require restarting the test from the beginning.

7.1.2 PERFORMANCE REQUIREMENTS AT RIA: Performance requirements for this project are listed in 23-1-01 Performance Test(s).

7.2 Shipping

7.2.1 RESPONSIBILITY: The contractor is responsible for delivery of the equipment to the Rock Island Arsenal. Adequate preserving of equipment surfaces, packing, marking, and skidding of materials for shipment shall be the responsibility of the contractor. If special lifting devices, such as hooks or eyes, are required for ease of handling, they shall be supplied with the equipment. Any special devices shall be returned to the contractor upon request only if they will not be required for future movement of the equipment, and at the contractor’s expense.

7.2.2 SHIPPING SCHEDULE: Be aware, the Rock Island Arsenal will only off-load equipment arriving between 6:00 am and 12:00 am (noon), local time on Mondays through

Thursdays except holidays. For information concerning holidays, the contractor should consult the contracting officer. There is no place to stage transporting vehicles awaiting the arrival of contractors. All equipment shall be delivered at the same time, meaning the same day (multiple trucks are acceptable) unless pre-authorized to deliver on multiple days by the RIA-JMTC contracting officer.

7.2.3 RECEIVER: All shipments to Rock Island Arsenal including installation tools and/or replacement parts, as well as the original shipment of the equipment, shall be marked “ATTN:

Mr. Robert Mcclure or Mr. Joe Carpentier, TARA-IFF”. Items not correctly marked are subject to being returned at the vendor’s expense.

7.2.4 ARRIVAL INSPECTION: Upon receipt of equipment at Rock Island Arsenal, a preliminary inspection shall be performed to determine condition and/or count. This inspection shall be performed by Rock Island Arsenal personnel.

7.3 Installation

7.3.1 SITE PREPARATION REQUIREMENTS: The contractor shall be solely responsible for any necessary site inspections required for determining the specifications of work that must be completed prior to final system installation. The contractor will then provide detailed information of any preparation work that the vendor must perform prior to system installation to Rock Island Arsenal.

7.3.2 PREPARATION EXECUTION SUPPORT: Rock Island Arsenal will support the preparation portion of the installation by providing utilities to the points of first connection.

7.3.3 LABOR AND MATERIAL: The supplier is solely responsible for providing all labor, materials, hardware, tools, and equipment necessary for complete installation of this system except as specifically listed in this document as being provided by the Rock Island Arsenal.

7.3.4 SUPERVISION: Supervision of the installation process will be the responsibility of the contractor. Rock Island Arsenal shall retain the right to periodic inspection and evaluation of the process, as it deems necessary.

7.3.5 OFF-LOADING/PLACEMENT: Off-loading of the equipment from the delivery vehicle, and placement of the equipment in position for the installation is the responsibility of the contractor. The contractor shall not be allowed to use government equipment to accomplish this work.

7.3.6 OFF-LOADING/PLACEMENT OPTION: At the request of the contractor, Rock Island Arsenal will perform the off-loading and placement of the equipment.

7.3.6.1 Any special requirements or precautions to be observed shall be the responsibility of the contractor to provide.

7.3.6.2 The contractor or his representative may be present during this process; however, such person will be responsible for being present upon arrival of the equipment at Rock Island Arsenal. Off-loading and placement shall not be delayed to allow arrival of the contractor or his representative.

7.3.6.3 If, due to contractor caused difficulties, the equipment or components of the equipment must be moved, removed or replaced by Rock Island Arsenal after initial placement, the contractor shall be billed for such work at current Rock Island Arsenal labor and overhead rates.

7.3.7 LIABILITY: In any case, the equipment remains the property of the contractor, and the contractor shall assume all responsibility and liability for the equipment and the work performed upon it. The government shall be held harmless for any damage done to the equipment at any time up until final acceptance of the equipment by Rock Island Arsenal, except in the case of intentional damage and/or gross negligence on the part of Rock Island Arsenal personnel.

7.3.8 SET-UP: The contractor shall be responsible for set-up and connection of the equipment beyond connections of the utilities to the points of first connection.

7.3.9 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safe guards, various precautions, and plant protection measures. At all times during the execution of this SOW, the contractor will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal Island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the Island.

7.3.10 Delivery Hours or Service Hours: Service calls, equipment installation, training, and equipment delivery (where the contractor offloads) will only be allowed from 0600 – 1530, Monday through Thursday, except for Government Holidays. Deliveries of items where the contractor has opted for Government “off-loading option”, must be received before 1200 hours.

These hours are subject to change, however, the Government will notify the contractor of such changes. The vendor will contact the designated COR to obtain an electronic key for their representative (i.e. delivery driver) in order to have access to the facility. Deliveries and service calls outside the normal hours stated above will be coordinated with the COR to address any emergency situations."

7.4 Completion

7.4.1 Final acceptance of the equipment shall occur after the following:

7.4.1.1 Set-up completion by the contractor.

7.4.1.2 Successful completion of performance testing at Rock Island Arsenal.

7.4.1.3 Final inspection approval by the government representative or inspector. This is to verify full compliance with this description to include amendments and modifications to the final…