SALIENT CHARACTERISTICS 24Q1744.pdf

Cylindrical Grinding Machine

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the government for a Cylindrical Grinding Machine. It is the government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification.

2. REQUIREMENTS

2.1. 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.

2.2. Construction. The Cylindrical Grinding 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 Cylindrical Grinding Machine to its maximum rating and capacity without distortion.

2.2.1. 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.

2.2.2. 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.

2.2.3. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion. All paint shall be lead and chromate free.

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

2.2.5. 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.

2.2.6. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's workstation(s).

2.2.7. OSHA Compliance. The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph

1910.303 and paragraph 1910.399.

2.2.8. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

2.2.9. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the Cylindrical Grinding Machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

2.2.10. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 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 three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

2.2.11. Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. 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 oil condition. When a low oil pressure condition occurs, the machine shall enter an emergency stop condition. All oil holes, grease fittings, and filler caps shall be accessible. A lubrication plate shall be securely attached to the equipment, see 2.15.2.

2.2.12. Interchangeability. 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. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

2.2.13. Measuring and Indicating Device Graduations. All measuring and indicating devices on Cylindrical Grinding Machine shall be graduated in the inch/pound or both inch/pound and metric.

2.2.14. Calibration. The contractor shall provide calibration control instructions for each calibrated item (if applicable).

2.3. Components. The Cylindrical Grinding Machine shall consist of not less than the following components.

2.3.1.1. Wheel-head. The wheel-head system shall contain high performance brushless AC servo-motor with absolute encoder feedback. The wheel-head shall consist of backlash-free precision ball screw using a direct coupling. The wheel-head shall contain a rigid wheel guard with an adjustable front hood, designed in compliance with OSHA requirements. The wheel-head assembly shall also include a set of V-belts (for wheel drive) and a flexible coolant nozzle.

2.3.1.2. Wheel Sleeve & Flange Assembly: 1.3” – 2.95” (Wheel Width), 10” (ID)

2.3.1.3. Wheel Size: 24” (OD) x 1.3” (Wide) x 10” (ID)

2.3.1.4. Wheel Use Range: 24” x 16.93”

2.3.1.5. Standard Wheel Surface Speed: 6,500 SFPM

2.3.1.6. Min. Move Increment (on dia.): .000010”

2.3.1.7. Wheel-head Rapid Feed (on dia.): 590 IPM

2.3.1.8. Slide: V and Flat Slide, 90° slide

2.3.1.9. Wheel Drive Motor (4P): 15 HP

2.3.1.10. Wheel Feed Drive Motor (AC servo): 4.15 HP

2.3.1.11. Wheel Spindle Lubrication Motor (2P): .67 HP

2.3.1.12. Fan Cooler for Spindle Oil (4P): .1 HP

2.3.2. Table. The table feed system shall contain high performance brushless AC servo-motor with absolute encoder feedback. The table feed system shall include backlash-free precision ball screw using a direct coupling. Shall include a two (2) piece swivel table arrangement for traverse taper grinding, with a dial indicator and taper conversion table.

2.3.2.1. Type: Two (2) Piece Swiveling/Traversing

2.3.2.2. Table Swivel (CCW to CW): 3° to 0°

2.3.2.3. Table Stroke: 72.2”

2.3.2.4. Slide: V and Flat Slide

2.3.2.5. Min. Move Increment: .000010”

2.3.2.6. Table Rapid Feed: 511 IPM

2.3.2.7. Table Feed Drive Motor (AC servo): 6.7 HP

2.3.3. Work-head.

2.3.3.1. Type: Dead Spindle

2.3.3.2. Work-head Center Taper: MT #5

2.3.3.3. Work Speed (Infinitely Variable): 7 – 140 RPM

2.3.3.4. Work Drive Motor (AC servo): 4.69 HP

2.3.3.5. Work Spindle: Jog Button

2.3.4. Foot-stock.

2.3.4.1. Type: Manual

2.3.4.2. Footstock Center: MT #5

2.3.4.3. Max. Center Retraction: 1.26” by Lever

2.3.4.4. Spindle Position Adjustment: 1.18”

2.3.5. Point to Point Dressing.

2.3.5.1. Type: Stationary Diamond Holder

2.3.5.2. Location: Work-Head Mount

2.3.5.3. Diamond Tool: Single Point

2.3.6. Coolant System.

2.3.6.1. Separator: Magnetic

2.3.6.2. Includes: Low Level Detection

2.3.6.3. Includes: 20 Gal. /Min. magnetic filtration

2.3.7. Required Tooling.

2.3.7.1. Wheel Balancing Stand: Standard Wheel

2.3.7.2. Wheel Balancing Arbor: Standard Wheel

2.3.7.3. Machine Light: LED

2.3.7.4. Front Cover: Manual Type (Open/Close)

2.3.7.5. Slide-ways covers and bed covers

2.3.7.6. Set of leveling screws and pads

2.3.7.7. Standard tool kit

2.3.8. CNC Controller System: Two (2) axis CNC controller, including swing type operation panel with keyboard for manual data input, manual pulse generator and the following features:

2.3.8.1. 12” color LCD display

2.3.8.2. Part program storage up to 30 steps per program, up to 64 programs

2.3.8.3. Grinding cycles for plunge, traverse and multi-plunge travers

2.3.8.4. Canned dressing forms and conditions

2.3.8.5. Jog feed and axis selector

2.3.8.6. Production counter, quality check counter, wheel dressing interval counter displays

2.3.8.7. Processing cycle time, grinding cycle time, wheel dressing time displays

2.3.8.8. Maintenance display including wheel and diamond change procedure, wheel change

2.3.8.9. Mode selection: Auto/Test Cycle & Manual/MDI

2.3.8.10. Grinding feed override switch from 0 to 150 in 10% steps

2.3.8.11. Rapid feed override switch from 0, 10, 50, and 100% steps

2.3.8.12. Work spindle override switch from 50 to 100% in 10% steps

2.3.8.13. Program number display

2.3.8.14. Feed hold switch

2.3.8.15. USB port and memory stick back-up

2.3.9. Coolant System. A flood type coolant system shall be provided with a magnetic separator to remove metal debris. The coolant system shall include a sump or reservoir, a power driven pump, and all necessary piping. The system shall have means for draining and cleaning. Means shall be provided to permit the operator to direct and control the amount of coolant over the entire work area.

2.3.10. Hydraulic System. The hydraulic system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls including protection from over-pressurization.

2.3.11. Air Assist System. The air assist system shall provide aide in repositioning the footstock and the work-head. The air assist system shall include filter(s) and individual regulator(s) for both footstock and work-head assemblies.

2.3.12. Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls including protection from over-pressurization.

2.3.13. Electrical System. The machine shall conform to NFPA 79. The existing electrical power source available at the installation site is 230 VAC, 3 Phase, 60 Hz.

The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

2.3.13.1. Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. 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 1 HP and above shall meet the requirements of NEMA MG 1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number written in the English language. Servo motors are exempt from these requirements. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s), unless otherwise specified herein.

2.3.13.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

2.3.13.3. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA Type 12.

2.3.13.4. Cable and Hose Carriers. All flexible power lines, cables, conduits, and hoses necessary to connect the linear sliding, powered, assemblies to stationary utilities and controls shall be contained within a flexible cable and hose carrier arrangement.

Conductors located on the cable and hose carrier shall be adequately cradled or secured at regular intervals and in an orderly manner. Cable and hose carrier design shall ensure that flexible conductors are not stretched, crimped, pinched, or scraped over the full travel of the track. A guide arrangement shall be provided to insure straight motion of the track, parallel to slide motion, without twist or binding. Each cable and hose carrier shall be in a position that will allow access and egress to the operator and control panel without interference as well as afford the best possible protection of the conductors. All conductors shall be of sufficient length to allow full travel of connected components and shall be connected at both ends to junction boxes and manifolds in proximity to the track ends to facilitate replacement of conductors. All conductors shall be labeled at both ends. Installation of the cable and hose carrier s in the overhead position is not allowed.

2.3.14. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

2.3.15. Work Envelope Lighting. The equipment shall include LED lighting to illuminate the work envelope. The lighting shall comply with NFPA 79 requirements, and have a protective shield.

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

2.5. Hour Meter. The Cylindrical Grinding Machine shall be equipped with an analog hour meter mounted on the main electrical panel visible from the outside. The hour meter shall be installed to display accumulated operating time of the main drive motor. The meter shall be of the non-resetting type and shall have a range of 0 to 99,999.9 hours in increments of 0.1 hours, and shall revert to zero (0) upon reaching the maximum count. The meter shall have a NEMA enclosure rating of 4X, and shall be mounted to withstand shock and vibration generated by the equipment in an accessible location.

2.6. Size and Capacity. The size and capacity of the Cylindrical Grinding Machine shall be not less than specified in Table I.

Table I. Size and Capacity Power 230 VAC, 3 Phase, 60 Hz Maximum Allowable Floor Space 250” x 140” Maximum Load Between Centers 1,100 LBS Maximum Machine Weight 22,500 LBS Distance Between Centers 62.5” Grinding Diameter 0 – 21.5” Swing Over Table 22”

2.7. Standard Equipment. All standard equipment required for proper operation of the Cylindrical Grinding Machine (such as special tools) shall be furnished.

2.8. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and 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.

2.8.1. PCB Label Plate. A label plate containing the PCB Certification information shall be permanently and securely attached in the vicinity of the manufacturer’s identification plate.

2.8.2. 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 applicable) Size and type of each lubricant filter

2.8.3. Nameplate. A nameplate shall be permanently and securely attached to each machine.

The 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, and frequency) Contract Number or Order Number Date of manufacture

2.8.4. 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.

2.9. Operating and Maintenance (O&M) Manuals. Three (3) hard copies and one (1) electronic copy(s) of the O&M Manuals shall be provided with the machine. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

i. All final “as-built” contract drawings shall be provided on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

2.10. OSHA Approved Certification. The equipment and its installation specified herein shall be inspected and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7 and approved as defined in section 2.2.7 of this statement of work, OSHA Compliance. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery and installation, and prior to destination testing.

2.11. PCB Certification. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

2.12. Workmanship. Workmanship of the Cylindrical Grinding 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.

2.13. Installation and Commissioning. It is the government’s responsibility to rig and secure the machine at the installation location. The government shall connect the Cylindrical

Grinding Machine to government provided utilities located within fifteen (15) feet from the installation location. The contractor shall commission the machine for operational status.

Commissioning shall include installation inspection and machine start up. Acceptance testing of the system shall be performed to ensure full functionality in accordance with the manufacturer’s O&M manual. The contractor shall exhibit operational status by grinding a work piece provided by the government.

2.14. Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is a United States citizen proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. Training shall comprise explanation of machine operations, machine set up instructions, and basic part programming, to include plunge, transverse, and combination plunge/traverse grinding functions. The training shall be for a number of operators and be performed at the customer’s facility and shall not be less than 5 consecutive, 8 hour workdays, excluding any federal holidays. The course shall utilize as-built drawings and manuals provided under this contract and shall include both classroom and hands-on portions. All printed training aids shall be supplied at no additional cost to the government and be in the English language.