Salient Characteristics_CNC Wire EDM.doc

Salient Characteristics

Commercial Availability Certification:

I have evaluated the commercial marketplace and determined that all of the salient characteristics documented below are available in products/services offered in the commercial marketplace.

Signature (typed name): Jon-Erik Mogonye, PhD Technical Point of Contact (TPOC) or Contracting Officer’s Representative (COR)

The computer numerical control (CNC) wire electrical discharge machine (EDM) system shall meet the following requirements.

1. Physical dimensions

1.1. Full machine floor print, (including water tank, water filters, electrical cabinet, machine center, wire collection system, and controls panel/station) shall be able to fit in an area 80 in (2032 mm) wide by 110 in (2794 mm) deep.

1.2. Maximum machine height shall be less than 84 in (2133 mm).

1.3. Gross system weight shall be less than 7500 lbs. (3400 kg).

2. Machining capacity, function, and precision

2.1. Machine axis limits, speed, and precision

2.1.1. X-axis travel of at least 14 in (355 mm)

2.1.2. Y-axis travel of at least 10 in (254 mm)

2.1.3. Z-axis travel of at least 8.5 in (215 mm)

2.1.4. U-V axis tilt up to 15° at maximum workpiece thickness, and 45° for workpieces up to 1.5 in (38 mm) thick.

2.1.5. System must come equipped with mounting and all control connections for a rotary B-axis or a fully functioning B-axis capable of 360°.

2.1.6. Linear axis (X, Y, Z) shall have rapid feed rates up to 25 in/min (635 mm/min)

2.1.7. Linear axis (X, Y, Z) shall have an absolute resolution of 0.00001 in (0.000254 mm).

2.2. Workpiece size and handling

2.2.1. Machine system must be able to support workpieces up to 500 lbs. (227 kg) in weight.

2.2.2. Maximum workpiece dimensions shall be greater than or equal to section machine axis limits in X, Y, and Z.

2.2.3. Machine workpiece table must be included and provided with bolt pattern for workpiece handling and fixturing.

2.3. Wire size, feed, and handling

2.3.1. Machine must be capable of operation with wire diameter within and including 0.004 – 0.012 in (~0.100 – 0.305 mm) and applying and maintaining wire tension suitable for machining.

2.3.2. Machine must be capable of automatically feeding wire through upper and lower wire guides and through workpeice.

2.3.3. Machine must be capable of automatically capturing waste wire for efficient handling and recycle.

2.3.4. Wire feed system must be able to utilize wire spools up to 10 kg in mass.

2.3.5. Machine system must come supplied with a wire alignment system for tilt correction between upper and lower wire guides.

2.4. Dielectric fluid, filtering, cooling, and handling.

2.4.1. Machine must be capable of using deionized water as dielectric fluid.

2.4.2. Machine must include filtration system for deionized water and be delivered with any and all consumables.

2.4.3. If dielectric fluid requires active cooling, then the machine system will include a water chilling unit with appropriate capacity.

3. Controls and software

3.1. Control system for all functions of axis motion, electrical discharge, wire handling, and dielectric flow, filtration, and level shall be included with the machine system.

3.1.1. Control system shall include keyboard for user control and monitor display and mouse / and or touchscreen.

3.1.2. Control system shall include a handheld pendant ‘walk around’ operator control device for axis jogging and wire alignment procedures.

3.2. Control software

3.2.1. Software provided shall be capable of manual operator programming of M and G code for machining operations.

3.2.2. Software must be capable of importing computer aided manufacturing (CAM) CNC programs from external source.

3.2.3. Controls, display, and machining workpiece programs must be able to read and operate in both standard (inch) and metric (mm) units.

3.3. Machine must come equipped with and emergency stop physical button accessible to operator that immediately inhibits all axis and power to the machining workpiece envelop.

4. Machine power and supply requirements.

4.1. The machine and ancillary support equipment and controls shall be fully operable by a 200 – 220 V alternating current (AC), 3 phase, electrical supply with a current requirement no greater than 50 A.

4.2. Compressed air requirements for machine operation shall not exceed 100 PSI (690 kPa) or 4 cubic ft./min (0.12 cubic m/min).

5. Documentation, Delivery, Installation, and Training

5.1. System must include at least one (1) hard-copies and one (1) soft-copy of all equipment manuals.

5.2. Contractor shall provide on-site delivery, set-up, and installation, at a time coordinated with the contractor by the Army Research Laboratory (ARL) Government Technical Point of Contact (TPOC).

5.3. Contractor shall provide training for up to 2 (2) ARL staff members for one (1) day at a location and time in the Baltimore-Washington Metropolitan area designated by the TPOC.

6. Warranty and Service

6.1. The Contractor shall provide technical support and software upgrades for a period of three (3) years or longer.

6.2. The warranty must include the following:

6.2.1. The replacement of all defective parts at no additional cost to the Government upon initial delivery and set up.

6.2.2. A response time of 48 hours form the time the Government contacts the Contractor with a request for service to diagnose and propose a plan to repair or recalibrate the UTS system.

Contracting Officer: