SOW-VTL.doc

SB1341-15-RQ-0573

Statement of Work

CNC Vertical Tuning Lathe

1. BACKGROUND:

The National Institute of Standards and Technology (NIST), Fabrication Technology Office (FTO) provides a wide range of engineering, fabrication and technical services to support the creation of unique measurement instruments and scientific apparatus needed by researchers in the NIST's Measurement and Standards Laboratories. FTO provides the mission critical engineering and manufacturing expertise and equipment needed to produce specialized parts and subassemblies for the extraordinary variety of one-of-a-kind instruments conceived by NIST scientists and engineers.

FTO’s primary line of service is metal fabrication, mechanical engineering, and electromechanical assembly. This service is used to engineer and fabricate high precision components and assemblies for use in one-of-a-kind measurement instruments conceived by NIST scientists and engineers. FTO depends on its installed base of manufacturing technology to support the many service needs of its customers. This manufacturing technology base includes a full family of automated and conventional milling machines, lathes, grinders, electrical discharge machines, boring mills and other related manufacturing equipment. FTO requires a Computer Numerically Controlled (CNC) Vertical Turning Lathe (VTL). The VTL uses rotating commercial cutting tools (live tooling) in various configurations with standard lathe tools to remove metal and other material from raw materials and assemblies creating designed features in an instrument. The work piece is positioned on a chuck on the base of the machine and the chuck is spun about the w axis. This action is much like a potter’s wheel used in making clay pots. Tooling moved verical via the z axis and horizontally via the x axis to cut material. With live tooling tooling also spins about the holder’s axis to add drilling and milling functions to the turning operation.

2. OBJECTIVES:

The objective of this procurement is to acquire a new commercially available Vertical Turning Lathe (VTL) and the associated installation, warranty, and training.

3. SCOPE:

The Contractor shall provide a VTL with the following features/capabilities:

This specification covers a CNC VTL with other components, as described below. The VTL will be used for manufacturing and fabrication support services provided by the NIST FTO.

The Contractor shall provide, deliver, install, and demonstrate the operation of the VTL. The VTL shall be installed at the NIST facility in Gaithersburg, Maryland.

4. FEATURES:

4.1 Machine Size

· Proposed VTL shall have a maximum installed height of no more than 134 inches at the tower and a cabinet height under 24 inches.

· Proposed VTL shall have a total weight of between 15,000 and 30,000 lbs

· Proposed VTL shall have an installed footprint of between 60 and 80 square feet with required assessories

4.2 Machine Construction

· Proposed VTL shall have a one piece sturdy meehanite cast iron bed

· Proposed VTL shall have X and Z axis driven by heavy ball screws over 1.5” diameter

· Proposed VTL shall have ball screws directly mounted to AC servo motors to reduce backlash

· Proposed VTL shall have hardened and precision gound guideways, fully protected with stainless steel covers

· Proposed VTL shall have a minimum of 50 horsepower (HP) spindle with a 2 speed gearbox

· Proposed VTL shall have class P4 spindle bearings

· Proposed VTL shall have class P4 angular thrust bearings

· Proposed VTL shall have at least a 15HP rotating tool motor capable to turning conventional tools at at least 2,500 Revolutions Per Minute (RPM)

· Proposed VTL shall have an automatic door

4.3 Machine Capacity

· Proposed VTL shall have a maximum turning diameter of 30” or more

· Proposed VTL shall have a maximum swing of 30” or more with swing over carriage of 15” or more

· Proposed VTL shall have a Z travel of 30” with a maximum work height over 27” with installed chucks

· Proposed VTL shall have a X travel of at least 18”

· Proposed VTL shall have a Z axis rapid traverse rate of at least 500 Inches Per Minute (IPM)

· Proposed VTL shall have a X axis rapid traverse rate of at least 300 IPM

· Proposed VTL shall a minimum of 1,300lb permissible weight with installed chuck

4.4 Machine Accuracy

· Proposed VTL shall have minimal spindle positional accuracy of .02 degrees with repeatability of +/-.010 degrees or better

· Proposed VTL shall have turret indexing repeatability of +/- .0005 degrees or better

· Proposed VTL shall have an X axis with a repeatability of .0001” or better

· Proposed VTL shall have a Z axis with a repeatability of .0002” or better

4.5 Machine Controller

· Proposed VTL shall have a Fanuc, Mazatrol, or Heidenhain controller

· Proposed VTL shall have conversational programming

· Proposed VTL shall include a post processor for Mastercam CAM software

· Proposed VTL shall have a .0001” minimum programmable increment

· Proposed VTL shall have common memory expansion slots(PCMCIA card or equivalent)

· Proposed VTL shall have USB port and Ethernet connection port

· Proposed VTL shall have a replaceable color LCD display

· Proposed VTL shall have a tool monitoring system

· Proposed VTL shall have programmable high-low chucking pressure

· Proposed VTL shall have rigid taping and continuous thread cutting

· Proposed VTL shall be compatible with current MTConnect systems or have provided software to remotely monitor machine operations in “real time”

4.6 Spindle

· Proposed VTL shall have programmable spindle indexing to .001 degrees

· Proposed VTL shall have a spindle rapid traverse rate of at least 50RPM

· Proposed VTL shall have at least a 2,000 RPM spindle

4.7 Turret

· Proposed VTL shall have a heavy duty turret capable of holding at least 12 tools with bi-directional tool selection

· Proposed VTL shall have live or static tools in all positions

· Proposed VTL turret shall be capable of accepting up to a 2.5” boring bar and turning tools with shanks up to 1” square

4.8 Additional Features and Components

· Proposed VTL shall include coolant system with a minimum pump pressure of 60psi and a minimum tank capacity of 50 gallons

· Proposed VTL shall include a chip conveyor with variable speed drive

· Proposed VTL shall include an oil skimmer

· Proposed VTL shall have a hydraulic tank capacity of at least 15 gallons

· Proposed VTl shall have a way lube tank capacity of at least 2 quarts

· Proposed VTL shall have a 3 color tower signal light

· Proposed VTL shall have an installed work light

· Proposed VTL shall include operation manual, maintenance manual, complete parts list and electrical schematics

4.9 Associated Tooling Included

· Proposed VTL shall include tool holders using readily available ER40 collets

· Proposed VTL shall include 3-Xaxis straight milling heads and 3-Z axis angular milling heads that can be positioned in any of the 12 turret locations. Rotary tool holders to accommodate thru spindle coolant.

· Proposed VTL shall include 2-ER40 Collet chuck adapters, 1-1” End mill holder, 1-3/4” shell mill adapter, 1-Face tool holder, 4-OD turning tool holders, 4-U-Drill bushings(1”,1.25”,1.5”, 2”), 6-ID bushings (.63”,.75”,1”,1.25”,1.5”,2”),3-U-Drill cap, and 6 ID tool holders

· Proposed VTL shall be supplied with 24” 3-jaw chuck and a 15” 3-jaw chuck with included hard jaw and soft sets for each

5. INSTALLATION

The contractor shall complete installation of the VTL within 180 days of award. NIST will supply any required air and electrical service as specified by Contractor. All transportation, rigging, and setup shall be the sole responsibility of the successful Contractor. The machine shall be delivered and installed in Building 304 at NIST, Gaithersburg, Maryland.

6. TRAINING

Training shall be provided by the Contractor, for up (3) NIST Technicians. The training shall include instructions on

a) Overall machine construction and routine of the machine.

b) Programming and operation of the machine, all accessories and features provided.

All training will be located in Building 304 at NIST and completed within 30 days of of installation. The Contractor shall submit a program of instruction for their proposed training with their response to this RFQ.

7. WARRANTY

The entire machine, including all components and tooling, shall be warranted for a period of not less than 730 days days after final acceptance of the machine by the Government. The warranty period shall commence only after the machine has passed the performance tests and evaluations set forth in Section 3 and the machine has been accepted by the Government. All parts, labor, travel, and other expenses required to repair any machine equipment shall be borne by the Contractor, and all repairs performed at no cost to the Government. Any repairs made by the Contractor to resolve any equipment problems discovered during the warranty period shall be warranted for 365 days.

8. PERFORMANCE TESTS

As part of the machine installation, the Contractor shall check the accuracy of the machine and make any required adjustments or repairs to ensure compliance with the listed performance specifications.

The Government reserves the right to perform such performance tests and evaluations as deemed appropriate by the Government to verify specified machine performance in accordance with the standards listed in this document within 30 days after final installation. Such tests and evaluations, if performed, will be conducted within the environment that the machine is to be operated. The Contractor has the right to be present during the tests and evaluations, if performed, at the Contractor’s expense. Contractor-specified values for performance parameters submitted as part of their response to the RFQ shall be subject to testing in accordance with ANSI/ASME B5.57 or ISO 230 standards, where applicable.

9. OPERATION TESTS

The machine shall be operated by the Contractor in accordance with the Contractor’s standard operating test procedure for warm-up and run-off checks within 30 days of completed installation. The run-off checks shall include tests of all mechanical and electrical functions of the machine and controls to determine proper functioning in each mode of operation provided. The machine shall be cycled continuously for a period of not less than four hours to check response to commands for all numerically controlled machine functions and auxiliary functions. The commands shall include positioning of each axis separately and in combination, feed rate changes, and checks of manual overrides. Should a malfunction occur, the cycle shall be restarted until a full four-hour cycle is successfully completed.

10. FAILURE OF TESTING/EVALUATION

The Contractor may make reasonable repairs and adjustments to the machine should it fail any testing and evaluations. Repairs, adjustments, or modifications of the machine shall only be made with the Government’s approval. The 30 day evaluation period mentioned in Section 8 will restart after these repairs, adjustments, or modifications. The Government reserves the right to duplicate the tests specified above to determine acceptance.

11. SUMMARY OF DELIVERABLES

12. GENERAL INFORMATION

Security: NIST is a restricted campus. An identification badge is required for access for entry into buildings and also is shown to the armed Security Police when entering the campus.

Identification Badges: Contractor employees shall comply with NIST identification and access requirements. The Contractor employee is responsible for absences due to expired identification and access documents. Each Contractor employee shall wear a visible identification badge provided by the NIST Security Office. The badge must show the full name, title, and if required by NIST, the words “Contractor” in front. The Contractor employee shall turn in the NIST identification badge and vehicle pass to the TPOC, COR, or Contracting Officer (CO) upon termination of their services under this contract.

Vehicle Registration: All Contractor employees must register their vehicles with the NIST Security Office to gain access to the campus. A valid driver’s license, Government-furnished civilian ID, proof of insurance and current registration must be presented to the NIST Security Office, at which time a NIST vehicle pass will be issued. The pass shall be displayed on the vehicle’s rear view mirror in accordance with instructions. The Contractor employee shall follow NIST procedures for removal and turn-in of the vehicle pass upon termination of services under this contract.

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