14-16-1015_PD_FINAL_(13SEP16).pdf

VIBB 14-16-1015

13 September 2016

Purchase Description for a CNC Milling Machine

1.0 SCOPE.

1.1 Scope. The purchase description set forth below describes the minimum requirements of the Government for a GROB 750 High Speed 5-Axis computer numerically controlled

(CNC) milling machine, which shall include all accessories and services as described herein.

2.0 APPLICABLE DOCUMENTS.

2.1 General. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government Documents.

2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

STANDARDS – FEDERAL

FED-STD-H28A: Screw Thread Standards for Federal Service (1994 Ed.)

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards (2015 Ed.)

(Application for copies should be addressed to the OSHA Publications

Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

DEPARTMENT OF DEFENSE

U.S. NAVY

OPNAV 5100.23G w/change 1: Navy Safety and Occupational Health Program

Manual (2011 Ed.)

(Application for copies of the OPNAVINST should be addressed to Office of the

Chief of Naval Operations, The Pentagon, Washington, DC 20350-2000 or to

Commander, Naval Safety Center 375 A Street Norfolk, VA 23511 or on the internet at http://www.public.navy.mil/navsafecen)

UNIFIED FACILITIES CODE (UFC)

UFC 3-301-01w/Change 1: Structural Engineering (2014 Ed.)

(Copies can be acquired at https://assist.daps.dla.mil/quicksearch)

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property

(2012 Ed.) Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems

Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://assist.daps.dla.mil/quicksearch)

2.2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

GOVERNMENT DRAWING: PE-21387F Machine Layout and Utilities Locations

FRCE Environmental Guide Spec

FRCE Work Restrictions

FRCEASTINST 5001.1: Access and Local Regulations Manual

(Applications for these documents should be addressed to the contracting officer)

2.3 Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. All documentation listed below is the minimum requirements. Any international documentation shall meet or exceed the listed documentation.

Aerospace Industries Association of America (AIA/NAS)

AIA NAS NA 979: UNIFORM CUTTING TESTS - NAS SERIES METAL

CUTTING EQUIPMENT SPECIFICATIONS - Rev 2 (2013 edition) http://www.public.navy.mil/navsafecen https://assist.daps.dla.mil/quicksearch https://assist.daps.dla.mil/quicksearch

(Applications for copies are available at www.aia-aerospace.org)

American National Standards Institute, INC. (ANSI)

ANSI B11.23- Safety Requirements for Machining Centers and Automatic, Numerically Controlled Milling, Drilling and Boring Machines (2002 edition)

ANSI/AGMA ISO 1328-1-B14: Cylindrical Gears - ISO System of Flank

Tolerance Classification - Part 1: Definitions and Allowable Values of Deviations

Relevant to Flanks of Gear Teeth (2014 Rev)

(Address application for copies to the American National Standards Institute, 11 West

42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME Y14.100-2013: Engineering Drawing Practices (2013 Rev.)

(Applications for copies should be addressed to ASME International Three Park

Avenue New York, NY 10016-5990 or www.asme.org )

International Organization for Standardization (ISO)

ISO 4413: Hydraulic Fluid Power-General rules and safety requirements for systems and their components (2010 Ed.)

ISO 4414: Pneumatic Power-General rules and safety requirements for systems and their components (2010 Ed.)

(Application for copies should be addressed to the International Organization for

Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 Volts Maximum) (2014

Ed.)

NEMA ICS 1: Industrial Control and Systems General Requirements (2015 Rev.)

NEMA ICS 6: Industrial Control and Systems: Enclosures (2011 Rev.)

NEMA MG 1: Motors and Generators (2014 Rev.)

(Application for copies should be addressed to the National Electrical

Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA) http://www.aia-aerospace.org/ http://www.asme.org/

NFPA 70: National Electrical Code (2014 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2015 Ed.)

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE EIA-267-C: Axis and Motion Nomenclature for Numerically Controlled

Machines (1990 Ed.)

SAE EIA-274-D: Interchangeable variable block data contouring, format for positioning and contouring/positioning numerically controlled machines (1979 Ed., 1988 Rev.)

(Application for copies should be addressed to: Society of Automotive Engineers 400

Commonwealth Drive, Warrendale PA 15096)

TECHAMERICA

TIA-232-F: Interface between Data Terminal Equipment and Data Circuit-

Terminating Equipment Employing Serial Binary Data Interchange (1997 Ed., 2012 Rev.)

(Application for copies should be addressed to: TECHAMERICA, 601 Pennsylvania Ave., NW, North Building Suite 600 Washington D.C. 20004-2650)

2.4 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

3.1 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.

3.1.1 New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer in order that the new developments may, at the Government's option, be included in the equipment.

Reports of such developments shall be addressed to the Contracting Officer.

3.1.2 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the inch/pound system.

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

3.1.4 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

3.1.4.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per

ANSI B11.23. The safety devices shall not interfere with the operation of the 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.

3.1.4.2 Machine Enclosure. The machining area shall be fully enclosed and have two (2) sliding doors to allow access to the work table. The system shall have an interlocking safety system to prevent entrance to the machining area during machine operation.

3.1.5 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 85 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 a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 85 dB requirements.

3.1.6 Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.1.7 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

3.1.8 Lead. Lead and materials containing lead shall not be used on or in the machine.

3.1.9 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl

(PCB) on or in the equipment is prohibited.

3.1.10 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.11 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. Shall a low oil condition occur, the machine shall enter a machine stop condition upon completion of the current operation. All oil holes, grease fittings, and filler caps shall be accessible. All oil reservoirs shall have drains and sight gages.

3.1.12 Replacement Parts. 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.

3.2 Construction. The 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 machine to its maximum rating and capacity without distortion.

3.2.1 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.

3.2.2 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.

3.2.3 Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein.

3.2.4 Gears. All gears of axis drive trains shall conform to or exceed all provisions of flank tolerance ISO 1328-1: class 7 in accordance with ANSI/AGMA ISO 1328-1-B14.

The gears shall be of proper width and size to transmit full-rated torque and horsepower without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel. Working surface hardness shall be not less than Rockwell 48 C scale.

3.2.5 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.

3.2.6 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.

3.2.7 Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

3.2.8 Workmanship. Workmanship of the 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.

3.3 Components. The CNC Milling Machine shall consist of not less than the following:

3.3.1 Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

3.3.2 Linear Axis Feed Drive. All linear machine slides shall be provided with position and velocity feedback devices forming a closed loop servo system. These shall conform to the NEMA ICS 1. The longitudinal and traverse motion shall be accomplished under numerical control. The feed drive mechanisms shall consist of infinitely variable AC servo motors, coupled to precision, pre-loaded, hardened and ground, anti-backlash type, ball screw and nut assemblies. Slide movements shall be controlled simultaneously and independently as programmed for various machining processes. Friction in the pre-loaded ball screw and nut assemblies shall not excessively load the feed motors under normal cutting operations for which the machine is designed. A positive means of lubrication shall be provided for the ball screw and nut assemblies. Ball-screws and nuts shall be shielded from contaminants and cutting debris by a method of the manufacturer's standard. All measurement transducers shall be precision glass devices with a minimum accuracy of 5.0 micrometers (linear).

3.3.3 Machine Axes. Axes shall be machined to accept way bearings of a precise fit to their respective ways. The way bearings shall be antifriction type and shall be provided with adjustable gibs, guides, or bearings to maintain and adjust alignment of the table to the ways and prevent causing excessive loading of the feed drive motor. Antifriction, re-circulating ball type linear ways are acceptable. Axis description shall conform to SAE-EIA-267-C - Axis and motion nomenclature for numerically controlled machines.

3.3.4 Safety Stops. All machine motions shall be provided with a means of over-travel protection to prevent damage to the machine’s power feed mechanisms in the event the machine is inadvertently fed or rapidly traversed into an over-travel limit switch. The machine shall have on all axes programmable travel limits and control-activated axes inhibit functions to prevent damage to the machine tool.

3.3.5 Operator’s Console. The machine shall be equipped with an operator’s console.

The console shall consist of at least, but not limited to, the following: Emergency Stop, Machine Start/Stop, Color Display with a Full Alphanumeric Keyboard, Handheld Pendant

(see para 3.3.6), and Machine controller interface.

3.3.6 Handheld Pendant. A handheld pendant control shall be provided to give the operator the capability of manual positioning control of all axes at selectable feed rates.

The pendant control shall be connected to the machine to enable the operator to control machine functions while in a close observation position. The control pendant functions shall include at least, but not limited to, the following:

a. Emergency Stop

b. Machine Stop

c. Axes Jog

d. Axes Positioning by Electronic Hand wheel

3.3.7 Controller Features. The machine controller shall consist of the latest Siemens

840D sl CNC Controller, incorporating all standard features. Controls shall conform to

SAE EIA 274D.

a. Additionally, the controller shall include a minimum of a 10” liquid crystal display (LCD) monitor.

b. Controller shall incorporate a local area network (LAN) port and a universal serial bus (USB) port with for data input/output.

c. The CNC unit shall provide automatic control of machine functions, operating modes, axis movement and other part program directed functions for the type machine specified herein.

d. Movement in all axes shall be independent and shall be capable of independent positioning. In addition the axes shall be capable of full simultaneous control to machine parts using five (5) axes control.

e. All axes movement shall be programmable. Control features shall include at a minimum manual data input (MDI), simultaneous control of five (5) axes, part program and buffer edit capability, part program storage, fixed cycles, and control diagnostics to at least board level.

f. The CNC shall direct machine functions from command data stored in memory.

g. The data stored in memory shall be input by the media specified herein.

h. The control shall initiate a halt or error signal should a fault condition occur in the control.

i. All necessary executive program routines shall be furnished in the form of

CD ROM.

j. Control resolution shall be min 0.0001inches for each linear axis.

k. Control resolution for each angular axis shall be 0.001 degrees.

3.3.7.1 CAD/CAM Post Processor and Simulation Software. The contractor shall provide a GibbsCAM post processor that is fully compatible with the CAD/CAM system, to be delivered with the equipment for creation of all machine programs. The post processor shall produce working programs for the machine tool required in the document from drawings created in the CAD/CAM system. The machine simulation software shall be included for safe testing of the program before execution. Testing of the post processor is the sole responsibility of the contractor. The post processor shall utilize all functions of the equipment (i.e. simultaneously utilizing ALL axes at the same time for machining, drilling, tapping, pocket milling, rough milling, etc…). The contractor shall utilize the post processor to create the machine program for the tests. Any and all damage/s from testing/prove out, of the post processer shall be the sole responsibility of the contractor and all repairs shall be made by the contractor at their expense. This working post processer shall become part of the final acceptance testing and witnessed by the Government. The final acceptance shall not be completed until a fully functioning post processor is demonstrated. Demonstration by the contractor involves designing/drawing a component or part using GibbsCAM 3D part model (utilizing the new laptop that will be procured for this machine) and machining a sample part provided by the Government utilizing all functions and tolerances of the equipment. The Government will under no circumstance change, modify, or test the post processor for functionality.

3.3.7.1.1 Network interface. An Ethernet network interface shall be provided with the machine to archive results and component programs to the facilities intranet system. The network interface shall comply with TIA/TIA RS-232F.

3.3.7.1.2 Network Cabling. The milling machine shall be directly connected to the local

DNC system using appropriate Ethernet cabling. The CAD/CAM Workstation shall also be directly connected to the local DNC system. Both of the network connections shall be independent of each other and connect without means of a gateway to the local switching hub. The contractor shall be responsible to make connections to the local switching hub in compliance with NFPA 70, NFPA 79, and INSTALLATION OF

TELECOMMUNICATIONS NETWORK(S) AND INFASTRUCTURE

3.3.7.2 CAD/CAM Laptop Computer. The contractor shall supply a Dell Precision

M6800 laptop computer or equal to with the following minimum features:

a. Windows 10 Professional, 64-bit (English) Operating System

b. Intel® Core™ i7-4910MQ (Quad Core 2.90GHz, 3.90GHz Turbo, 8MB 47W, w/HD Graphics 4600)

c. 32GB (4x8GB) 1600MHz DDR3L Random Access Memory

d. Nvidia® Quadro® K5100M w/8GB GDDR5 Graphics Adapter

e. 2.5" 500GB Solid State Hybrid Drive

f. 500GB 2.5" 7200rpm Hard Drive

g. 8X DVD+/-RW Drive Tray Load Optical Media Drive

h. Intel® Dual Band Wireless-AC 7260 802.11ac/a/b/g/n 2x2 Half Mini Card +

Bluetooth 4.0

i. US Power Cord

j. English Shipping Docs

k. 5 Year Basic Hardware Service with 5 Year NBD Limited Onsite Service After

Remote Diagnosis

l. Smart Card Reader (Contact Only, No Contactless Smart Card Reader) and No

Fingerprint Reader Palmrest

m. 9-cell (97Wh) Lithium Ion battery with ExpressCharge™

n. Smartcard Reader Base

o. 17.3" UltraSharp™ FHD(1920x1080) Wide View Anti-Glare LED-backlit with

Premium Panel Guarantee

p. Dell UltraSharp 24 Monitor - U2414H

q. Intel® Core™ i7 Processor Label

r. Dell Applications for Windows 10

s. 240W AC Adapter

t. TAA Shuttle

u. Dell Backup and Recovery Basic

v. E-PRT Plus, APR,USB 3.0 (Docking Station)

3.3.9 Coolant System. A flood type coolant system shall be provided. The coolant system shall include a sump or reservoir, a power driven pump, and all necessary piping.

The system shall have means for draining, cooling, and cleaning. Means shall be provided to permit the operator to direct and control the amount of coolant over the entire work area.

3.3.9.1 High Efficiency Particulate Air (HEPA) Mist Collector. A HEPA mist collector shall be provided with the machine. The filters located inside the HEPA system shall be easily accessible for maintenance.

3.3.10 Chip Conveyor. The machine shall include a chip conveyor system that removes chips from machine area, separates out the coolant and sends coolant back to reservoir.

3.3.11 Hydraulic System. The hydraulics system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.3.12 Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.3.13 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 480VAC, 3PH, 60Hz. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete.

This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. The disconnect switch shall be installed adjacent to the motor controller to serve as a primary disconnecting means for equipment. It will be used to turn on/off power fed from branch circuit breaker to motor controller. The disconnect switch shall be sized to carry the entire electrical load and lockable.

3.3.13.1 Arc Flash. All electrical enclosures shall be marked for arc flash hazard per

NFPA 79.

3.3.13.2 Motors. Motors shall be rated for continuous duty. 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 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. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3.13.3 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capacity. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.13.4 Electrical Enclosure(s). Construction of the electrical enclosure(s) shall conform to NEMA ICS 6 standards. The enclosure(s) shall be a NEMA 250 type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 and 2 standards. The main electrical cabinet shall be atmospherically controlled with an air-conditioning unit, controlling humidity and temperature Per UFC 1-200-01.The Electrical cabinet shall have a provision for removing the condensate to a sanitary sewer drain or return to the coolant tank.

3.3.13.5 Work Light. An LED work light shall be provided. The light shall comply with

NFPA 79 requirements, have a protective shield and be adjustable to reflect maximum light on the work area. If a built-in lighting system is provided, the adjustable light described above shall not be required.

3.3.13.6 Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70. Facility connections (i.e. electrical conduit runs, piping, etc.) shall not interfere with overhead bridge crane and/or hoist operation.

3.3.13.7 Labeling. The contractor shall provide 3” x 5” (H x W) engraved identification placard for new fusible safety disconnect switch, transformer, and motor controller with the following information: equipment name, volt, amp, hertz, and power source feed from.

Placard shall be black lettering on a white background and attached to the center of the motor controller and disconnect switch cover with rivets. Also, provide all power feed information if the motor controller has multiple power sources (120VAC, 208VAC, and

480VAC etc.).

3.4 Size and Capacity. The size and capacity of the CNC Milling Machine shall be not less than specified in Table I.

Table I

Characteristic Capacity/Range

Table Size (Pallet) 31″ × 31″

T-Slots Pallet Tapped hole Grid pattern or std. T-slots

X-Axis Travel 39″

Y-Axis Travel 43″

Z-Axis Travel 46″

A-Axis (Trunnion) Rotation Degrees

225° (-180°/+45°)

B-Axis (Pallet) Rotation Degrees +/− 360˚ (0.001º increments) continuous

Spindle 0-16,000 rpm variable/controllable with torque of 150 ft-lbs.

Spindle Taper HSK 63

Feed Rate Travel Speeds

X-Axis 0.01-375 in/min

Y-Axis 0.01-375 in/min

Z-Axis 0.01-375 in/min

Distance From (A-Axis)

Table Center to spindle nose when (A-

Axis) is horizontal (0°)

3.35” to 49.4” (46” Z-axis stroke)

Table Surface to spindle nose when (A-

Axis) is vertical (-90°)

7.7” to 53.7” (46” Z-axis stroke)

Table Surface to spindle axis when (A-

Axis) is horizontal (0°)

-13.3” to +30” (43” Y-axis stroke)

Table Center to spindle axis when (A-

Axis) is vertical (-90°)

-17.7” to +25.5” (43” Y-axis stroke)

Automatic tool changer 60 place tool holder

Chip to Chip time 4.0 sec.

3.5 Accuracy Tolerances. The accuracy tolerances of the CNC milling machine shall be as specified in Table II.

Table II

Characteristic Tolerance

Positioning Accuracy

X-Axis ±.0003in

Y-Axis ±.0003in

Z-Axis ±.0003in

A-Axis 10 arc seconds

B-Axis 10 arc seconds

Repeatability Accuracy

X-Axis ±.00015in

Y-Axis ±.00015in

Z-Axis ±.00015in

A-Axis 5 arc seconds

B-Axis 3 arc seconds

3.6 Tooling. The following tooling shall be provided with the equipment. Please note that the part numbers provided are from the Jergens® Catalog and the Tungaloy® Catalog and are used for identification purposes. Other brands of tooling may be substituted as long as they meet the same specifications of the P/N’s in the Jergens® Catalog.

QTY. Nomenclature Jergens Part Number

2 5-Axis Subplate, Square 5SP500S

2 5-Axis Risers, Bargell Style, Steel 5RS130003

1 5-Axis Risers, Rectangle, Steel 5RS150001

3 5-Axis Riser Top Plates, Round 5TP130002

3 5-Axis Vise Adapter Plates, Round 5VA250001

3 5-Axis Top Tooling-Pallet Changer, Round 5QP130002

16 Pull Studs for use with Top Tooling-Pallet

Changer

N/A

3 5-Axis Top Tooling-Self Centering Vise 80100

8 Soft Jaw for Milling Workpiece Contours 80115

3.6.1 Tool Balancer. A tool balancer shall be included with the machine for precision balancing of the milling cutters due to the high RPM’s (15,000). This will ensure the longevity of the high speed spindle. This also improves the surface finish of the parts being manufactured. The surface finish is critical in the production of aircraft parts due to stress risers. The balancer shall balance the rotating cutters to within a measuring accuracy of <

0, 5 gmm. There shall be an adapter for HSK tools included with the machine.

3.6.1.1 Tool Balancer Training. Training shall be for three (3) operators for full control and understanding of the operation of the balancer, and shall be from an English speaking instructor. A minimum of two (2) full eight (8) hour days of training shall be given between the hours of 6:30am and 3:00pm Mon-Fri.

3.7 Marking on Instruments, Control Panels, and Plates. All words on 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.

3.7.1 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

3.7.2 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

Date of manufacture

3.7.3 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. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

3.8 Technical Data. One (1) hard copy and two (2) electronic copies of technical data shall be provided with the machine. All copies of technical data shall be legible and written in the English language.

3.8.1 Machine Manuals. Machine manuals shall contain technical information, specifications, instructions for the operation and maintenance of the machine and all associated accessories. The manuals for the machine shall include the full detailed electrical schematic and diagrams along with any pneumatic drawings. The manuals shall include all disassembly and reassembly procedures to repair the machine. The manuals shall include detailed drawings of assemblies so as to be able to disassemble the machine and repair it, placing it back in service. The maintenance manuals shall be comprehensive as to be able to fully diagnose and repair the machine back to factory operating conditions.

3.8.2 Installation Drawings.

3.8.2.1 Preliminary Installation Drawings. Preliminary Installation Drawings shall be provided during the Post Award Conference (see paragraph 3.9.5) for review. Contractor shall submit installation drawings which include physical dimensions of the machine, supporting equipment, and accessories with required placement dimensions in relation to the main machine components and in relation to the features of the area of the building, as well as all foundation drawings. Contractor drawings shall include all utility requirements

(i.e. electrical, air, etc. ). Electrical requirements provided by contractor shall include voltage, current, phase, and frequency, full load amps, and any other information applicable to connecting the machine. Minimum compressed air requirements provided by contractor shall include pressure, flow, and any other information applicable to connecting the machine. The Government shall have fifteen (15) days to review and return the preliminary drawings to the contractor with comments and/or approval. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period. The Government shall notify the contractor in writing within fifteen (15) working days of receipt of drawing if they comply with this specification.

3.8.2.2 Final Installation Drawings. Final installation drawings shall be submitted by the contractor within (15) working days after Government approval of preliminary drawings.

These final drawings shall bear a complete title block with a permanent drawing number, signature, date, and an original stamp. In addition, the machine foundation drawings shall be certified by a North Carolina Professional Engineer (P.E.) and submitted to the contracting office.

3.9 Installation. The contractor shall be responsible for the complete installation of the machine. This shall include, but is not limited to, any required demolition and removal of equipment/materials no longer needed as well as foundation and installation of all components and systems. The contractor shall provide all labor, services, materials, and material handling equipment to complete the installation including, but not limited to the following: off-load and load trucks; deliver new equipment/materials to a designated area outside/inside building; install the equipment and perform start-up and testing to ensure that the complete machine is fully operational. The premises shall be kept neat and clean, satisfactory to the receiving activity. See attached “Installation Responsibilities” sheet for clarification of Installation Responsibilities.

3.9.1 Space Constraints. The equipment shall be designed and positioned allowing access to all serviceable components. Available space for installation of the equipment is shown on FRC East Drawing PE-21387F sheet 6 of 9. Machine height restriction is 13 feet 6 inches above floor finish height to allow crane hook access to machine centerline. The envelope of the machine shall include all equipment, machinery, controls, guards, and complete operator footprint. The vendor shall provide a Computer Aided Design (CAD)

File of the requested end item, to be submitted with the proposal in a .dwg or .dxf format.

The data shall be supplied on a computer grade Compact Disc(s) (CD) Read Only Memory

(ROM). The CD ROM shall be readable by an IBM-compatible PC running Microsoft

Windows 2007 or later operating system. The electronic format shall be compatible with

AutoCAD .dxf format. The CAD file shall show footprint of new equipment to include ancillary pieces, utility connection points, access doors and required maintenance clearance dimensions. CAD file shall also show side and elevation views. File will be used by the government to verify equipment will fit into allotted space prior to award. The vendor shall also provide one (1) set of "hard copy" drawings. The vendor shall apply ASME Y14.100-

2013 and drawing standards.

3.9.1.1 Government use of Contractor Supplied Drawing (Riggers use). After contract award, the government will provide Rev.A of drawing PE-21387F using vendor supplied dimensioned CAD file of new machine, all ancillary equipment and all required utility connections and clearance requirements. Electronic file shall be compatible with AutoCAD

.dxf format. Auto Cad saved in .dwg format is compatible. This drawing revision shall be used by the vendor riggers to position and orient the new machine. It shall be the vendor’s responsibility to position the machine foundation to obtain the dimensions of Rev. A.

3.9.2 Removal. Existing Toyoda 5 Axis milling machine and all ancillary pieces of equipment associated with the Toyoda shall be removed from the shop by the contractor.

Please reference drawing PE-21387F for details on removal. Material removed shall be properly disposed of per FRCE Environmental Guide Spec. In addition, any existing utilities that will no longer be needed shall be disconnected and properly secured. If any utilities are required to be shut down for any period of time, the customer requires minimum 10 days notice before any action is taken.

3.9.3 Foundation. The contractor shall be responsible for the installation of the foundation in accordance with contractor provided installation/foundation drawings (see paragraph 3.8.1). The contractor shall remove the old concrete, excavate dirt and remove from the customer facility, and pour new concrete foundation.

3.9.4 Connection to Utilities. The contractor shall only use a licensed electrical contractor licensed by the State of North Carolina (SNC) or recognized by the SNC. Power source and compressed air utilities will be available onsite. Contractor shall make all utility tie-ins. Interruptions of utility services (electrical and pneumatic) shall be kept to a minimum and at such times and duration as agreed and coordinated with the facility. Electrical construction materials and techniques shall comply with the applicable sections of the

National Electric Code, NFPA 70. The contractor shall be responsible for the complete electrical installation of the equipment including electrical service from power panel to new equipment as shown on FRC East Drawing PE-21387F in Section 2.2.2. Any power outage request shall be submitted two (2) weeks in advance for FRCE Production management approval.

3.9.5 Post Award Conference. A Post Award Conference (PAC) shall be conducted at customer facility after award of contract. Representative(s) from the contractor’s plant who are familiar with both the equipment to be furnished and the requirements of the specification shall attend the PAC. During the PAC a Plan of Action and Milestone

(POA&M) chart shall be submitted to the Government in hard copy and electronic format

(Microsoft Project) (see paragraph 3.9.5.1). Other items that shall be discussed are the contract and all requirements regarding regulatory compliance, equipment, layout, delivery, demolition, installation, disposal, training, and warranty.

3.9.5.1 Plan of Action and Milestones. A Plan of Action and Milestones (POA&M) shall be provided by the contractor at the Post Award Conference and an updated POA&M (30) calendar days before start of installation. During installation, the contractor shall provide updates if dates change from last POA&M provided to the customer POC.

3.9.6 Contractor Responsibility. The contractor shall not utilize U.S. Government personnel, facilities, equipment, or consumable materials for any task related to the paid service provided, except as specifically identified and authorized by the contract.

3.9.7 Tool and Material Controls. All tools used on the job shall be marked with the name of the owner or the company. Please see paragraph 2.3.15.6 in “Fleet Readiness

Center East Work Restrictions” attachment. Also, all other requirements of the “Fleet

Readiness Center East Work Restrictions” attachment shall be followed during installation.

4.0 QUALITY ASSURANCE.

4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the

Government. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Contract quality assurance inspection (Origin) (see 4.4).

b. Final Inspection/Acceptance test (Destination) (see 4.5).

4.3 Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions between 55° F to 100° F and 10% to 95% relative humidity.

4.4 Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. Quality assurance inspection shall consist of the examination in 4.6 and the tests in 4.7. The machine shall pass the examination, all tests, and the contract quality assurance inspection to be acceptable for shipment.

4.5 Final Inspection/Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the machine to ensure conformance with this purchase description. The acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of the examination in 4.6 and all tests in

4.7. The machine shall pass the examination, all tests, and the final inspection to be accepted.

4.6 Examination. The machine shall be examined to determine compliance with all requirements of this purchase description.

4.7 Tests. All disks, instruments, materials, and tools required to perform and evaluate the tests shall be furnished by the contractor unless otherwise specified. The contractor shall demonstrate that the machine and all associated equipment performs as required herein using the contractor’s standard test procedures, provided these tests demonstrate all performance requirements stated in this purchase description (see paragraph 3.8.3). If the contractors standard test procedures are not approved (see paragraph 3.8.3) or do not fulfill any of the test requirements below, the contractor shall be required to perform the tests in this paragraph.

4.7.1 Accuracy Tests. Tests shall be conducted to ensure the machine meets the

Accuracy Tolerances specified in paragraph 3.5, Table II. During accuracy testing the machine shall be ran in each mode of operation (Manual and Automatic) to test the machine’s control functions and response to command data. The machine repeatability and accuracy for slide motions, tool changing, spindle speed changes, feed rate changes and auxiliary functions shall be checked. The safety limit stops shall be checked by attempting to exceed the limits of travel in all axes.

4.7.2 Operational Test. The machine shall be operated at no load for not less than four

(4) hours. Proper operation of all axis, components, controls, motors, adjusting mechanisms, and accessories shall be verified during the trial period.

4.7.3 NAS Test. The machine shall demonstrate compliance with AIA/NAS-979 Uniform

Cutting Tests - NAS Series Metal Cutting Equipment Specifications paragraph 4.3.3.5.1.

but cutting two (2) identical parts. The contractor shall provide all tooling and material necessary to perform tests as specified in paragraph 4.3.3.5.1 of NAS 979. The machine shall also pass Practical 5-Axis cone test, and a Traverse Tilt Test. All dimensions shall be checked using a certified CMM. Each part shall not deviate from the standards listed in the NAS 979. The report shall be given to the Government and reviewed for accuracy before final acceptance.

4.7.4 Performance Test. Two identical parts shall be machined utilizing 3D Gibbs Cam designed 3D part and a program created with the fully functioning Post Processor provided by the contractor (see paragraph 3.3.7.1). The material shall be mild steel (4140) or equivalent and shall be provided by the contractor. Test shall produce a part using the full

5 axes of the machine and contain several diameters, milled slots, flats, helical milling, and rigid tapping. The testing shall prove the following:

a. Roundness: 0.001”

b. Concentricity of all diameters: 0.001”

c. Perpendicularity: 0.001”.

d. Squareness 0.001”.

e. Location of all geometry to within 0.001”.

All dimensions shall be checked using a certified CMM. Each part shall not deviate more than 0.001” from each other. The report shall be given to the Government and reviewed for accuracy before final acceptance.

INSTALLATION RESPONSIBILITIES

Government Contractor

( ) (X) a. Provide machine foundation in accordance with the

Manufacturer’s design requirements

( ) (X) b. Furnish labor and material handling equipment for off-loading and placing item on foundation

( ) (X) c. Provide and install anchor bolts and nuts

( ) (X) d. Set and rough level the machine on its foundation

( ) (X) e. Level and align machine

( ) (X) f. Connect machine to the provided utilities hook-up

( ) (X) g. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests

( ) (X) h. Provide and charge all systems with fluids in accordance with manufacturer's instructions

( ) (X) i. Material for performance testing at Government facility

( ) (X) j. Material for performance testing at Contractor's facility

GOVERNMENT RESPONSIBILITIES

( X ) Assure utilities hook-up is available.

( ) Government will connect utilities to the machine based on the contractor's accepted site drawings.

( ) Assign one mechanic (mechanical/hydraulic) and one maintenance mechanic

(electrical/electronic) to provide information and any additional materials for the contractor's representative during installation, verification, and initial startup of the machine.

(X) No work shall be performed by customer personnel when the contractor's representative is not in the immediate work area during installation, verification, and initial startup of the machine.

CONTRACTOR RESPONSIBILITIES

( ) If installed by customer, upon verifying and certifying the machine is correctly installed, demonstrate the operation and performance of the equipment. Verification of installation shall be included within the warranty.

Verification: The meaning of verification for the purpose of this contract is to assure that the items installed and/or connected by Government personnel are correct.