Amend.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT 1

1; CONTRACT ID CODE

I

PA

E OF PAGES

I

2. AMENDMENT/MODIFICATION NO. 3. EFFECTIVE DATE 4. REQUISITION/PURCHASE REQ. NO.

5. PROJECT NO. (If applicable)

0003 10/25/2016 16-20-1200

6. ISSUED BY CODE SPM4A8 7. ADMINISTERED BY (If other than Item 6) CODE I DLA Aviation ATTN: DSCR-VICA (Chanda Tyler I chanda.tyler@dla.mil) 8000 Jefferson Davis HWY Richmond, VA 23297-5372 Tel: 804-279-2805 FAX: 804-279-5948

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code) ft

9A. AMENDMENT OF SOLICITATION

NO.

SPM4A8-16-Q-0130

99. DATED (SEE ITEM 11)

08/31/2016

10A. MODIFICATION OF CONTRACT/ORDER NO.

D 109. DATED (SEE ITEM 13)

CODE I FACILITY CODE

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

[8J The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers D is extended, � is not extended.

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods:

(a) By completing items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment an each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment your desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DA TA (If required)

13. THIS ITEM ONLY APPLIES TO MODIFICATION OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

CHECK ONE A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT ORDER NO.

IN ITEM 10A.

D

D B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

D

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor D is not, � is required to sign this document and return ----- copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

See attached pages for additional information.

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 1 OA, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

159. CONTRACTOR/OFFEROR

(Signature of person authorized to sign)

NSN 7540-01-152-8070

Previous edition unusable

15C. DATE SIGNED

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

169. UNITED STATES OF AMERICA 16C. DATE SIGNED

(Signature of Contracting Officer)

STANDARD FORM 30 (REV. 10-83)

Prescribed by GSA FAR (48 CFR) 53.243

SPM4A8-16-Q-0130 Amendment 0003

Amendment is issued to update the following:

The following has been removed from the Purchase Description: 3.6.2 (d) Hoist. An electrically operated 2 speed hoist for lifting work pieces onto the work table shall be furnished. The hoist unit shall be floor mounted or machine attached. The hoist shall callable of lifting 3,000 lbs. The hoist and related equipment shall comply with the Navy Crane Center Regulations and requirements. The Government shall provide the Navy Crane Center Regulations and requirements.

Salient Characteristics for VIBB 16-20-1200 dated August 2, 2016 will now be replaced with Salient Characteristics for VIBB 16-50-2115 dated October 26, 2016 (attached).

Questions:

(1) Can we have a plant layout showing the dimensions of the existing foundation at the location where the new machine will be set?

Answer: See attachment for copy of the footer

(2) What is the trade name and specification number of the paint we must put on the floor where the wall is removed?

Answer: Contractor will be required to use a variety of Tennant paint coating materials for all floor painting. ECO-HTS, ECO-MPE and ECO-Hard-N-Seal will be primary coating materials for the shop area;

however, other Tennant floor painting products can be used if approved by the government POC.

Coatings shall not have a lead content over .06 percent by weight of nonvolatile content. Coatings shall not contain zinc-chromate or strontium-chromate. Materials shall not contain asbestos, mercury, or mercury compounds. Coatings as applied will have VOC limits below 350 g/l for primers and below 420 g/l for topcoats.

(3) What is the existing electrical supply rating to the existing machine that will be taken out?

Answer: 300 amps

(4) Removal of non-load bearing wall. (95’ long x 32’ tall) – what material is the wall? Concrete block or wood?

Answer: The wall is concrete block.

(5) Existing floor where the machine will sit. Is it concrete or reinforced concrete? What is the depth?

What is the soil compaction underneath?

Answer: The floor is 3 feet thick reinforced concrete. It held a large Vertical CNC lathe. It should be more than adequate for this grinder

(6) Placement of the new machine. Is the area accessible without moving other machines?

SPM4A8-16-Q-0115 Amendment 0002

Answer: That will depend on your grinder and the way it is shipped. Should be enough room.

(7) Is a foundation required for this machine? We were told during the site visit that that we do not need to supply a foundation for this machine as they are removing a machine where the new grinder will be located at. The current foundation is more than adequate to accommodate the new grinder. Can you please confirm that a foundation for the new machine will not be necessary?

Answer: Based on the attachment provided, the size of the machine the foundation was constructed for a larger machine, therefore it does not appear that this project will require a new foundation.

No other changes to the original solicitation or amendment 0001 have been made.

End of Amendment

VIBB 16-20-1200

26 October 2016

PURCHASE DESCRIPTION FOR A CNC VERTICAL

GRINDER

1.0 SCOPE.

1.1 Scope. This purchase description specifies the minimum Government requirements for the procurement, installation, and training for a Computer Numeric Control (CNC) Vertical Grinding Machine, to be installed at the Fleet Readiness Center South East (FRCSE), Jacksonville, Florida. The contractor shall provide complete installation services as described herein and be responsible for the operation and interfacing of the end item systems. The machine described in this document is intended for use in the Aerospace Manufacturing and Repair Industry. The machine is to provide precision grinding, deburring, and measurement of the F-414 jet engine High Pressure Compressor (HPC). The machine shall perform contour grinding of the HPC segments, measurement of the ground segments and the checking of the alignment of the grinding fixture.

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 shall 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.)

(Copies of Federal and military specifications, standards, and handbooks are available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-0001)

CODE OF FEDERAL REGULATIONS (CFR)

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

(OSHA)

OSHA 29 CFR 1910: General Industry 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)

UNIFIED FACILITIES CRITERIA (UFC)

UFC 1-200-01 w/Change 2: General Building Requirements (2011 Ed.)

(The Unified Facilities Guide Specifications and the Military Handbook are available from the Whole Building Design Guide web site http://dod.wbdg.org/ )

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 listed in the solicitation or contract.

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.

2.3.1. Specifications, Standards, and Handbooks.

AMERICAN CONCRETE INSTITUTE

ACI 301 - Specification for Structural Concrete. (2016 edition)

ACI 304R - Guide for Measuring, Mixing, Transporting and Placing Concrete.

(2009 Rev.)

ACI 305R - American Concrete Institute, Hot Weather Concreting. (2010 edition)

ACI 306R - American Concrete Institute, Cold Weather Concreting. (2010 edition)

(Possible purchase sites; www.aci-int.org or http://www.concrete.org/general/home.asp, http://global.ihs.com) http://dod.wbdg.org/ https://assist.daps.dla.mil/quicksearch http://global.ihs.com/

AMERICAN GEAR MANUFACTURER'S ASSOCIATION (AGMA)

AGMA 2001-C95: Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. (2014 edition)

AGMA 2011-A98: Cylindrical Wormgearing Tolerance and Inspection Methods. (1998 edition)

AGMA ISO 1328-1-B14: Accuracy Classification System - Tangential Measurements for Cylindrical Gears (2014 Rev.)

(Application for copies should be addressed to the American Gear Manufacturers Association, 500 Montgomery Street, Suite 350, Alexandria, VA 22314-2560)

American National Standards Institute (ANSI)

ANSI B11.9: Machine Tools: Safety Requirements for Grinding Machines (2010 Ed.)

ANSI B5.1M: T-Slots, their Bolts, Nuts, and Tongues, Revision of ANSI B5.1- 1975 (1985 Ed., 2014 Rev.)

(Address application for copies to: American National Standards Institute, Inc. 25 West 43rd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME B5.48: Ball Screws (Rev. 2013)

(Applications for copies should be addressed to the 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) http://www.asme.org/

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

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

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

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

(Address application for copies to National Electrical Manufacturer's Association, 1300 N. 17th St., Suite 1847, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

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)

TECHAMERICA

TECHAMERICA EIA-267-C: Axis and Motion Nomenclature for Numerically Controlled Machines (1990 Ed.)

(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 catalogs 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. The offerer must provide with their offer proof of ability to grind F-414 jet engine components to General Electric (GE) Transportation Aircraft Engines specification required in solicitation.

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine shall be graduated in the U.S. Customary System of Units (US). All Measuring and Indicating device(s) shall be located to allow ease of reading for the operator.

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

3.1.3 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. Reports of such developments shall be addressed to the Contracting Officer in order that the new developments may, at the Government's option, be included in the equipment.

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. All system and operation standards shall comply with OSHA standards on Human Factors Engineering (Ergonomics).

3.1.4.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.9. 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 easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.5 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 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 84 dB requirements.

3.1.6 Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture with the exception of fluorescent lighting where required.

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 with the exception to radiation cladding and lead solder in circuits.

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 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. Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as chrome plating, galvanizing and other electrical/chemical process, or stainless steel is acceptable. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint.

Contact of dissimilar metals especially brass, copper, or steel in contact with aluminum or magnesium, shall be avoided. Where it is not possible to avoid contact of dissimilar materials, a suitable barrier shall be required for preventing electrolytic corrosion. Plating and galvanizing shall not be used in the enclosure where it can be exposed to coolant.

3.1.12 Lubrication. Means shall be provided to ensure adequate lubrication (oil, grease, coolant, etc.) 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 lubrication condition. When a low lubrication condition occurs the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required and the operator shall refill the lubrication reservoirs according to machine manuals. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.13 Slideways and ballscrews lubrication. A separate pump unit feeding positive displacement metering at lubrication points for the machine slideways and ballscrews shall be provided. The pump unit shall be provided with a monitoring feedback system for low oil level and pressure. The feedback system shall be interfaced to the CNC system, and display warning messages.

3.1.14 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 machine construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards (such as dust, debris, or residue) shall be sealed or otherwise protected. The structure shall withstand all forces encountered during the operation of the machine to its maximum rating and capacity without permanent distortion or failure.

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, either US or SI, used on the machine and its related attachments and accessories shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration.

3.2.4 Gears. All gears of spindle and axis drive trains shall conform to or exceed all provisions of AGMA 2001-C95, AGMA 2011-A98, and 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.

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 those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts. Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment. Any loose, spattered solder, flux, metal chips, insulation scrap or other foreign material shall be removed from the equipment. Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections.

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

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.

3.2.9 Human Engineering. The machine shall be ergonomically designed to reduce/eliminate injury to the operator while performing the task. All points of operation shall be easily accessible to the operator with minimal motion. There shall be no overextending conditions as to loading and unloading of work pieces that might cause back injury. The system shall be designed and manufactured to minimize the possibility of human error or injury and to ensure human/machine compatibility. Adequate access to support maintenance functions and maintenance personnel/equipment clearance to perform maintenance actions shall be provided as part of the installation.

3.2.10 Maintainability. The equipment shall be designed and constructed to permit Maintenance Personnel to easily service the equipment using a minimal number of tools.

All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair. Consistent with required maintenance and design of the equipment, the contractor shall provide any special tools required to service the unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair, or replacement of parts.

3.3 Components. The machine shall consist of but not be limited to the following described principle components, attachments, and accessories necessary to meet the operational and performance requirements specified herein. Any additional components necessary for the operation of the machine shall also be furnished in accordance with the manufacturer's standard practice. The machine shall be of a traversing horizontal slide configuration and shall consist of not less than a base and column, table, spindle assembly, tool changer, coolant system, hydraulic/pneumatic system, electrical system, stator measuring system, and computerized numerical control system. The machine shall be equipped with over-travel protection devices and limit switches for all slide motions. All castings are to be close-grained meehanite cast iron or equal.

3.3.1 Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize thermal and vibration effects, distortion, deflection, maintain accuracy, provide the strength and size to assure maximum rigidity and support for any load within the normal operating and load capacities for which the machine is designed and rated for. The base shall form a foundation for the entire machine and be constructed with the column machined and attached so as to be sufficiently rigid to maintain mutual component alignment for assuring accuracy required herein. The base shall incorporate a means of removing spent coolant. Fluid reservoir(s) shall be supplied as a separate external unit for coolant maintenance purposes. The base shall have means for securing and leveling the machine on a flat mounting surface. The base shall have access or removable plates as necessary for servicing components housed within. The base shall also provide for accurate, ease of leveling and anchoring.

3.3.2 Column. The column shall be an iron casting or equal, internally ribbed and braced to minimize distortion and deflection under normal tool loads. The column shall be of the sliding type, designed to support and accommodate the machining head and spindle drive mechanism. Column slides and screws shall be shielded and protected from foreign contamination by either telescoping or curtain type way covers and way wipers.

3.3.3 Spindle. The contractor shall design and provide a precision grinding spindle for grinding application on F414 HPC. The spindle shall be equipped with ultra-precision pre-loaded bearings and be precision balanced. A precision balanced AC motor shall be incorporated in the spindle. The spindle shall be designed and manufactured with good vibration damping characteristics. The grinding spindle shall be designed for operation in both an abrasive dust and wet environment.

3.3.4 Spindle swivel. The spindle swivel (B axis) shall be CNC driven with dual worm gears so the system can be preload electrically. The swivel shall be supported by roller bearing for maximum support. Positioning feedback shall be by direct mounted absolute rotary encoders. The system shall be seal from high pressure coolant (1,000 psi. or greater) intrusion by the use of seals and air pressure.

3.3.5 Table. The table shall be a casting of iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights and tool thrust loads. A direct drive AC servomotor, protected by table housing, shall provide the drive for the table. The table shall have eight (8) radial T-slots for fixture location. The size and configuration of T-slots shall be in accordance with ANSI B5.1M. The table and base shall be designed to preclude fluid intrusion into critical components with air purging. The table shall be configured to supply coolant though the center of table.

3.3.6 Tool changer. The tool changer shall be fully automatic, servomotor driven, and fitted with a position encoder. The automatic tool changer shall store not less than ten (10) tools. The storage magazine or tool turret shall permit loading and unloading of grinding wheels, coolant nozzles and part measurement probe. The tool changer shall be arranged for random tool selection, and shall reuse tools that have been returned to the magazine after a program operation. The tool changer shall be integrated into the machine control system together with tool identification coding.

3.3.7 Measurement system. Resolution, accuracy and repeatability in accordance with the requirements in 3.5, Table II. Data from the measurement system shall be stored in a database, and shall be downloaded to the printer.

3.3.8 Wheel dresser and holder. The machine shall be provided with a mounted wheel dressing unit. The dresser shall utilize a single point diamond and a motor driven diamond disc. Coolant shall be directed at the point of wheel dress, and switched on and off through the CNC unit in addition to the automatic cycle. Wheel dressing compensation shall be automatic, and the dressing cycles controlled by the machine CNC control. Programmable contour dressing of the grinding wheel shall be provided.

3.3.9 Machine Enclosure. The machine shall be fully enclosed and shall be manufactured of steel. The manufacturer shall minimize the panels that have to be removed for operator or machine maintanence personnel to perform routine maintance functions. The enclosure shall contain the coolant mist and isolate the grinding operation from the machine operator.

A wash down hose to clean part and inside of enclosure shall be provided.

3.3.10 Doors. Doors shall retract fully in front and overhead to allow full access to the work holding surface with an overhead crane. The machine shall have a device to keep the operators viewing window clear from coolant splash (a rotary spinning window is not acceptable). The doors shall be fitted with interlocks to prevent the operator from opening the doors during operation of the machine. The interlock shall be disabled during part setup to allow for movement of the table and axes. All components shall be designed to withstand the atmosphere within the enclosure without premature failure due to coolant contaminants.

3.3.11 Axes. The axes of the machine shall be actuated through a closed loop, high-gain electrical servo mechanism driving re-circulating ball screws and nuts. Infinitely variable feed drives shall be provided for all axes. Axes shall be machined to accept way bearings of a precise fit to their respective ways. All ball screws shall be of the double nut design meeting the requirements of ASME B5.48 Class 3, and equipped with seals to exclude foreign material and prevent loss of lubricant. Axis description shall conform to EIA-267- C.

3.3.12 Machine Ways. The ways shall be of a type suitable for high grade precision numerically controlled machines covered by this purchase description. Movement of the slides on the way surfaces shall be through adjustable preloaded, re-circulating roller bearing cartridges or nonmetallic way liners having a low coefficient of friction, with excellent slip-stick and damping properties. Protection of the machine ways shall be either telescoping or curtain type way covers with way wipers. 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.

3.3.13 Powered Rapid Traverse. Powered rapid traverse shall be provided for movement of all axes. The rate of rapid traverse shall be independent of any feed adjustment.

3.3.14 Coolant System. The machine shall be supplied with a complete flood type coolant system with CNC selection of on/off coolant flow. The coolant system shall be a three-stage system, with a cellulose filter. The contaminated coolant shall flow through the cellulose to remove ferrous particles and deposit grinding swarf in a hopper. The system shall contain power driven pumps, and all necessary piping to deliver at a minimum 6 to 120 GPM at pressures from 40 to 1500 psi of coolant. The sump or reservoir shall have a 700-gallon capacity to permit full flow of coolant. The system shall have means for draining and cleaning and shall include a baffle or a removable strainer for ease of cleaning. Means shall be provided to permit delivery of coolant onto each tool holder, allowing the operator to direct and control the amount of coolant to point of application. An air to water type coolant chiller shall be provided to maintain optimum coolant temperature of 68 degrees +/- 3 degrees.

3.3.15 Ventilation. The equipment shall be adequately cooled and ventilated to preclude premature deterioration of the equipment or any component thereof when utilized under the ambient and operating conditions specified herein.

3.3.16 Hydraulic System. If the design of the equipment requires hydraulics, the hydraulics system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

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

Overpressure protection shall be provided to prevent damage to components and air conductors. A filter system shall be provided to insure delivery of clean, dry air to the system.

3.3.18 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 480 Volt, 3 Phase, 60 Hertz (Hz) input power. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including 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 electrical system shall be complete with all accessories such as electric motors, conductors, controls, relays, transformers, and switches, pre-wired for operation upon connection to the main power source. All the equipment shall include, but not limited to, Busway plug-ins that are circuit breaker type, conduits, cabling, main breakers, distribution panel cabinets and branch breakers. All electrical enclosures shall conform to the requirements of NEMA ICS 6. Servo drives, overloads, contactor, etc., shall be mounted in a totally enclosed air-conditioned cabinet conforming of NEMA 250.

Secondary voltage shall be 110 Volts, 1 Phase, 60 Hertz for ancillary equipment.

3.3.18.1 Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 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 standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79. The electrical cabinet shall be atmospherically controlled with an air-conditioning unit, controlling humidity and temperature per UFC 1-200-01, condensate lines shall be plumbed to the coolant tank.

3.3.18.2 Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

3.3.18.3 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 capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.19 Computer Numerical Control (CNC). The machine controller shall consist of a Fanuc 32io series controller or newer, a fully automatic, solid state soft wired, integrated circuit, 64-bit RISC microprocessor based-type computer numerical control. The machine control unit (MCU) shall provide automatic control of machine functions, operating modes, spindle operation, tool change, and other part program directed functions for machines of the type specified herein. The controlled axes shall be identified in accordance with EIA-267-C.

Control features shall include linear and circular interpolation, manual data input (MDI), simultaneous control of axis, programmable interface, buffer storage, fixed cycles and buffer edit capability, and control diagnostics to at least board level. Position feedback for the linear axis (X and Z) shall be through heidenhain absolute linear glass scales, and the position feedback for tilting B axis and the rotary C axis shall be through high precision digital rotary encoder or rotary glass scales. The MCU shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein or MDI from the full American Standard Code (ASC) II keyboard. The control shall initiate a halt or error signal should a fault condition occur in the control. All necessary executive program routines shall be furnished in the form of Erasable Programmable Read-Only Memory (EPROM’s). A line voltage of plus or minus 10% from normal shall not adversely affect the numerical control system. The control shall be capable of functioning in ambient temperatures from 50 degrees to 120 degrees Fahrenheit (F) and humidity ranging from 5% to 95% percent non-condensing. The control shall automatically shut down if an over temperature condition shall be detected.

3.3.19.1 Computer control system. The shop floor computer shall be constructed for operation in an industrial shop environment, with the atmospheric conditions between 40 and 110 degrees Fahrenheit for temperature and the relative humidity between 20 and 95 percent, non-condensing. All control displays shall be provided on the monitor with input through the keyboard. Cycles for grinding and measuring required for the overhaul process of F414 HPC shall be provided. All machine program data and measurement results that the system generates shall be capable to be archived to a storage media. The CNC controller with incorporated Liquid Crystal Display (LCD) screen, keyboard and pointing device shall be located on a swing away pendent capable to movement to and away from the enclosure opening. The printer (see j. below) shall be positioned on a portable printer cart, which shall be interfaced and located near the controller. A sufficient length of printer cable to the controller shall be provided. The computer control system shall consist of, but not limited to, the following features:

a. MS Windows 7 or newer workstation operating system

b. Pentium Processor – 2.5 GHz or greater

c. 500 Gigabyte hard drive (minimum)

d. 4 Gigabyte Ram (minimum)

e. USB ports (2 each)

f. 17-inch color light Emitting Diode (LED) touch screen

g. Compact Flash card port for back-up storage (2 each 2 Gigabyte cards to be furnished)

h. Alphanumeric QWERTY style keyboard

i. DVD-ROM drive for program loading

j. Color inkjet graphics printer with large capacity ink cartridges

k. 10/100 Base-T Fast Ethernet

l. Ethernet adapter card and RS 232 port

m. Grinding/measuring program for F414 HPC

3.3.19.2 Computer software/firmware control system. The control system shall be capable of, but not limited to, the following functions:

a. Fault history log on Cathode Ray Tube (CRT) with date stamp

b. Linear & circular interpolation

c. Decimal point programming

d. Programmable dwell

e. Constant surface speed

f. Automatic zero referencing

g. Software travel limits

h. Work piece coordinate system

i. Graphics - two-dimensional (minimum)

j. Conversational programming

k. English/metric programmable and operator/programmer selectable

l. Offsets

m. Machine linear comp

n. Manual Data Input (MDI) capabilities

o. Positioning display - all axis

p. Linear feed display – ipm

q. Production part logging

r. Maintenance PM’s and logging to view trouble shooting guide and repair procedure on monitor

s. Modem link for PC to PC communication

t. Part program and storage of programs with data and results

u. Results from measurement system stored in result database

v. Controlled subroutines containing parameters:

(1) Plunge grind

(2) C Axis contour grinding

(3) Traverse grind

(4) Face grind

(5) Measurement cycle in-cycle dress

(6) Dress new wheel

(7) Contour wheel dressing

3.3.19.3 Operator Remote Pendant. The machine shall have a remote pendant or mobile operator main control panel to aid operator setup. 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 be limited to, the following:

a. Emergency stop

b. Cycle start

c. Mode selection

d. Feed hold

e. Feed rate override

f. Spindle speed override

g. Manual pulse generator capable of controlling individual axes

h. End of Block (EOB) stop

i. Incremental feed selection

j. LED for axis position and information

3.3.20 Maintenance Diagnostic System. Maintenance diagnostics software shall be furnished either in the control as nonvolatile memory or as a separate program that is compatible with the input media specified herein. The diagnostic software shall test, exercise, and display failures. The system shall monitor operating conditions and have an automatic means of rapidly stopping operations to prevent damage when malfunctions are detected.

3.3.21 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 in accordance with OSHA 29 CFR 1910 and NFPA 79. 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.

Hazardous energy includes electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy that could harm employees involved in servicing or maintenance of the equipment.

3.3.22 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 listing manufacturer, model number, 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). All motors shall have overload protection devices.

3.3.23 Work-light. A cold type 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. Where a built-in cold type lighting system is provided, the adjustable light described above shall not be required.

3.3.24 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. The contractor shall connect to the Government single-point drops and provide distribution and connection of the utilities to the machine tool.

3.3.25 Hour meter. The machine shall be equipped with a non-resetting type, analog hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type) shall be considered to meet this requirement.

3.4 Size and Capacity. The size and capacity of the machine shall meet the requirements of Table I. The machine shall conform to the minimum dimensions, sizes and capacities and shall be not less than the stated requirements nor greater than 10% over the stated requirements. When a range is given, the required performance shall be from the stated minimum or less to the stated maximum or greater.

Size and Capacity Table I

Physical size limitations shall not exceed (including guarding)

Characteristic Capacity/Range Length 24’ Width 20’ Height 20’

B Axis (angle swivel/pivot axis) Characteristic Capacity/Range

Spindle swivel range 180 degrees Speed (Programmable) 1 to 600 degrees / min

C Axis (Rotary Table & Drive) Characteristic Capacity/Range

Diameter of table 36" Table speeds infinitely (Programmable) 0-150 rpm Rotation / Travel Continuous Rotation (Programmable) CW & CCW Position (Programmable) 0 – 360 degrees Hold Downs 8 Tee Slots Load 4,000 lbs

X Axis (horizontal slide) Characteristic Capacity/Range

Horizontal “X” axis stroke 36" Axis feed rates (Programmable) 0 – 300"/min

Z Axis (vertical slide grinding wheel) Characteristic Capacity/Range

Vertical “Z” axis stroke 36" Axis feed rates (Programmable) 0 – 300"/min

Vertical Slide Measuring System Axis Characteristic Capacity/Range

Vertical axis stroke 27.5" Axis feed rates (Programmable) 0 – 300"/min Resolution 0.0001"

Grinding Wheel Spindle Characteristic Capacity/Range

Grinding wheel diameter 4" or 15” Grinding wheel motor 25 Hp Grinding spindle speed (Variable speed) 1500 – 15,000 rpm Spindle nose HSK 80

Wheel Dresser Characteristic Capacity/Range

RPM 0-3,600 rpm Disk diameter maximum 6.0” Width maximum 1.0”

3.5 Alignment and Accuracy Tolerances. The alignment and accuracy tolerances used for inspection of the machine shall be as specified in the following table.

Alignment and Accuracy Table II

Resolution Characteristic Accuracy Tolerance

Linear (X and Z Axis) ±0.0001"/12” Angular ±0.0002 degrees

Accuracy Linear (X and Z Axis) ± 0.0002”/12” Alignment Squareness (X and Z Axis) ± 0.0004”/12” B-Axis ± 5 arc seconds B-Axis Parallelism to X axis 0.0008”/12” B-Axis Parallelism to Z axis 0.0008”/12” Radial Table Run-out (C Axis) 0.0002” Axial Table Run-out (C Axis) 0.0002”

Repeatability Linear Axis Repeatability (X and Z Axis) ± 0.0002”/12” – 36” of travel B-Axis Repeatability ± 5 arc seconds

3.6 Standard Tooling and Equipment. All standard equipment required for proper operation of the machine (such as special tools needed for regular periodic maintenance) shall be furnished. A list of these items shall be provided at time of proposal.

3.6.1 Tooling. All tooling shall remain in the possession of the contractor until final acceptance at destination. At no time shall the contractor deliver any tooling, accessories or delivered machine parts to be signed for by the Government. The Government shall not at any time take possession of any items until final acceptance. The following F414 work holding tooling and the associated process tooling shall be provided:

a. Two (2) Part measuring stylus with roller - Roller/Feeler P/N DZ-100

b. Two (2) wheel adaptor(s)

c. Six (6) Grinding wheels for F414 stator grinding - Wheel ID CBNS4005, Wheel Shape

C1A1S, Specification B181-B128-V3F0

e. Two (2) 51606 Diamond Roll

f. One (1) 49912 Single Point Diamond Disk

g. Two (2) Part probe - Sony Probe, P/N DG10BPM

3.6.2 Optional equipment. The following items shall be a separate line item each and be each separately listed and priced under Section B of Contract.

a. Moisture/dust extractor system. A moisture fume/dust extractor system to permit observation of the internal enclosure during the part machining process shall be provided.

The de-misting system shall be a closed loop design, returning collected water to the water system at 900 CFM.

b. Laser tool probe. The laser probe shall check the diameter of the grinding wheel at grinding speed. It shall also check the wheel arbor for proper positioning before grinding part.

c. Work Platform. A work platform with guard rails and steps shall be furnished.

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. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. 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 available) Size and Type of Each Lubricant Filter

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