8072-3000_REVISED_SPECIFICATION.pdf

Purchase Description for

One (1) Vertical Machining Center

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a Vertical Machining Center. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification. The Contractor will be responsible for shipping the Vertical Machining Center to Puget Sound Naval Shipyard. The Government will Method 50 crate the machine and ship to Yokosuka, Japan where it will be installed and tested. THE MACHINE WILL NOT BE READY FOR FINAL LEVELING OR

TESTING UNTIL THE MACHINE IS INSTALLED BY THE GOVERNMENT IN

YOKOSUKA, JAPAN. GOVERNMENT INSTALLATION WILL TAKE A MINIMUM OF

ONE (1) YEAR FROM TIME OF DELIVERY AT PUGET SOUND NAVAL SHIPYARD.

2. REQUIREMENTS

2.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.2. Construction. The Vertical Machining Center 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 Vertical Machining Center to its maximum rating and capacity without distortion.

2.2.1. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

2.2.2. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

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

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

2.2.5. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

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

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

1910.303 and paragraph 1910.399.

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

2.2.9. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.23. The safety devices shall not interfere with the operation of the Vertical Machining Center. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

2.2.10. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at 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.

2.2.11. Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable.

Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. When a low oil pressure condition occurs, the machine shall enter an emergency stop condition. All oil holes, grease fittings, and filler caps shall be accessible. A lubrication plate shall be securely attached to the equipment, see 2.15.2.

2.2.12. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

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

2.3. Components. The Vertical Machining Center shall consist of not less than the following components.

2.3.1. Controller Features. The machine controller shall consist of a CNC Controller. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the Vertical Machining Center. Movement in the X, Y, Z, and W axes shall be independent and shall be capable of independent positioning. Control features shall include simultaneous control of four axes (X, Y, Z, and A), linear and circular interpolation, programmable interface, part program and buffer edit capability, part program storage, fixed cycles, and control diagnostics to at least board level. The CNC shall direct machine functions from command data stored in memory.

The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits.

2.3.1.1. Software Features. The CNC controller shall have the following software features:

a. DXF Transfer

b. NC/Conversational Merge

c. UltiPocket with Helical Ramp Entry

d. Auxiliary Graphics 2nd Screen w/ Shelf (19" screen)

e. Industry Standard NC

f. Swept Surface

g. Conversational Part Probing including canned cycles and centerline probing

h. Conversational Tool Probing

i. Solid model verification graphics

j. Interactive help system

k. Tool and material library

2.3.1.2. Operator’s Remote Pendent. The Vertical Machining Center shall have a remote pendant with an LCD display that allows for axis motion control through jog, incremental and manual pulse generator. An Emergency Stop Button, and a manual pulse generator shall also be provided. The pendant shall have enough cord to allow the operator to use the device from anywhere within the work envelope of this machine.

2.3.2. Rotary 4th Axis. The Vertical Machining Center shall come with a rotary 4th axis table.

The table shall have the ability to be mounted horizontally or vertically and be complete with all cabling and software to perform 4-axis simultaneous machining and meet the requirements in Table I.

2.3.2.1. Tailstock. The rotary 4th axis shall come with a compatible tailstock matching the rotary spindle to quill centerlines.

2.3.3. Surface Sensing Touch Probe. The Vertical Machining Center shall be equipped with a Renishaw RMP 600 high accuracy touch probe. The spindle probe shall be automatically changed from the tool storage area or loaded into the spindle manually.

2.3.4. Tool Measurement System. The Vertical Machining Center shall be equipped with a Renishaw RTS cable-free tool setting probe. The system shall automatically measure the tool tip length and diameter of any tool loaded into the automatic tool changer. The system shall identify the tool from the automatic tool changer magazine, calculate the delta between the measured tool length relative to the set zero Z-axis position and diameter, and adjust the tool’s associated tool offset registers without operator intervention.

2.3.5. Automatic Tool Changer (ATC). The Vertical Machining Center shall be equipped with an automatic tool changer (ATC) that meets the minimum requirements in Table I.

2.3.6. Kurt Vises. The following Kurt stationary machine vises shall be supplied:

a. 3400V, 4-inch wide jaw, 6-inch opening capacity, 7,500 lbs. capacity

b. 3600V, 6-inch wide jaw, 6-inch opening capacity, 6,356 lbs. capacity

c. D810, 8-inch wide jaw, 10-inch opening capacity, 11,596 lbs. capacity

2.3.7. Tool Holding, CAT 40. The following CAT 40 tool holders shall be provided:

2.3.7.1. Kennametal Collet Chuck Adaptors:

a. 1261619 CV40BER32275, ER-32, 0.08-inch to 0.787-inch capacity, 2-3/4 inch projection, through spindle coolant, 1 each

b. 1901045 CV40BER32600, ER-32, 0.08-inch to 0.787-inch capacity, 6- inch projection, through spindle coolant, 1 each

c. 1901019CV40BER16250, ER-16, 0.02-inch to 0.3937-inch capacity, 2-1/2 inch projection, through spindle coolant, 1 each

d. 1901046 CV40BER16500, ER-16, 0.2-inch to 0.3937-inch capacity, 5-inch projection, through spindle coolant

e. 2987306, TG 100, 5/64-inch to 1-inch capacity, 2-3/4 inch gage length, through spindle coolant, 1 each

f. 1261624 CV40BTG100600G, TG 100, 5/64-inch to 1-inch capacity, 6- inch projection, through spindle coolant, 1 each

2.3.7.2. Kennametal End Mill Adaptors:

a. 1026408, ¼-inch hole, 1-3/8 inch projection, through spindle coolant

b. 1026409, ¼-inch hole, 4-1/2 inch projection, through spindle coolant

c. 1026412, 3/8-inch hole, 1-3/8 inch projection, through spindle coolant

d. 1013350, 3/8-inch hole, 4-1/2 inch projection, through spindle coolant

e. 1026380, ½-inch hole, 1-3/4 inch projection, through spindle coolant

f. 1013374, ½-inch hole, 4-5/8 inch projection, through spindle coolant

g. 1026381, 5/8-inch hole, 1-3/4 inch projection, through spindle coolant

h. 1025923, 5/8-inch hole, 3-3/4 inch projection, through spindle coolant

i. 1026382, ¾-inch hole, 1-3/4 inch projection, through spindle coolant

j. 1025944, ¾-inch hole, 3-3/4 inch projection, through spindle coolant

k. 1013378, 7/8-inch hole, 1-3/4 inch projection, through spindle coolant

l. 1025945, 7/8-inch hole, 4 inch projection, through spindle coolant

m. 1026383, 1-inch hole, 1-3/4 inch projection, through spindle coolant

n. 1025946, 1-inch hole, 4 inch projection, through spindle coolant

2.3.7.3. Morse Taper (MT)Adaptors:

a. 1025949 CV40-MT2-244, 2MT, 2-7/16 inch projection

b. 1025950 CV40-MT3-300, 3MT, 3-inch projection

c. 1025987 CV40-MT4-338, 4MT, 3-7/8 inch projection

2.3.7.4. Drill Chuck:

a. Kennametal 3583505, DIN69871-40, 1mm to 13mm integral shank drill chuck

2.3.7.5. Boring Heads:

a. ETM 4550093, MB50 inside modular connection

b. Iscar 4550256, 80mm body diameter, MB50 connection, manual single cutter boring head

2.3.8. Kennametal Collet Sets:

a. 2269968, ER16, 12 piece, 1/16-inch to 13/32-inch, increments of 1/32-inch

b. 2269974, ER32, 23 piece, 1/8-inch to 13/16-inch, increments of 1/32-inch

c. 1288917, TG100, 59 piece, 3/32-inch to 1-inch, increments of 1/64-inch

2.3.9. Machining Area Enclosure. The machining area shall be enclosed to protect operating personnel from moving machinery and parts, cutting debris and fluid splash. The enclosure will be designed to efficiently contain and channel coolant for recirculation, as well as, cutting debris to the chip conveyor. Adequate door panels with safety rated windows shall be provided to allow for operator egress during machine set-up and the mounting of work pieces by overhead crane and for pallet changing. Safety interlocks shall be provided to disable machine operations with the doors in an open position. The enclosure shall be constructed so that when attached to the machine, it does not encumber or interfere with any loading, machining, or unloading operations.

2.3.9.1. Enclosure Lighting. The equipment shall include a minimum of two (2) LED lights to illuminate the work envelope. The lighting shall comply with NFPA 79 requirements, and have a protective shield.

2.3.10. Chip Conveyor. The machine shall be equipped with a self-contained chip conveyor(s) for removal of chips. The conveyor drive shall be mechanically and/or electrically protected from overload and jamming of the conveyor, and be manually reversible in direction to provide a means of dislodging jams. Means shall be provided to collect and return coolant from the conveyor to the coolant reservoir. The chip conveyor controls shall be mounted in a location convenient to the operator’s normal workstation and at the discharge point. The chip conveyor shall have M-code capability.

2.3.11. Way Covers. All machine ways shall be protected with telescoping corrosion resistant way covers made of metal.

2.3.12. Ball Screws. Precision ball screws shall provide linear motion and able to meet the accuracy requirement of Table II.

2.3.13. Glass Scales. Glass scales for X, Y, and Z axes shall be provided and provide position feedback to the CNC control.

2.3.14. Rotary Table. A 4th axis rotary table shall be supplied with all interface and cabling and meet the minimum requirements in Table I.

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

2.3.15.1. Through Spindle Coolant. The coolant system shall have through spindle coolant up to 300 psi.

2.3.15.2. Coolant Wash Down Wand With Nozzle. The coolant system shall include a coolant wash down wand complete with hose and nozzle. The wash down wand shall be capable of washing chips and debris to the chip conveyor system.

2.3.16. Electrical System. The machine shall conform to NFPA 79.

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

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

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

Installation of the cable and hose carrier s in the overhead position is not allowed.

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

2.4. Size and Capacity. The size and capacity of the Vertical Machining Center shall be not less than specified in Table I.

Table I Size and Capacity Axis travel distance (X, Y, Z) 40-inch x 20-inch x 20-inch Table working surface 46-inch x 20-inch Table T-slots 5 x 0.71 on 3.94 centers Maximum table load 2000 pounds Spindle nose to table 4-inch to 24-inch Rotary table 7.8 inches

Spindle Taper CAT 40 Speed 10,000 RPM Motor HP 20 HP Motor torque 75 foot pounds

ATC

Number of stations 20 Tool diameter 3.5 inches Tool length 9.8 inches

2.5. Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the Vertical Machining Center shall be as specified in Table II.

Table II Alignment and Accuracy Least command increment 0.0001 inches Positioning accuracy 0.0002 inches Positioning repeatability 0.00016 inches

2.5.1. 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, frequency) Contract Number or Order Number Date of manufacture

2.6. Technical Data. Two (2) hard copies and one (1) electronic copy(s) of technical data shall be provided with the machine. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

2.6.1. Origin Quality Assurance Test Report. An origin quality test report shall be provided. The test report shall include all tests performed at origin and meet the requirements of section 2.5, alignment and accuracy tolerances.

2.6.2. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

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

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

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

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

e. Trouble-shooting guides.

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

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

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

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

2.8. Workmanship. Workmanship of the Vertical Machining Center 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.

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Provide machine foundation in accordance with the manufacturer's design requirements.

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

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

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

( ) (XX) e. Level and align machine.

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

2.3.1.2. Operator’s Remote Pendent. The Vertical Machining Center shall have a remote pendant with an LCD display that allows for axis motion control through jog, incremental and manual pulse generator. An Emergency Stop Button, and a manual pulse g...

2.3.17. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the compon...