Statement_of_Work__AJW-L960 Abrasive Waterjet REV 2.pdf

FEDERAL AVIATION ADMINISTRATION

FAA LOGISTICS CENTER (FAALC)

STATEMENT OF WORK

ABRASIVE WATERJET CUTTING MACHINE

1.0 Introduction and Overview

This statement of work establishes requirements for the contractor's responsibilities and quality control program. These requirements pertain to the inspection, test procedures, tests, and records necessary to substantiate that the assembly complies with and performs in accordance with its intended use.

1.1 Scope

This statement of work (SOW) is to define workmanship criteria, testing requirements and high-level test methods to be followed by the contractor's testing of the product. The SOW provides the basis of understanding between the contractor and the F AALC regarding product and testing.

1.2 Objectives

This specification provides the minimum requirements of the new equipment request. It also identifies old equipment that will need removal.

2.0 References

3.0 Requirements

The machine is intended to cut metal plates of material, primarily metals.

I. FINISHED PART ACCURACY FOR CONVENTIONAL 2 AXIS CUTTING

The machine shall be able to cut apart from 8 to 12 mm (approximately½ inch) steel 100 mm x 100 mm to a surface finish of no greater than 10 RA (250 u-inch RA). The part is to have a no dimension in error, including taper (draft) greater than+/-0.005 inch.

a) FINISHED PART ACCURACY WHEN MINI-WRIST IS USED

When the machine is operated under the 5-axis mode, the part accuracy described in the paragraph 5.1 shall be+/-0.0025 inch.

II. HIGH PRESSURE EQUIPMENT

FAALC intends to purchase a single head machine.

HIGH PRESSURE PUMP

A 50 horsepower High Pressure linear Intensifier-based pump, 30 horsepower rotary direct drive pump, or a hybrid direct drive electric servo pump capable of 60,000 psi of continuous output capability at 1.0 gallon per minute. The contractor is to specify the following:

• Water output flow rate at full pressure

• Specifications pertaining to hydraulic, rotary, or electric servo pump manufacturer.

Intensification ratio (low pressure ratio to high pressure ratio)

Effect of efficiency and pressure on cutting performance. Deliverable horsepower at the nozzle.

Effect of software on cutting performance.

Electric motor manufacturer, power, and style (for example: Totally Enclosed Fan Cooled-"TEFC")

• Enclosure around pump. Proximal location of pump in relation to the catcher tank.

• All certifications that apply to the pump, such as UL, TUV, CE, ASME, etc.

c) Positive over-pressurization shall be accomplished through the use of redundant hydraulic pressure safety relief valves. Rupture disks, prone to fatigue failure, shall not be used for positive over pressurization protection.

d) A slow start system shall allow the unit to be preset to a desired operating water pressure and, when started, will automatically and slowly increase water pressure to the preset level, thus extending high-pressure component life or, a software system to control pump speed, control pressure settings, and extend pump life i.e., intuitive operating system for the pump.

f) The entire flow of oil going through the pump shall be filtered (full flow filtration), or other means of filtration and lubrication.

g) The hydraulic pump shall be a radial piston, variable displacement, pressure compensated pump for developing hydraulic pressure; or the pump shall be a direct drive pump, not using hydraulic oil to create high PSI water pressure, while creating power and efficiency to comparable higher-pressure pumps; or a hybrid direct drive electro servo motor pump utilizing servo linear actuators and ball screw technology to deliver the high-water pressure.

h) The pump shall operate on a minimum inlet water pressure of 65 psi.

i) The pump control unit shall be isolated by from the mechanical pump components; or the pump control unit shall be integrated together.

j) To conserve floorspace, the inlet water booster pump shall be integrated into the main pump frame; or the unit shall integrate into one.

k) The high-pressure pump system shall utilize one 124 cubic inch shock attenuator in the ultra-high-pressure circuit to ensure the pressure signal at the nozzle will exhibit minimal pressure spikes; or the pump will control pressure through variable frequency drive technology for specific needs and

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requirements. Or the pump system’s pressure control through an intuitive system that controls pressure spikes and therefore reducing HP tube and fitting life.

III. WARNING AND SHUTDOWN SENSORS

• Water temperature

• Cutting water sensors

• Servo actuator temperature sensors

• Overpressure

• High technology sensors

• Dump or bleed-down valve sensors

• High hydraulic oil temperature

• Low inlet water pressure

• Check valve temperature

• Bleed down valve temperature

The pump system shall have the following shut down sensors:

• Water temperature protection

• Overpressure protection

• Low hydraulic oil level

• High hydraulic oil temperature

• Low inlet water pressure

IV. PUMP MAINTENANCE OPERATION

• Expected seal life

• Expected check valve life

• Electrical control system on the pump (for example: PLC)

• All special tools for the pump must be included

• Medical alert cards for operators must be included

• Description of operator controls (where are they located, what are control features)

V. INLET WATER FILTRATION

The intensifier, direct drive, and direct drive servo electric pump shall have integral inlet water filtration.

Contractor is to describe in the proposal the filtration system provided and describe if the FAALC requires any special water requirements.

VI. MACHINE TOOL REQUIREMENTS

The Contractor shall provide a machine tool that will meet the stated Purpose as well as the following criteria.

VII. MACHINE PERFORMANCE

a) Linear axis accuracy ±0.001” (±0.025 mm)

b) Linear axis repeatability ±0.001” (±0.025 mm)

c) Ball bar circularity ±0.003” (±0.076 mm)

VIll. ENVIRONMENTAL PROTECTION

Full environmental protection shall be provided to protect all machine, pump, and control components from the harsh abrasive Waterjet cutting environment. The machine's Z-axis and cutting head must be able to be hosed down from the operator's position for cleaning. The abrasive delivery system must be able to withstand both the typical cutting environment as well as hose cleaning.

a) Since hose cleaning of the machine will be readily used, the design must not depend on positive air pressurization within the bellows chambers to keep out unwanted moisture, grit, or dust.

b) At no point during the pressurizing or conveying of the abrasive from the bulk transfer into the cutting head shall the abrasive be exposed to the environment. Such exposure can cause the abrasive to become moist or wet during the machine cleanup process.

IX. TEMPERATURE

The machine shall be subject to temperature ranges from 15 to 30 degrees C.

X. MACHINE DESIGN

a) The machine shall be of rigid steel structure and stress relieved prior to machining. Contractor to describe stress relieving and machining. Aluminum machine frame components are not acceptable due to thermal expansion, short-term and long-term rigidity.

XI. ACCESSIBILITY TO WORK AREA

Accessibility work area for loading and unloading parts, as well as loading and unloading sheets is critical.

a) The machine shall have at least 3 sides open where the operator need not lean over machine rails to access the catcher work area.

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b) The linear motion of the machine shall be able to move away from the work area to facilitate overhead crane loading. Describe how overhead loading will be performed or other optional features that can be purchased for a safer work area.

XII. 5 AXIS MOTION CHARACTERISTICS AND DESIGN

The machine will be capable of utilizing a 5-axis mini-wrist to minimize or eliminate taper on any part shape, through any material, with any standard jet parameter set.

a) The machine shall include not only the X and Y-axis of programmable motion, but also Z, B, and C.

b) The 5-axis wrist will automatically compensate for taper and stream lag errors, thereby providing a finished part of higher accuracy at higher cut speed than a conventional 2 axis abrasive waterjet machine of equal power can produce.

c) The operator shall not be required to program this mini wrist. Instead, the operator shall program a simple 2 axis part and the control system shall automatically create the advance a 5 axis moves necessary to angle the head and compensate for the part taper. Highly accurate mathematical models will work behind the scenes to create these 5 axis programs.

d) Re-alignment of the wrist shall be performed in less than 7 minutes.

e) In addition of motors with the A-B wrist system, which is strictly used for lag and taper, the cutting head shall have the capability to cut on a taper and produce bevels.

XIII. ABRASIVE SYSTEM

The abrasive system shall comprise of the following components.

a) DRY ABRASIVE STORAGE.

Abrasive storage will be totally dry, and have a minimum capacity of 270 kg (600 lbs.)

b) METHOD OF FEEDING THE ABRASIVE

c) WARNING AND OUTPUT SENSORS FOR BULK HOPPER.

d) One warning and one shut down sensor shall be provided on the dry abrasive storage hopper.

e) Warning lights must be provided. Any safety features to ensure the system does not run out of abrasive should be described.

f) The warning and out sensors will be integrated directly into the machine tool control system to alert the operator of low level of abrasive or stop the machine if the abrasive runs out.

g) Contacts will be provided and described in the manuals by which warning and out sensors can be integrated into a F AALC supplied monitoring station.

h) The contractor shall make recommendations to the type, grain size, and manufacturer of the garnet.

XV. ON/OFF FUNCTION OF METERING

Metering device feeding the abrasive into the cutting head shall be very accurate and consistent over time. Contractor shall describe metering approach. The on/off function shall be separate from the

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metering function; thus, eliminating the constant closing and re-opening of the metered opening, as such action can induce abrasive feed inconsistency.

XVI. METERING

To ensure consistent abrasive flow, the abrasive shall pass through a fixed opening via gravity and then drawn through the abrasive feel line into the cutting head chamber via the suction (venturi) created by the Waterjet stream in the cutting head. The abrasive shall not be forced by pressurized air into the cutting head, as this may allow for an inconsistent abrasive flow rate. The use of vibration for inducing metering or any other reason within the metering s stem is also not acceptable. An acceptable method would be programmable abrasive feeder which is controlling feed rate for high-and low-pressure cuts. An explanation to the prevention of the backflow of water/garnet into the cutting head hopper through new technology.

XVII. DESCRIPTION OF RECTIFYING AN ABRASIVE ERROR

In the case of abrasive problem or feed error, the Contractor shall describe how the operator or maintenance personnel will quickly correct problems. An abrasive system that utilizes automatic shutoff at the cutting head’s abrasive hopper.

XVIII. CUTTING SYSTEM AND CATCHER TANK

a) CUTTING HEAD WEAR COMPONENTS

The cutting head shall have only two consumable components -the orifice and the mixing tube. A separate mixing chamber of carbide or other material that is replaced separate from the main cutting head body is not acceptable. The components of the cutting heads body, orifice, and mixing tube will be engineered in such a way as to make it impossible to create an alignment issue between the orifice and mixing tube.

b) CONSUMABLE COMPONENT LIFE

The jewel orifice, which creates the waterjet stream, shall have a minimum average life of 800 hours.

The mixing tube, which acts as the rifle barrel to mix and accelerate the abrasive particle into the supersonic waterjet stream, shall have a minimum average life of 120 hours.

1) ALIGNMENT OF THE HEAD COMPONENTS

The means and accuracy by which the cutting head orifice and mixing tube are aligned shall be fully explained.

2) ATTACHMENT OF THE HEAD TO THE MACHINE

The method by which the cutting head is attached to the machine shall be described. The attachment of the head will eliminate the possibility of misalignment.

XIX.HIGH PRESSURE PLUMBING

The high-pressure plumbing design shall be described, including the use of swivels and whips, manual shut off valves, and water pressure level readout.

XX. CATCHER TANK AND WORKPIECE SUPPORT

The contractor shall clearly describe in the proposal the catcher tank and work piece support system. The requirements for the system are detailed below.

• Must hold 2000 pounds, and I 00 pounds per square foot.

• Contractor to describe material support a roach (for example, slats or grates)

• Material support replacement -frequency and cost

• Material clamps for work piece hold-down to be described by Contractor.

• Slats or grates, hold down clamps must be stainless steel.

a) Contractor to quote an optional sludge removal system. Contractor shall describe how it will be removed from the tank, and how most of the water will be removed from the abrasive and where that water will be sent. Also, Contractor is to describe the container that the waste will be deposited. The contractor shall explain the process of the garnet/metals waste disposal to their system and a study showing its environmental impact.

b) The tank shall have an adjustable water level control of at least 2 inches. The Contractor shall describe in the proposal the design characteristics and the operation procedure.

c) The work piece support shall be level to nozzle travel to at least+/-I mm (+/- 0.040 inch over the 3.5-meter travel length.

d) The catcher and workpiece support will be designed so the catcher tank and motion system (linear ways, ball screws and drive system) shall be integrated. The major parts of the structure shall be steel, providing column support on both sides for the cutting head.

The contractor shall describe the integrity of their design.

XXI.CONTROL SYSTEM

a) KERF COMPENSATION The control system shall have the function of kerf compensation.

b) AUTOMATIC TOOL PATH The control system shall have the function of automatic tool path generation to quickly create a part program.

c) CORNER VELOCITY CONTROL The Contractor shall describe in the proposal how the control system will control the comer cutting speed to ensure parts are produced as fast as possible at the desired quality level.

1) NETWORK COMPATIBLE

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The control of the machine shall have an interface to connect to a network.

2) IMPORTABLE FILES

Machine shall be able to import into its' CAM software DXF, IGES, files.

3) ROLL-AROUND OPERATOR STATION

The machine should be equipped with an easily moveable roll-around operator's station that can reach at least one-half of the way across the front of the machine. For example, if the machine travel is 3.5 meters in the X direction, then the roll around control station must be able to be moved to a center position of 1.75 meters in front of the catcher.

4) NESTING SOFTWARE

The Contractor shall provide a Nesting software package with a remnant material tracking feature. This nesting package shall be easy to operate and provide the ability for the programmer to change the manually cutting sequence, or manually manipulate a part (move, rotate, copy, delete, etc.) after the nest has been created.

XXII. SAFETY DESIGN, ACCESSORIES & CERTIFICATIONS

The machine shall be CE certified, with all corresponding paperwork in order. The machine shall match all pertinent electrical codes. The high-pressure components will be manufactured in accordance with ASME pertinent codes (see paragraphs below).

XXIIII ELECTRICAL EQUIPMENT

a) All electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminal/circuit boards and bussing. In no instance shall splicing of wiring between terminations be permitted in neither the construction nor the repair of the equipment.

b) One connection point for the three-phase power shall be provided. The equipment shall be 460 V, 3 phase, 60 Hz.

c) All components are electrically integrated; all motor starters, transformers, and critical cabinets are to be integrated into a single frame, with FAALC connecting to a single utility point for power, water, and compressed air.

d) Electrical identification of wiring, bussing, terminals, and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color-coding, permanently engraved plates, and permanent markings on the devices.

c) Adequate electrical spacing shall be maintained throughout to avoid excessive banding of cabling and wiring, to maintain adequate separation distance between electrical potentials and between these potentials and ground, and to permit ease in connecting a disconnecting wiring and cabling during troubleshooting and repair.

XXIV. SAFETY SYSTEM

a) SAFETY WORK ZONE

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The standard safety equipment at the machine shall comprise of a safety work area of one meter around the cutting tank.

XXV. ASME CODE COMPLIANCE.

a) The Vendor shall adhere to ASME Boiler and Pressure Vessel Code, SECTION VIII, Div 3.

All appropriate high-pressure components shall meet this code.

b) Copy of U3 ASME Certification Vendor shall be certified by ASME to apply the ASME Code Symbol Stamp (U3) to items which the vendor builds in accordance with the ASME Boiler and Pressure Vessel Code and prove such certification by supplying with the proposal a copy of the U3 Certificate of Authorization for the manufacturing site.

XXVI. ACCESSORIES

Essential accessories shall be quoted with the standard system, non-essential accessories as an option.

XXVII. INSTALLATION AND TRAINING

The Contractor shall include in the proposal all necessary installation and training that will ensure a smooth startup of the system. All components shall be included, such as CAM software, control software, pump, cutting system, and motion system. The Contractor shall provide all training in English.

XXVIll. INSTALLATION

A) CONTRACTOR RESPONSIBILITY

General installation details should be described. Generally, the Contractor is to provide a detailed installation layout drawing to Buyer prior to shipment of equipment. This layout drawing must meet Buyer's approval. The Contractor is then responsible for installation supervision on-site. Any interconnections required between any components are the Contractor's responsibility.

XXIX.TRAINING

a) Training of staff who will be using this equipment after installation.

XXX. TECHNICAL SERVICE

a) GUARANTEED SERVICE LEVEL

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Contractor shall describe and guarantee in the proposal the service level for technical service for phone support, detailing hours available and any associated fees, and for response time for on-site visits.

b) ON-SITE SERVICE

The Contractor shall provide on-site technical assistance at FAALC's request. Such technical assistance shall include process development support, machine upgrades, operator training, and problem solving.

XXXIII. MANUALS

All hard copy manuals shall be in English language. Contractor must specify alternate languages that will be available. The manuals must be sent to FAALC prior to machine arrival at MMAC FAALC. Without manuals the machine will not be accepted. Other resources of support through online documents, videos, and phone support will be made available or how to gather this information.

XXXIV. QUALITY CONTROL

• If more than one manufacturing facility is used, please treat the facilities as separate in your description.