Technical Specifications.pdf

STATEMENT OF SPECIFICATION FOR CONVERSATIONALLY

CONTROLLED CNC VERTICAL 3-AXIS MACHINING CENTER

1. SPECIFICATIONS:

1.1. SCOPE: THE PURCHASE DESCRIPTION SET FORTH BELOW REFLECTS THOSE

CHARACTERISTICS WHICH ARE ESSENTIAL TO THE MINIMUM NEEDS OF THE

GOVERNMENT. This specification covers the requirements for one each (1ea) conversationally controlled vertical milling center HURCO VMX42i VMC or equivalent with training. The size and capacity of the machine shall be not less than specified below.

2. EQUIPMENT DESCRIPTION: The equipment shall consist of one each Vertical 3-AXIS CNC

Machining center (HURCO VMX42i VMC or equivalent) with conversational CNC control. The machine shall primarily be programed by use of conversational programming and have the capability to be programed using NC/G-code programming.

2.1. SALIENT CHARACTERISTICS: Machine shall have the following salient characteristics.

2.1.1. Design/ Construction:

2.1.1.1. Frame: Heavily Ribbed Fine-Grade Cast Iron Frame Optimized with Finite Element Analysis (FEA). One-piece machine base

2.1.1.2. Linear Rails: Wedge-locked Heavy duty Linear Rails for All Three Axes.

Mounted to a machined shoulder for increased

2.1.1.3. Precision Ball Screws: Ball screws shall be premium grade double-nut, pre-tensioned type anchored at both ends.

2.1.1.4. Sigma Digital Drives: state of the art premium servos and drives from Yaskawa

2.1.1.4.1.1..625 millisecond velocity loop frequency response time (1.6 kHz) min.

2.1.1.4.1.2. Encoders: 1,048,576 counts per revolution min.

2.1.1.5. Machine Weight: Machine shall weigh no greater than 16,000 lbs.

2.1.1.6. Machine Maximum Operating floor Space: 180 x 146.2 in.

2.1.1.7. Maximum Machine Height: 115 in.

2.1.1.8. Full Enclosure with Wide Front Access and Side Access Doors

2.1.1.8.1.1. Front Enclosure Door Opening minimum 47"

2.1.1.8.1.2. ANSI door interlock (B11.23)

2.1.2. Spindle: Machine spindle shall be manufactured of air purged Chrome-molly Alloy and be equipped with ABEC class 7 P4 angular contact and roller bearings that are permanently grease packed and precision balanced. Spindle shall meet the following minimum requirements.

2.1.2.1. Spindle Tool Type: CAT 40 / Big Plus® (CAT/BT 40)

2.1.2.2. Spindle Speed Range: 0-12000 RPM

2.1.2.3. Spindle Motor Horsepower: 24 hp. (18.0 kW)

2.1.2.4. Spindle Torque: 175 / 146 ft.-lbs.@ 720 rpm.

2.1.3. Automatic Tool changer (ATC): Machine shall be equipped with an electric Swing-arm 40

Station Automatic Tool Changer- Random Access

2.1.3.1. ATC Max. Tool Diameter: 3.1 in. (80 mm)

2.1.3.2. ATC Max. Tool Length: 11.8 in. ( 300 mm)

2.1.3.3. ATC Max. Tool Weight: 15.4 lbs. (7 kg)

2.1.3.4. ATC Tool to Tool Time: 2 Seconds

2.1.4. Probing: Renishaw OMP600 / RTS Complete with Probe Interface Package

2.1.4.1. High accuracy touch probe with radio signal transmission, automated job set-up

2.1.4.2. Combines strain gauge technology with frequency hopping radio transmission

2.1.4.3. Repeatability: 0.025um, battery type AA

2.1.5. Table Capacity: Machine shall accommodate the following table capacities

2.1.5.1. Table Size: 50" x 24" (1,270 x 610 mm) (Minimum)

2.1.5.2. Table T-slots: 5 x 0.71" slots on 3.94" Centers (5 x 18 x 100 mm)

2.1.5.3. Max. Weight on Table Capacity: 3,850 lbs. (1,746 Kg)

2.1.6. Coolant System: Machine Coolant System shall meet the minimum requirements

2.1.6.1. Capacity: 80 gallons minimum

2.1.6.2. Flood Coolant System: Machine shall be equipped with a flood coolant system.

2.1.6.3. Thru Spindle Coolant: Machine shall be equipped with a thru-spindle coolant system that is designed to produce a coolant pressure of 300 PSI.

2.1.6.4. Washdown System

2.1.6.5. Air-Blow Machining

2.1.7. Lubrication System: Machine shall be equipped with an automatic central lubrication system. Machine shall be equipped with a low oil-level alarm and Way Lube Separation

2.1.7.1. Oil Skimmer Assembly: Machine shall be equipped with an oil skimmer assembly that reduces the amount of oil deposited in coolant.

2.1.8. Splash Guarding: Machine shall be equipped with full coverage chip and coolant splash guarding.

2.1.9. Work light: LED Work Lights installed on Right and Left Side

2.1.10. Work Signal Light: 3 Stack work end signal light

2.1.11. Power Requirements: Machine shall be built to NFPA 79 and operate with power system which is 480V, 3PH, 60 HZ or quote package should include step down transformer to machine operation voltage.

2.1.12. Machine Capacity: (Minimum Requirements)

2.1.12.1. Y Travel: 24"

2.1.12.2. X Travel: 42"

2.1.12.3. Z Travel: 24"

2.1.12.4. Spindle Nose to Table: 6" to 30"

2.1.12.5. Floor to Table Surface: 34" (minimum) to 38" (maximum)

2.1.13. 4th axis interface & cabling:

2.1.13.1. H200 Hurco Rotary Table Complete, Sigma V

2.1.13.2. HTS160 Hurco Tailstock

2.1.13.3. 7 Inch, Hurco 3-Jaw, Scroll Chuck and Adaptor Plate for H160 /H200 rotary tables

2.1.14. Tooling and Work-holding:

2.1.14.1. 1ea. Tool Holder kit, 40 Taper (10 pc. tooling pkg., including collets and wrench)

2.1.14.2. 2ea. HV689 Hurco Vise, 6" Jaw, 8.9" Opening

2.1.15. Feed rates/Motion: (Requirements)

2.1.15.1. Rapid Traverse Rate X, Y, Z: 1,469 ipm X, Y / 1,260 ipm Z

2.1.15.2. Max Programmable Feed rate: 1,469 ipm X, Y / 1,260 ipm Z

2.1.15.3. Least Command Increment: 0.0001"

2.1.15.4. Direct Drive Ballscrews X/Y/Z

2.1.15.5. Yaskawa Sigma V Digital AC Servos

2.1.15.6. Metal Telescopic Way Covers

2.1.16. Accuracy/ Repeatability: (Minimum Requirements)

2.1.16.1. Positioning Accuracy: 0.0004"

2.1.16.2. Repeatability: 0.0002"

2.1.16.3. Circularity: 0.0008"

2.1.17. CNC Features: Conversational CNC control that includes the following Programming, Verification and Operational features.

2.1.17.1. Programming Features: Programming features shall include the following.

a. Constant Engagement Cutting

b. AutoCalc

c. Canned Cycle Blocks

d. Canned Hole Cycle

e. Centerline Probing*

f. Concurrent Programming

g. Context Sensitive Help

h. DXF Transfer*

i. Font Magnification

j. Frame Mill with Enhanced Corner Geometry

k. Helical Interpolation I. ISO/EIA NC Support

m. Inch-Metric Toggle

n. Indexer Routine

o. Industry Standard NC (ISNC)

p. Job List*

q. Leadscrew Compensation

r. Lines & Arcs

s. Linear Repeat

t. Linear Thermal Comp*

u. Mirror Image

v. NC/Conversational Merge*

w. NC Editor

x. NC Probing Cycles

y. NC Productivity Package (NCPP)

z. Pattern (Scaling, Rotation, Translation)

aa. Peck Mill

bb. Program Manager Functions

cc. Program Parameters

dd. Program Review with Cut/Copy/Paste

ee. Programmable Safety Zones

ff. Rectangular Repeat » Rigid Tap

gg. Roughing Stock Allowance

hh. Select Surface Finish Quality (SFQ)

ii. Serial Number (Letter & Part Serialization)

jj. Slots

kk. Speed and Feed Edit while Running II. Stick Lettering » Stream Load

mm. Swept Surface with 3D Mold

nn. Thread Milling

oo. Tool & Material Library

pp. Tool Change Optimization

qq. Tool Life Management

rr. Lettering Package

ss. UltiPocket with Helical Ramp Entry

tt. Unlimited Work Offsets (Conversational)

uu. Z Offset Shift

vv. 4th Axis Rotary Wrap

ww. 99 Work Offsets (G-Code)

2.1.17.2. Verification Features: Verification features shall include the following.

a. Automatic Error Check

b. Advanced Verification Graphics with 3D Solid Rendering

c. Data Block Search

d. Fast Draw Graphics Engine

e. Graphics Display (Tool Path, Solids, Projection in 3 Planes, Isometric)

f. Graphics Error Verification

g. Graphics Scaling

h. Graphics Zoom

i. Real Time Tool Simulation

2.1.17.3. Operational Features: Operational features shall include the following.

a. Auto Interrupt Cycle

b. Automatic Tool Home

c. Backlash Compensation

d. Basic Remote Jog

e. Control and Machine Diagnostics

f. Coolant Select (Dual)

g. Customizable Digital Readout Overlay (ORO)

h. Distance To Go

i. Dynamic Variable Look Ahead (capable of over 10,000 blocks@ 900 ipm)

j. Estimated Run Time

k. Feed Hold Button I. Feed-Rate Override

m. Programmable Feedrate

n. Spindle Load Monitor

o. UltiMonitor®

p. UltiMotion®

q. 4GB RAM Memory

r. 2.7GHz Dual Core Intel Processor

s. 128GB Solid State Hard Drive

t. 4000/sec. G-code Processing »

u. Dual 19" Touch Screen Monitors Adjustable Control: 45° Swing, 6" Vertical

Movement

v. Angular Keyboard W. 2 each USB Ports

x. LCD Remote Jog

y. Renishaw Rotating Tool Setting Software (for RTS Tool Touch Probes)

z. Renishaw Inspection Plus Software

3. TECHNICAL MANUALS: Three (3) complete sets of technical manuals covering operation, service and maintenance, and part-listing shall be provided and one (1) electronic copy

4. QUALITY ASSURANCE PROVISIONS - Inspection and acceptance of the supplies, performed at destination by Code 900F.21 and shall consist of type and kind; condition; operability, if readily determinable; preservation; packaging.

5. PRESERVATION, PACKAGING AND PACKING - The equipment shall be packaged, packed and preserved for shipment to reach ultimate destination undamaged. Package shall be prominently marked "NOT FOR OUTSIDE STORAGE". Yellow packaging, packing, preservation and marking are prohibited.

6. Additional Requirements:

Machine Hardware: Machine shall include any necessary lifting, leveling, and floor attachment hardware for machine installation.

Nameplate: A nameplate shall be permanently and securely attached to each machine the information provided on the plate shall be as 1isted below.

a. Nomenclature

b. Manufacturer's name

c. Manufacturer's model designation

d. Manufacturer's serial number

e. Power input (volts, total amps, phase, frequency)

f. Amp rating of 1argest motor

g. Short circuit/over-current protection rating

h. Contract Number or Order Number

i. National Stock Number or Plant Equipment Code

j. Date of manufacture

Operating and Maintenance Manual: Machine shall be provided with operating and Maintenance Manual (O&M), Electrical Manual, Mechanical Manual & Schematics three (3) each shall be provided with the machine and one (1) each searchable electronic copy (PDF) shall be E-mailed to TPOC.

Verification Test: After delivery the Contractor shall test run the machine at the site to ensure conformance with this purchase description.

Warranty: This machine shall be warranted against any defects in material, parts, and workmanship for 24 months after the date of installation. The control, servomotors and main spindle motor shall be warranted against defects in material, parts, and workmanship for 24 months after the date of installation.

Installation:

Installation/Foundation Drawings: Not later than sixty (60) calendar days after effective date of contract; installation requirements and drawings shall be provided to Norfolk Naval Shipyard TPOC.

Lifting and Handling Equipment: No later than sixty (60) calendar days after effective date of contract, the contractor shall provide a lifting sketch / rigging diagram that meets the requirements listed below.

• The weight of the load.

• The location of the center of gravity.

• The minimum capacity I length of slings.

• The minimum capacity of other standard rigging gear.

• The attachment (lifting) points for the load.

o The attachment points for multiple leg lifts shall be sized such that each attachment point can support half the load's weight at the anticipated lift angle.

o The attachment point for single leg lifts shall be sized such that the attachment point can support the entire load's weight.

• Limitations on allowable orientations for any parts making up the lifting assembly.

• For single leg vertical lifts using twisted rope (wire or synthetic), two parallel ropes each capable of supporting the entire load alone shall be required unless a method is used to prevent unlaying the rope.

• A minimum D/d ratio of one shall be required where wire rope slings pass over any object, or in the eyes of wire rope slings. A minimum D/d ratio of two shall be required where synthetic rope slings pass over any object, or in the eyes of synthetic rope slings.

o "D" represents the diameter of the object the sling passes over.

o "d" represents the diameter of the sling.

o Table 14-3 of NAVFAC P-307 lists efficiency factors at vaious D/d ratios.

• Components in each handling assembly shall be sized based on the worst case distribution of loads.

Note: When making a two, three, or four point lift, the handling gear shall be sized so that two legs can support the load without exceeding the safe working load (SWL) at the lift angle expected, unless an equalizing method is used.

• When non standard gear is required (i.e. round stock lifting bars) written instructions shall be provided that ensure:

o The proper material is being used, o The item is certified.

o Any special requirements or dimensions are followed to ensure that engineering assumptions are met (i.e. eccentricity of the bearing points).

Location: Machine shall be installed inside Bldg.171 3rd floor NNSY (Norfolk Naval Shipyard, Portsmouth, VA 23709).

Mechanical Installation: The Contractor shall provide fluids, (with the exception of coolant)

Training: The contractor shall provide training to familiarize Norfolk Naval Shipyard personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be performed at customer facility between 7:20 am and 3:50 pm excluding any federal holidays.

Operator I Programmer On-Site Training: Training shall be provided at the receiving activity.

Training shall include preparation of part programs, and preparation of equipment for safe operation. The trainees shall be provided instruction for all aspects of machining operations. Trainees shall be provided instruction for the care, use and operation of all attachments and accessories. Training shall be provided for three (3) operators/programmers. The training period shall not be less than three (3) consecutive, eight (8) hour work days. A training manual (which could be an additional operator's manual) shall be provided for each student.

FACILITIES ENTRY REQUIREMENTS:

All personnel expected to visit NNSY shall be US citizens. All personnel shall provide two forms of identification. Accepted required identity documentation for proof of US citizenship, US Birth

Certificate, US Passport, Certificate of Citizenship, Birthright Citizenship, Certificate of

Naturalization, Birth Abroad for US citizens.

30 days before arrival, contractor shall provide SECNAV 5512 data on all personnel expected to visit

NNSY to the TPOC. This shall include list of all personnel expected to visit, identifying those that require SECNAV 5512 forms & those with existing valid base passes. All personnel expected to visit

NNSY shall be US citizens. All personnel shall provide two forms of identification. Accepted required identity documentation for proof of US citizenship, US Birth Certificate, US Passport, Certificate of

Citizenship, Birthright Citizenship, Certificate of Naturalization, Birth Abroad for US citizens. The

TPOC shall provide SECNAV 5512 forms upon request. The TPOC will endorse the SECNAV 5512 form and forward to the NNSY Pass Office.

Vehicle Entry: The Contractor shall display the company name on each door of the Contractor's vehicles in a manner and size that is clearly visible. All contractor vehicles shall display a valid state license plate that complies with State Vehicle Code with Company's name clearly displayed on the sides on vehicle. Contractor vehicles shall meet all other requirements of the State Vehicle Code, such as safety standards, proof of insurance and state registration. Contractor vehicles shall have insurance and registration in