Two New Deep Hole Boring Machines Specification 3-21-3416.docx

Equip Engr Spec # 3-21-3416 Dated 17 March 2021

Two New Deep Hole Boring Machines

Table of Contents

1. Scope

1.1 Abbreviated Description 2

2. Applicable Standards and Publications 2

3. Requirements

4. Quality Assurance Provisions

5. Preservation, Packaging and Delivery Instructions 24

6. Instructions for Preparing Technical Offers 24

1.

Scope:

1.1 Abbreviated Description. This specification defines the requirements for two new UNISIG model B500 pull bore deep hole drilling machines or equivalent with a Rotating Tool and Counter-rotating Workpiece and all necessary ancillary equipment, tooling and features required to bore the materials stated in paragraph 3.2.2.

2. Applicable Standards and Publications. All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal, OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

3. Requirements. All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

3.1 General Requirements.

3.1.1 Design and Engineering. The machine shall be designed and engineered in accordance with latest standards recognized or adopted by the Association for Manufacturing Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use.

3.1.2 Materials. Materials incorporated in the construction of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability.

3.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.3.1 Alignment Retention. Nonintegral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of accidental dislocation.

3.1.4 Slideway Design and Construction. All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Please state in your proposal details of the way system being offered.

A. Integral cast iron ways shall be hardened to RC 50 to RC 54 to a depth of .100 inch or more.

B. Hardened and ground steel ways for mating with Turcite, Rulon or other such low friction forgiving materials shall be hardened within the range of RC 55 to RC 62. Actual hardness within this range shall not very more than 5 RC points.

C. Hardened and ground steel ways for use with antifriction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more. Slideway systems other than the three (3) referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.1.4.1 Replaceable Ways. If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.1.4.2 Way Wipers. All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall also be easily removable and replaceable.

3.1.5 Workmanship. Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology.

3.1.5.1 Shimming. Shims that do not appear on the engineering drawings shall not be incorporated in the machine.

3.1.5.2 Spacing. Spacers that do appear on the engineering drawings are permissible.

3.1.6 Maintainability. All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement or adjustment as applicable. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

3.1.7 Interchangeability. All parts bearing the same part number shall be functionally interchangeable.

3.1.8 Applicable Power Source. The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts.

3.1.8.1 Electrical Safety Devices. The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plugin circuit breakers or currentlimiting fuses are not acceptable.

3.1.8.2 Conversion Equipment. If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be furnished with the machine by the contractor.

3.1.8.3 Motors. All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. All motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service. Each motor shall bear an identification plate containing, as a minimum, the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency and frame or mounting. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 hp or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 Hp or greater shall be of the high efficiency type.

Note: All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

3.1.8.4 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.1.8.5 Utility Outlet. The machine shall be provided with an operational 120volt singlephase, 20-ampere dualreceptacle 3wire utility outlet. This outlet shall be protected by a groundfault interrupter and shall be externally mounted and easily accessible. A “noise" suppression device shall be provided.

3.1.9 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment D and comply as applicable

3.1.9.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent state, federal, local laws and regulations.

3.1.9.2 Protection of the Machine. The machine shall be fully equipped with the devices necessary to prevent selfdamage in the event of malfunction and/or ordinary operator negligence insofar as practical.

3.1.9.3 Noise Levels. The government's preference is to achieve noise levels not in excess of 80 dba and shall be accomplished at no additional expense to the Government. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities (see 3.4.1.2), and shall be measured at any or various times during this test at the discretion of the Technical POC or other appointed representatives. Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a properly calibrated sound level meter set for "A" weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the proper operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.1.9.4 Ozone Depleting Substances. Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozonedepleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: OzoneDepletionPotential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC11, CFC12 and CFC 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

3.1.9.5 Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

3.1.9.6 LeadFree and ChromiumFree Paint Certification. All paints and primers applied to the system shall be certified as lead free and chromiumfree. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery.

3.1.9.7 PCBFree Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection (see section 3.4), these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and its equipment shall be certified as PCBfree prior to being shipped.

3.1.9.8 Lockout/Tagout Procedures. The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.10 Identification Plate. A corrosionresistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and total amps) Government Contract Number Date of Manufacture

3.1.11 Lubrication. The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon Inc. Gearboxes or transmission cases shall be lubricated by the wetsump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Systems of the foregoing types are considered automatic systems and they shall be equipped to be fail safe to the maximum extent possible. Any sensors or other devices used to detect the presence (or absence) of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods (e.g. Grease fittings, oil cups etc.) are permissible for lubrication points not practically served by automatic systems. For nonrecirculating automatic systems (such as slideway lubrication), the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems (such as pressure spray), easily cleanable or replaceable filtration devices shall be provided. Wetsump type systems shall be equipped with means to confirm proper oil level. Sight gages, if used, shall be of the external standing tube type rather than the flushmounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.1.11.1 Lubrication Plate. A lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

3.1.11.2 Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor is requested to choose the required lubricants, hydraulic fluids, oils and coolants from Attachment A, enclosed or where designated (*see note) approved industry/commercial equivalents. If a substitute is required, the contractor shall provide, at time of machine delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.12 Hydraulic System. Hydraulic systems provided shall be sized and powered for the intended application and shall conform industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120 degrees f in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure as well as underpressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, antisurge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

3.1.13 Painting. All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromiumfree and leadfree. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semigloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.1.14 Machine Hold Down and Leveling. The machine base shall be provided with sufficient and properly located holes for positive holddown when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended holddown and leveling hardware.

Note: All holddown and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

3.1.15 Gears. All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.1.16 Handwheels. Where power feed and/or rapid traverse of a machine component is provided or specified, associated handwheels or cranks, if any, shall not rotate when power feed or rapid traverse is engaged.

3.1.17 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

a. Foundation Drawings, Standard or Special (see note): Shall be in sufficient detail to permit pricing and construction by a general contractor and shall be furnished 180 days prior to scheduled delivery of the machine. All drawings shall be dimensioned in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010 or later.

Note: A special foundation is one which exceeds, in required load bearing capability and vibration insulation, Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires specificallyshaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc. Important: See instruction par. 6.5

b. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in AutoCAD 2004 shall be provided on a CD. This plan shall contain the dimensioned bolt-hole pattern of the holddown bolts for the machines. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power including the full load amperage requirements, air, water, etc.) required to operate the machine. This data shall be furnished 60 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010.

c. Catalog of Standard Tooling and Accessories shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (two copies)

d. NonStandard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010.

e. Installation Instructions and Drawings containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished 60 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010.

f. Lubrication Diagram or Instruction. To be delivered at time of machine delivery. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010.

g. Operating Instructions. These instructions shall be in provided in separate manuals from other technical data provided. To be delivered upon machine delivery. Four copies minimum.

h. Maintenance and Troubleshooting Instructions for all machine systems. This material shall also include the machines mechanical assembly drawings. To be delivered at time of machine delivery. Four copies minimum of the Maintenance and Troubleshooting Instructions. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010 of the machines mechanical assembly drawings.

i. Electrical and hydraulic schematics to be furnished. To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

Note: If, during installation and testing, the actual electrical and/or hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "AsBuilt" schematics shall be a condition of final acceptance.

j. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be furnished not later than 30 days prior to delivery of the machine. (two copies)

k. Programming Manuals. Where a CNC machine is offered or specified, programming manuals shall be supplied. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented and usable on the system offered or specified. These manuals shall be delivered at machine delivery. (two copies)

l. Software Documentation. The offeror shall provide three copies of all system software and/or ladder logic developed to control and interface the new control/drives with the existing machine tool. Two copies shall be on 3.5" high density computer disks or CD and the third copy shall be a paper (hard) copy. To be delivered to the technical POC 30 days after final acceptance of the machine.

3.1.18 Training Required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with a CNC control. All instructions and materials, oral or written, shall be in English. "On-Site" means at Watervliet Arsenal and "Off-Site" means a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor. ". If specialized formal “off-site” training is available specify on offer availability and price as an option. The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Hydraulic maintenance (if applicable)

Spindle/Axes Drives (if applicable)

Note: For all types of training, the associated technical data (see 3.1.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A training schedule showing the hours of training for each person under their assigned category, shall be sent in with proposals for review.

3.1.19 Repair/Replacement Parts and Service. The offeror shall also agree to provide parts and/or service for the contracted equipment within 72 hrs of notification of a problem. Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify Watervliet Arsenal’s POC within two business days and shall provide a delivery schedule to be approved by Watervliet Arsenal’s POC. The offeror further agrees, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and be sufficient in detail to permit successful acquisition of the parts and associated repair service. In the event of a national emergency the U.S. Government reserves the right to obtain the data and use it to support operation of the machine tool(s) purchased under this contract.

Note: The offeror shall supply a list of recommended spare machine parts as an option with the offer.

3.1.20 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 85 psi max (volume undetermined) and if higher or lower pressure is needed at the machine, the machine shall be fully equipped with the devices needed to modify the available supply pressure. The machine shall also be equipped with devices to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig.

3.1.21 Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.1.22 Control of Cutting Fluids. If the machine is equipped with a coolant system, the contractor shall insure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine or leaking to the floor when producing workpieces of a size within the machine's normal working range. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leakproof metallic or nonmetallic liner.

3.1.23 Site Conditions. The machine covered by this specification will be installed in general machine shop space and in most cases there will be no environmental conditioning. Temperatures will range from 65 degrees f. To 95 degrees f. and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4 degrees f. per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying whatever is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.1.24 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine wherever it is needed to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable.

3.1.25 Chip/Coolant Removal. An automatic chip and coolant supply and removal system of a type appropriate for the machine being offerred shall be provided as part of the machine. The system shall convey chips of any material from the machine to an external container without manual aid. The unit shall be reversible to facilitate clearing of blockages. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. Automatic means shall be provided to return cutting fluids to the machine's coolant tank which shall be separate from the unit. The chip removal unit shall be engineered for the machine so that when fully installed in accord with instructions all points subject to periodic maintenance and lubrication shall be externally accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself. Operation of the chip conveyor shall be possible both at the operator’s control station and the discharge end of the conveyor

3.1.26 Machine Installation, Startup and Testing.

3.1.26.1 Work to be performed by the Arsenal. Upon receipt of the required installation and foundation drawings (see 3.1.17), Watervliet Arsenal will prepare the intended installation site prior to delivery of the machine. If a special foundation is required Watervliet will contract a general contractor to construct based on drawings provided by the machine tool builder.

3.1.26.2 Work to be Performed by the Contractor. This project shall be turn-key with the Contractor being solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. All machine tool fluids associated for operation shall be provided by the contractor and must be an approved equivalent to what is utilized by WVA on attachment A. The contractor shall provide competent Englishspeaking service personnel to install the machine, rough and finish level the machine, startup, and conduct the acceptance tests specified in section 4. The contractor shall remain until the machine activation and testing have been successfully completed.

Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenalfurnished equipment.

The contractor shall remove from WVA and dispose of all wastes (other than hazardous wastes) generated from uncrating and unpacking the machine at a permitted off-post disposal facility, in accordance with Attachment D of this specification and the document "WATERVLIET ARSENAL (WVA) INFORMATION FOR CONTRACTORS" which is available on the Watervliet Arsenal website.

Once requirements of paragraph 4.1 and 4.2 have been completed contractor personnel shall coordinate the shipment of the machine to Watervliet. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded. Outside rigging services should be advised that only certified chain hoists are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Contractor personnel shall supervise the placement of the machine on the installation site by the rigging service.

In most cases no Arsenal forklift services and/or Arsenal personnel will be available for the installation. Only propane powered forklifts are permitted and must also be equipped with a roll cage. All personnel operating the forklift shall be licensed for the forklift. Arsenal overhead pendant cranes (within load capacities) can be used by the contractor/rigging service for the installation operated by Arsenal personnel only. Contractor personnel shall also adhere to the WVA requirements to wear OSHA approved safety glasses and safety shoes while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine(s). Watervliet does not have the resources to provide such material. Crane capacity within each building is limited (2, 5, 10 or 15 tons) and therefore if not adequate then the contractor will need to provide alternate means necessary for the installation.

3.2 MachineSpecific Requirements. The following are the desired machine specific requirements.

3.2.1 Machine Tool Description. This specification defines the requirements for the two new UNISIG model B500 pull bore deep hole drilling machines or equal with a Rotating Tool and Counter-rotating Workpiece and all necessary ancillary equipment, tooling and features required to bore the materials stated in paragraph 3.2.2.

Important: Offered machine must meet or exceed the following general characteristics. If additional features, equipment and/or options not specifically mentioned in paragraphs 3.2.3 through 3.3 are required to successfully and efficiently produce the workpieces detailed in paragraph 3.2.2 then the additional features, equipment and/or options shall be provided with the offered system and shall be detailed in the proposal submitted for this project. Also, the sole intent of this purchase is to produce the workpieces specified herein. Therefore, if anything within this specification conflicts with this intent then those conflicting areas shall be detailed in the proposals submitted.

3.2.2 Component Characteristics. The following are the characteristics and parameters of the components to be processed through the new machine. Note: This equipment will be machining round 4340 alloy steel pre-heat treated to Rc 36-42 and Inconel 718 (Triple Melt) tubes and therefore the machine design shall be appropriate for these materials. The machine and system design shall be such that when producing the components specified that the machine shall not be operating at maximum power. The following is a summary of the components that are processed through an existing machine and will be what the new machine must be capable of efficiently processing to all component specifications. If in doubt about the expectations of the machine or requirements of the components to be produced please contact the Contracting Officer for clarification.

60mm Tube:

- Material will be Inconel 718 (Triple Melt) with a hardness between Rc 36-42

81mm Tube:

- Material will be 4340 steel alloy with a hardness between Rc 36-42

- Comes in at 51.85”+.25 long with a bore size of 2.78" with a 6.5” bell shape OD on one end down to 4.6” straight OD for the main body.

120mm Tube:

-4340 steel alloy -Bore to 119.760+0.127mm DIA. Then it gets skived in the same machine to 120.45+.0.05mm -Finish requirement of RA 63.

-Straightness should be within 0.126mm T.I.R. finished, measured on a granite table.

-The forging should be 1.5mm Max per whole length for straightness.

3.2.3 Machine Capacity.

a.) Drilling diameter (maximum from solid) 4.9” b.) Counter-boring diameter (maximum) 3.5” c.) Swing over bed 19.7” d.) Workpiece length 72” (minimum).

e.) Machine needs to fit within a 40’ in length footprint.

3.2.4 Tool Headstock:

a.) Tool feed force 12,027 lb.

b.) Tool headstock maximum feed/ traverse 197 in/min c.) Tool headstock power 90 hp 67 kW.

d.) Tool headstock torque 1,401 ft-lbs e.) Tool headstock speed (infinitely variable) 10-1,000 rpm.

f.) Tool headstock transmission Single reduction.

g.) Tool headstock spindle nose ISO 702/1 A2-8.

h.) Tool headstock spindle bore 3.6”

3.2.5 Workpiece Headstock:

a.) Workpiece headstock power (options) 40 hp 30 kW.

b.) Workpiece headstock torque 1,866 ft-lbs.

c.) Workpiece headstock speed (infinitely variable) 1-275 rpm.

d.) Workpiece headstock transmission Single gear reduction.

e.) Workpiece headstock spindle nose ISO 702/1 A2-6.

f.) Workpiece headstock spindle bore 8.5”

3.2.6 Coolant System:

a.) Coolant volume (minimum) 10 gpm b.) Coolant volume (maximum) 140 gpm.

c.) Coolant pressure (maximum) 725 psi d.) Pressure pump 20 hp 15 kW.

e.) Coolant tank capacity 600 gal minimum.

f.) Filtration 10 micron.

3.2.7 Required General Characteristics of Machine. The following are the general minimum or equal characteristics of the machine desired.

3.2.7.1 Drilling and Workpiece Headstock.

a.) Spindle class tapered roller bearings.

b.) Alloy steel spindle shaft, heat treated and ground bearing journals.

c.) Tapered spindle nose, large thru-bore.

d.) High performance AC spindle motor with vector drive technology reliable, infinitely variable speed under heavy load.

e.) Cast iron headstock housing.

f.) Forced-oil spindle bearing lubrication.

3.2.7.2 Drilling Headstock Feed.

a.) Servo driven ballscrew feed.

b.) Planetary gear reducer for bolt-on reliability of primary reduction.

c.) Digital servo drive with absolute positioning.

d.) No homing required after power off.

3.2.7.3 Workpiece Headstock Positioning.

a.) Alloy steel precision lead screw, fine pitch.

b.) AC gear motor with jog control for workpiece length adjustment.

3.2.7.4 Pressure Head Carriage.

a.) Cast iron housing with precision mounting bore and top clamp to hold various pressure head assemblies.

b.) Hydraulic advance and retract with adjustable force.

c.) Pressure head carriage position interlocked with machine control to stop cycle during unexpected operation.

d.) Coolant is ported through manifold on carriage, pressure head mounting prepared for automatic coupling.

e.) Design to hold industry standard pressure heads.

3.2.7.5 Guarding.

a.) Removable shields cover the pressure head, tool holder and workpiece chuck.

b.) Full enclosure guarding optional.

3.2.7.6 Coolant System.

a.) Coolant and chips flow through spindle and exhaust into a chip basket.

b.) Steel reservoir with top access for in-ground or above-ground installation.

c.) Dirty coolant is pumped through a multi-bag filter canister with a differential pressure switch to alert operator when filters are clogged.

d.) Clean coolant is pumped by a positive displacement coolant pump driven by a variable speed vector motor, allowing programmable coolant flow rates as required by tool type.

3.2.7.7 Lubrication. Automatic lubrication systems supply oil to all way surfaces and ballscrews.

3.2.7.8 Machine Control.

a.) Programmable and manual adjustable feed rates, spindle speeds, hole depths with push/pull boring options.

b.) Spindles/feed override control for fine tuning process.

c.) Six-inch color touch screen interface for process display, data entry and machine diagnostics. Allen Bradley programmable logic controller.

d.) Allen Bradley digital servo system.

e.) Allen Bradley PowerFlex vector drives.

f.) Electrical devices are enclosed in a NEMA 12 cabinet following applicable National.

g.) Electric Code and NFPA standards of construction for machine tools and industrial equipment.

h.) Machine will be wired for 460 volts, 3phase, 60Hz.

3.2.7.9 Communications

a.) RS-232 with DB9 connection b.) RJ45 10 Base-T Ethernet Card c.) MT Connect Adapter

3.2.7.10 Vibration Dampener Carriage. Cast iron carriage(s) to be supplied that will hold vibration dampener cartridges.

3.2.7.11 Rotating Pressure Head. High performance pressure head to be supplied that introduces fluid into the drill and aligns bushings to the workpiece when starting a hole.

3.2.7.12 Workpiece Chuck.

a.) 15”, 3 jaw chuck.

b.) Mounting adaptor plate.

c.) Set of breakthrough seal bushings.

3.2.7.13 BTA Tube Clamp.

a.) Size range for 800-821 drill tube.

b.) Holds industry standard split clamp reducers.

3.2.7.14 Options to be Provided.

a.) 1 - Rotating pressure head, 15” chuck, 0.50” – 5.0” tool.

b.) 1 - Workpiece chuck, 15” 3-Jaw, breakthrough seals and offset jaws.

c.) 1 - BTA tube clamp spindle adapter, 118mm bore.

d.) 1 - Vibration dampener carriage, 280mm.

e.) 1 – 100,000 btu/hour Refrigerant chiller.

3.2.7.15 Durable Tooling to be Provided. All tooling that is required to work with the 60mm, 81mm and 120mm mortars must be included. These include: packing adapters and reducers, rotating vibration dampeners, vibration dampener mounting collets, drill tubes (one for each mortar size), split clamp reducers, and master bushing inserts.

3.3 Machine Control System. The control system provided as part of this project shall be programmable and include all controls, functions and features necessary to control and program all parameters necessary to produce tubes specified herein. As a minimum, the control shall permit programming of feed rates, spindle speeds, hole depths with push/pull boring options and shall provide fine tuning features as well. The machine shall also permit manual control of the various process parameters. The control system shall include at least a six inch color touchscreen interface for process display, data entry and complete machine diagnostics. Either An Allen Bradley or GE Fanuc logic controller shall be used.

3.4 Requirements for Demonstration of Conformance.

3.4.1 Certification, Drawings and Tests Required. The contractor shall demonstrate both the machine’s conformance to all requirements elsewhere specified in section 3 of this specification. As part of this demonstration, the contractor shall furnish at least 30 days prior to conformance testing, a dimensioned and toleranced drawing of one or more workpieces exhibiting the Watervliet component characteristics of 3.2.2 for approval by the Arsenal contracting officer. After approval the drawing shall be the basis for the conformance test required in 3.4.1.5. The contractor shall also, as a minimum, provide the following certification and perform the following specific tests.

3.4.1.1 Certification of Completeness. The contractor shall provide written certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements.

3.4.1.2 Test of Conformance to Specified Performance Characteristics. The machine shall be dry cycled at least 30 minutes, during which time the machine shall be tested for conformance to specified performance characteristics, including but not limited to, feeds, speeds and manual as well as automatic cycling.

3.4.1.3 Test of Conformance to Specified Alignments and Accuracies. The machine shall be laser tested for conformance to the manufacturers quoted machine accuracies as well as the machines geometric alignments.

3.4.1.4 Test of Conformance to Specified Horsepower Characteristics. At the discretion of the WVA POC the machine may be tested for power and rigidity. The vendor shall provide a proposed test part of their choosing for this test. The test shall pull full load spindle horsepower for at least three minutes. The workpiece finish and machine rigidity will be evaluated. Material used is at the discretion of the contractor.

3.4.1.5 Test of Conformance to Specified Performance on Workpieces. Paragraph 3.2.2 outlines the Watervliet component characteristics/accuracies which the machine shall be capable of producing on actual workpieces. Paragraph 3.4.1 further requires the contractor to prepare and gain approval of a workpiece drawing which shall become the basis for the test. The suggested workpiece shall sufficiently demonstrate the capabilities and features of the machine and component characteristics/accuracies. Workpieces shall be 4340 alloy steel pre-heat treated to Rc 38-42 but the machine also must be capable of producing the Inconel 718 material.

3.4.2 Provision of Materials and Equipment for Preliminary and Final Acceptance Testing.

3.4.2.1 Material for Workpieces. All materials necessary to produce the workpieces required in paragraphs 3.4.1 shall be furnished by the contractor for preliminary acceptance testing and by Watervliet Arsenal for final acceptance testing.

3.4.2.2 Tooling. Tooling for all testing shall be provided by the contractor.

3.4.2.3 Cutting Fluids. Any cutting fluids necessary to perform the tests specified in paragraphs 3.4 shall be furnished by the contractor during preliminary and final acceptance testing. All machine tool fluids provided by the contractor shall be an approved equivalent to what is utilized by WVA on attachment A.

3.4.2.4 Hydraulic Fluids and Lubricants. All hydraulic fluids and lubricants necessary to perform any of the required tests shall be furnished by the contractor during preliminary and finial acceptance testing. All machine tool fluids provided by the contractor shall be an approved equivalent to what is utilized by WVA on attachment A.

3.4.2.5 Testing and Measuring Equipment. All testing and measuring equipment (laser equipment included) needed to perform any of the required tests and measure the results shall be furnished by the contractor and shall be properly calibrated to standards traceable to the National Institute of Standards and Technology (NIST).

4. Quality Assurance Provisions.

4.1 Responsibility for Inspection. The contractor shall be responsible for performing all certifications and tests required in paragraph 3.4 and shall provide such materials, supplies and equipment as are specified in paragraph 3.4.2.

4.2 Preliminary Acceptance Inspection. Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in paragraph 3.4. However, prior to officially scheduling the preliminary acceptance inspection the contractor shall perform preliminary machine geometry alignments, laser accuracy tests (if accuracies warrant it) and cut a test part. When these tests are completed successfully, the contractor shall provide no less than 14 calendar days notice to the Arsenal Contracting Officer that the machine is ready for the preliminary acceptance inspection. This notification shall also include for review the test results of all preliminary tests performed. If acceptable, the Arsenal representatives will schedule an inspection and the contractor shall await the arrival of the Arsenal representatives before starting the official inspection.

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection.

4.3.1 Examination for Completeness. The contractor shall furnish the Arsenal's representatives with a certification of completeness (see par. 3.4.1.1). The Arsenal's representatives will reserve the right to examine the machine to ascertain the presence of all specified features, equipment, markings and safety devices.

4.3.2 Examination of Performance Characteristics. During the test of conformance to specified performance characteristics (see par.