Attachment 0001 RIPD E4000-24-3-06 - Turning Center r2.pdf

ROCK ISLAND ARSENAL RIPD: E4000-24-3-06

PURCHASE DESCRIPTION DATE: 22-Nov-23

CNC TURNING CENTER

1. GENERAL SYSTEM DESCRIPTION

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

2.2 National Standards and Specifications

3. DESIGN

3.1 Ownership

3.2 General Design Standards

3.3 Safety, Security and Environmental

3.4 Responsibilities

4. COMPONENT SPECIFICATION

4.1 Dimensions:

4.2 Bed

4.3 Headstock and Spindle

4.4 Carriage Base (Z-Axis)

4.5 Cross-Slide (X-Axis)

4.6 Tailstock (R-Axis)

4.7 Y-Axis

4.8 Long Boring Bar Axis

4.9 Turret

4.10 Steady Rests

4.11 Accessories

4.12 Controls

4.13 Accuracies and Tolerances

5. INFORMATION TECHNOLOGY SYSTEMS AND SUPPORT

5.1 Installation IT Support:

5.2 INSPECTION/FINAL ACCEPTANCE:

5.3 Media/ Devices

5.3 INFORMATION ASSURANCE AND ACCREDITATION:

6. APPROVAL/SHIPPING

6.1 Shipping

6.2 Installation

6.3 Completion

7. TRAINING

7.1 Schedule

7.2 Location

7.3 Type

8. SERVICE

8.1 Service/Support Requirements

1. GENERAL SYSTEM DESCRIPTION

• This requirement describes a CNC turning center. The vendor shall be responsible for the provision and the installation of the equipment. The turning center shall have X, Z and Y axis capabilities with live tooling. The turning center shall include a long boring bar attachment for long boring bar capabilities. The solution shall include any and all necessary auxiliary equipment or attachments to create a safe functioning system that complies with all applicable standards.

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal.

Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.2 National Standards and Specifications

The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.2.1 Occupational Safety and Health Act of 1970 (OSHA).

2.2.2 American Society of Testing and Materials (ASTM).

2.2.3 American Society of Mechanical Engineers (ASME).

2.2.4 American National Standards Institute (ANSI).

2.2.5 National Electrical Manufacturers Association Standards (NEMA).

2.2.6 Electronic Industries Association (EIA).

2.2.7 Institute of Electrical and Electronics Engineers (IEEE).

2.2.8 American Code for Information Exchange (ASCII).

2.2.9 American Welding Society (AWS).

2.2.10 American Gear Manufacturers Association (AGMA).

2.2.11 National Fire Protection Association (NFPA).

2.2.11.1 NFPA-70 National Electrical Code

2.2.11.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.12 International Standards Organization (ISO).

3. DESIGN

3.1 Ownership

3.1.1 This equipment is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

3.2 General Design Standards

3.2.1 DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a 10-hp motor would not be acceptable.

3.2.2 UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English- US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.2.3 ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable):

Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine Weight. This information is necessary for compliance with the governments Unique Identification Program (UID).

3.2.4 DATA PLATES: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering.

Lettering shall be permanent and have a contrasting background.

3.2.5 ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID 2-D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

3.2.6 UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component http://dodprocurementtoolbox.com/site/uidregistry/ https://wawftraining.eb.mil/ and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.2.7 UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2.8 UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

3.2.8.1 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

3.2.8.2 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

3.2.8.3 Connection of 1.5-in diameter natural gas pipe to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional.

3.2.8.4 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

3.2.9 ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.2.10 CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.2.11 SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

3.2.12 DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

3.2.13 NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

3.2.14 COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.2.15 REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.2.16 CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.2.17 SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.2.18 FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.2.19 CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.2.20 PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.2.21 LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

3.2.21.1 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be English and the units shall be English standard (i.e. pints, quarts, and gallons)

3.2.21.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.2.21.2.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.2.21.2.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.2.21.2.3 All filters shall be either cleanable or replaceable.

3.2.21.2.4 All pumps shall be self-priming.

3.2.22 FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

3.2.22.1 Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load.

3.2.23 HYDRAULICS: The machine will be equipped with a hydraulic system and the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir. All components necessary to make the system completely functional shall be provided.

3.2.23.1 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

3.2.23.2 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions.

3.2.23.3 Protection shall be provided to prevent damage to components.

3.2.23.4 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

3.2.23.5 Anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads.

3.2.23.6 The hydraulic reservoir shall be provided with means for draining and cleaning.

3.2.23.7 Means shall be provided to enable the operator to determine fluid level.

3.2.23.8 Each hydraulic system shall include a filter, which shall be either cleanable or replaceable.

3.2.23.9 All pumps shall be self-priming.

3.2.24 COOLANT: The machine will be equipped with a coolant system and it shall be equipped with external flood coolant capabilities, as a minimum. Machines using cutting tools shall be equipped with both through the tool and external flood coolant capabilities. Coolant on/off shall be a machine control function.

3.2.24.1 The coolant systems shall include all necessary components necessary to provide completely functional systems, with sufficient capacity to give satisfactory service and provide adequate pressure and flow under normal operating conditions.

3.2.24.2 Coolant troughs and chip screens shall be provided around the machine table base to trap, direct, and return the coolant to the reservoir. An easily removable strainer shall be provided in the return line to the reservoir. "Easily removable" is defined as being removable after no more than 5-min of work by experienced personnel.

3.2.24.3 All machine coolant systems and their components shall provide drip-proof coolant delivery to the coolant point of discharge. In addition, the machine shall be designed and constructed to prevent coolant from escaping the confines of the machine or leaking to the floor when producing work-pieces of a size within the dimensions of the machine table.

3.2.25 CHIP REMOVAL: A chip conveyor is required and it shall be an automatic, reversible chip removal unit shall be provided, by the contractor, capable of conveying various types of ferrous and nonferrous chips from the entire work area of the machine to a suitable container outside of the machine without manual aid.

3.2.25.1 The unit shall be of watertight construction.

3.2.25.2 The conveyor belt shall be equipped with a master link, easily disconnected, allowing the belt to be removed for maintenance purposes. All pillow block bearings shall be mounted for ease of replacement. Pillow block bearings shall be fitted with external lubrication fittings. The system shall allow manual movement of the conveyor belt for maintenance.

3.2.25.3 The conveyor shall facilitate draining of excess coolant back to the sump before chips are discharged.

3.2.25.4 The height of the discharge chute from the floor shall be not less than 49.5-in.

3.2.25.5 The chip removal unit shall be installed in a manner facilitating collection of chips from the entire work area without interfering with normal operation of the machine.

3.2.25.6 As a minimum, the chip removal unit shall be provided with an on/off switch or buttons, stop button, and reversing switch.

3.2.26 MOTORS:

3.2.26.1 All motors shall be rated for continuous duty.

3.2.26.2 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

3.2.26.3 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.2.26.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.2.26.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.2.27 DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.2.28 HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.2.29 CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

3.2.30 FOUNDATION: The requirement for a separate foundation is permissible, if necessary to meet the specified alignment tolerances, to provide isolation, or to conform to a standard system configuration. The contractor shall describe the foundation requirements at the time of bid. RIA-JMTC shall be responsible for installation of the foundation based upon the drawings provided by the vendor.

3.3 Safety, Security and Environmental

3.3.1 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

3.3.1.1 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

3.3.1.1.1 Access to RIA: Contractor and all subcontractor employees performing work at RIA shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The COR shall provide guidance to complete the Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

3.3.1.1.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti- Terrorism Training.

3.3.1.1.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

3.3.1.1.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or paced in a drop box at a RIA-JMTC access point.

3.3.1.2 Security Training: The contractor shall complete the following training:

3.3.1.2.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete.

The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.1.2.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

3.3.1.3 For Contractors requiring Common Access Card (CAC): Before CAC issuance, the contractor employee requires a favorably adjudicated National Agency Check with Inquiries (NACI) or an equivalent or higher investigation in accordance with Army Directive 2014-05.

The contractor employee will be issued a CAC only if duties involve one of the following:

(1) Both physical access to a DoD facility and access, via logon, to DoD networks onsite, or remotely or (2) Remote access via logon, to a DoD network using DoD-approved remote access procedures, or (3) Physical access to multiple DoD facilities or multiple Non-DoD Federally controlled facilities on behalf of the DoD on a recurring basis for a period of 6-months, or more. At the discretion of the sponsoring activity, an initial CAC may be issued based on a favorable review of the FBI fingerprint check and a successfully scheduled NACI at the Office of Personnel Management. Contractors needing a NACI or equivalent investigation or higher investigation will coordinate this investigation through their COR.

Contractor personnel shall turn in CAC cards upon completion of their contractual obligations, or at the request by the COR, or at the request of the Contracting Officer.

3.3.2 FEDERAL MARIJUANA LAWS REMAIN UNCHANGED: Note: Rock Island Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering Rock Island Arsenal.

3.3.3 REAL ID: Starting May-2025 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

3.3.4 FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

3.3.5 INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

3.3.6 MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.7 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.3.8 SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.9 LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.10 TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.11 WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.12 ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

3.3.13 BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.14 EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

3.3.15 CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.3.16 OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.3.17 AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.4 Responsibilities

3.4.1 SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for this process.

4. COMPONENT SPECIFICATION

Equipment: The supplier shall furnish all equipment normally considered by him to be standard for his machine unless identified in this requirement to be of specific manufacture. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication.

4.1 Dimensions:

4.1.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high, and shall not exceed 32-ft in length.

4.1.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 35,000-lbs.

4.1.3 INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 15-ft long and 33-ft long, excluding the operator’s area. Maximum height shall not exceed 10-ft. Width is defined as front to back from the operator’s normal operating position.

4.1.4 WORKPIECE:

4.1.4.1 Max Swing Diameter (minimum): 33-in

4.1.4.2 Max Swing Diameter Over Carraige (minimum): 20-in

4.1.4.3 Max Machining Diameter (minimum): 22-in

4.1.4.4 Max Workpiece Length (minimum): 120-in

4.2 Bed

4.2.1 CONSTRUCTION: The bed/base shall be a heavily ribbed, close grained casting and shall form a rigid structure supporting the spindle head, carriage, and the tailstock. The bed/base shall provide access to components housed within for adjustment and servicing. The length of the base and bed ways shall be such that the spindle, tailstock and carriage are fully supported and shall not overhang the bed in any position within the machine’s rated travel. Means shall be provided for leveling and securing the base on the foundation.

4.2.2 MOUNTING: The bed/base shall be anchored to the foundation using a chemical anchoring system. (Can type anchoring shall not be considered acceptable.)

4.2.3 HARDWARE: All necessary leveling wedges, bolts, nuts, and foundation hardware required for the installation shall be furnished by the manufacturer.

4.3 Headstock and Spindle

4.3.1 CONSTRUCTION: The headstock shall be a heavily ribbed, close grained casting and shall form a rigid structure. This shall provide a rigid structure for maintaining accuracy during heavy machining operations.

4.3.2 DRIVE: The spindle shall be equipped with a variable speed, AC spindle motor. All spindle drive shafts and hearing shall be of steel or steel alloy, hardened and ground. Gear drive is required. (Belt Drive is not acceptable).

4.3.3 SPINDLE NOSE: The spindle nose shall be hardened to a minimum of 60 Rockwell C and ground. The chuck mounting shall be A2-15. Smaller spindle nose sizes are not acceptable.

4.3.4 CHUCK MOUNTING: The spindle shall be capable of mounting the hydraulic chuck included in this purchase description.

4.3.5 SPINDLE LUBRICATION: The spindle head shall be provided with a separate, positive means of lubricating the components housed within it.

4.3.6 COOLING: The spindle shall have a thermal controlled cooling jacket/system or a method of maintaining constant temperature such as a circulating lubrication oil bath. This will extend the life of the spindle and minimize distortion during heavy machining operations.

4.3.7 CHUCK BLAST: The system shall include a flood coolant system above the chuck for removal of chip nests prior to tool exchange.

4.3.8 Spindle Nose Size: A2-15 (Larger acceptable with adapters)

4.3.9 Spindle Bore Diameter (minimum): 7.28 inches

4.3.10 Max Draw Tube Capacity (minimum): 7.2 inches NOTE: The current configuration with the requested chuck will limit the capacity to that of the chuck which is 6.5” however the machines capacity shall be a max of at least 7.2 inches.

4.3.11 Spindle Speed Range (minimum): up to 2000 rpm (main spindle) 4,000 rpm (milling)

4.3.12 Spindle Horsepower: 60 hp/ 1760 ft-lbs/ 10 min

4.3.13 Spindle Torque: 1760lb-ft

4.4 Carriage Base (Z-Axis)

4.4.1 AXIS DEFINITION: The Z-axis or longitudinal turret motion shall be provided by movement of the carriage base on way surfaces supported by the machine base/bed. It is defined as the movement of the turret along the rotational axis of the material being cut. (Reference

ISO-13041)

4.4.2 FEED RATES: This shall be program controlled. The program increments shall be no greater than 1-ipm.

4.4.3 CONSTRUCTION: The carriage base shall be a close grained casting forming a rigid structure. The carriage base shall be stress-relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower cuts. The spindle head shall be fully supported and shall not overhang the frame in any position within the machine’s rated travel.

4.4.4 CONTAMINATION: Wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement. Also, each axis shall be provided with a cover system that will prevent large contamination reaching the guide blocks, rails, and ballscrews.

4.4.5 TRAVEL: Linear resolution shall be 0.0001-in or less

4.4.5.1 Z-axis Travel (minimum): 125 inches

4.4.5.2 Z-axis Rapid Traverse Rate (minimum): 945-ipm

4.4.5.3 Z-axis Cutting Feed Rate (minimum): 315-ipm

4.5 Cross-Slide (X-Axis)

4.5.1 AXIS DEFINITION: The X-axis motion shall be provided by movement of the cross-slide on way surfaces supported by the carriage base. It is defined as the axis perpendicular to the rotational axis of the material being cut. (Reference ISO-13041)

4.5.2 FEED RATES: This shall be program controlled. The program increments shall be no greater than 1-ipm.

4.5.3 CONSTRUCTION: The cross-slide frame shall be a close grained casting forming a rigid structure supporting the cross-slide frame. The frame shall be stress-relieved, and internally ribbed and braced to minimize vibration and distortion which may be imposed during full horsepower cuts. The supporting surfaces for the milling spindle carriage shall be such that the spindle head is fully supported and shall not overhang the frame in any position within the machine's rated travel.

4.5.4 CONTAMINATION: Wipers shall be provided for all linear axes, capable of sweeping ways clean of extraneous material in either direction of movement. Also, each axis shall be provided with a cover system that will prevent large contamination reaching the guide blocks, rails, and ballscrews.

4.5.5 TRAVEL: Linear resolution shall be 0.0001-in or less

4.5.5.1 X-axis Travel (minimum): 13-in

4.5.5.2 X-axis Rapid Traverse Rate (minimum): 1100-ipm

4.5.5.3 X-axis Cutting Feed Rate (minimum): 315-ipm

4.6 Tailstock (R-Axis)

4.6.1 AXIS DEFINITION: The R-axis motion shall be provided by movement of the tailstock carriage on way surfaces supported by the machine base/bed. It is defined as the axis collinear to the rotational axis of the material being cut. (Reference ISO-13041)

4.6.2 R-axis Travel (minimum): 116-inches

4.6.3 Tailstock Sleeve Internal Taper (minimum): MT#5

4.6.4 POSITIONING: The tailstock shall be positioned by an independent ball screw drive to create positioning and to adjust the end load on the work-piece. Once positioned, the tailstock shall hydraulically clamp to the bearing rails to maintain position during machining. The tailstock shall include a rotary sleeve. The bearings of the rotary sleeve shall allow the taper to rotate and reduce friction and vibration while cutting.

4.7 Y-Axis

4.7.1 AXIS DEFINITION: The Y-axis motion shall be defined as the movement of the turret off the centerline of the rotational axis of the material being cut.

4.7.2 The equipment shall have a minimum Y-axis capability of 8-inches and shall be programmable.

4.7.3 Traverse Rate (minimum): 500 IPM

4.8 Long Boring Bar Axis

4.8.1 AXIS DEFINITION: This is the movement of the long boring bar system parallel to the rotational axis of the workpiece. This is defined as the movement (extrusion) capabilities of the long boring bar out of the long boring bar attachment on the tail body. This movement is co-linear to the movement of the tail body and Z axis.

4.8.2 Axis Travel (minimum): 46-inches

4.8.3 Axis Traverse Rate (minimum): 945 IPM

4.8.4 Axis Cutting Feed Rate (minimum): 315 IPM

4.9 Turret

4.9.1 The system shall be equipped with a standard VDI turret capable of I.D and O.D. turning operations.

4.9.2 TURRET BLAST: The system shall include a method of clearing chip nests from the turret tool area.

4.9.3 Number of Tools in Turret (minimum): 12

4.9.4 Tool Shank Height (minimum): 1.25-in

4.9.5 Tooling Type: CAT40. Turret shall have VDI style live tools that accept CAT40 Tool holders for heavy duty rigid machining operations as opposed to VDI live tools with collets.

4.9.6 The system shall have live tooling capabilities via an integral spindle motor driving mill tooling up to 4000 rpm.

4.9.7 HIGH TORQUE TOOLING: The system shall be designed to accept High Torque tooling consisting of 81ft-lbs/ 4000rpm. The tooling shall be VDI Live tool holders capable of accepting CAT40 tool holders as opposed to a collet.

4.10 Steady Rests

4.10.1 STEADY REST DEFINITION: The steady rest shall include a base attached to the bearing rails, a bracket which mounts to the base and holds the clamps, and clamps. The steady rest shall be a SMW Autoblok K5-Z steady rest (or equivalent).

4.10.2 QUANTITY: The system shall include 1 complete steady rest

4.10.3 STEADY REST BASE: The base shall be supported by bearing rails. The base shall be positioned by a ball screw drive. This shall be programmable to operate as a steady rest and to operate as a follower rest. The base shall remain in the machine even if the bracket is removed.

4.10.4 STEADY REST BRACKET: The bracket shall mount to the base and shall allow the clamp to be attached. The bracket shall be removable to allow clearance for work-pieces and for the tailstock to approach the headstock unimpeded.

4.10.5 STEADY REST CAPACITIES: The installed steady rest shall have a capacity of at least 3.15”-15.35”.

4.11 Accessories

4.11.1 CHUCK: The system shall include a KITAGAWA BB-218A15 + S-2816 Chuck (or equivalent). It shall have a bar diameter capacity of at least 6.5 inches

4.11.1.1 All chucks will have standard identical standard top jaw mountings.

4.11.1.2 The chuck shall have at least 6.5-in diameter through hole.

4.11.1.3 The system shall allow for M-code automatic chuck jaw opening and closing.

4.11.1.4 The system shall confirm the status of the chuck jaws (Open/Close) prior to execution of machining operations.

4.11.1.5 The system shall allow M-code programming to change the pressure applied to opening and closing of the chuck jaws.

4.11.2 TOOL PROBING: The system shall include a tool probe which can be used to measure the tool length and automatically update the tool offset table. This feature shall be accessible through G-code programming or through MDI request.

4.11.3 PART PROBING: Lathe work gauging probe shall be of Renishaw manufacturer and radio controlled. Work gauging probes shall provide measurement of machine surfaces without removing the part from the machine. The system shall be capable of probing multiple points to to verify inside and outside diameters. Work gauging probes shall measure a wide range of diameters that would normally require a variety of outside micrometers and bore gauges.

4.11.4 WORK LIGHT: The system shall include a high-intensity light for inspection of machined components prior to removal from the system.

4.11.5 HIGH PRESSURE THROUGH COOLANT: The system shall include a pressurized coolant system. The pressure shall be 1000 psi with a max flow rate of at least 5-gpm.

4.11.6 CHIP CONVEYOR: The equipment shall include an enhanced hinged side exit for the chip conveyor.

4.11.7 BORING BAR MODIFICATION (TURRET): The turret shall be modified to allow for a 4-inch boring bar socket. The tailstock shall accommodate long boring bars. The turret shall have capabilities to mount a 2-in ID Boring Bar Holder to utilize the turret as a boring bar.

4.11.8 LONG BORING BAR SYSTEM (TAIL BODY): The Tail Body shall include a Long Boring Bar System. This should provide capability for a boring bar to extrude into the part from the tail body. Means of using the Tailstock should still be provided without need for tailstock teardown. The tailstock and Boring Bar system are not to be used at the same time. In the event that a need arises to use the boring bar, the tail stock shall index on the tail body shifting the boring bar attachment to be on center with the part. Other means of tailstock indexing can be evaluated and be considered acceptable but must be identified. One of the main concerns is not having to tear down the tailstock and install the boring bar system.

4.11.8.1 Boring Bar Holders: The system shall come with (1) each boring bar holders to accept 3.15-in ID and 4-in ID boring bars.

4.11.9 LIVE TOOL EYE: The system shall include an automatic tool eye.

4.11.10 MULTI-SPINDLE ORIENTATION: The system shall include multi position spindle orientation capabilities.

4.11.11 HIGH TORQUE TOOLING: The equipment shall be designed to accept High Torque Tooling consisting of 81 ft-lbs/ 4000 rpm. This shall be provided with the equipment in a CAT40 tool set configuration.

4.11.12 BORING BAR HOLDERS: The system shall come with (1) each of long boring bar holders for 3.15-in ID and 4-in ID boring bars.

4.11.13 CAP PLUGS: The system shall come with qty (6) cap plugs for the VDI Turret

4.11.14 MILL HOLDERS (TOOLING): The system shall come with qty (2) Offset V-Type CAT40 4000rpm External Coolant VDI Turret mill holders and qty (2) Heavy duty H-Type CAT40 4000rpm External Coolant VDI Turret mill holders. The system shall come with qty. (2) Offset Vertical CAT40 4000rpm External coolant VDI mounting base VDI turret mill holders and qty. (2) Heavy Duty Horizontal CAT40 4000rpm External Coolant VDI mounting base VDI turret mill holders. These tool holders shall be VDI live tool holders that accept CAT40 toolholders as opposed to collets.

4.11.15 MIST COLLECTOR: The equipment shall include a mist collection unit to assist with environmental hazards of the machining process of the equipment.

4.11.16 COOLANT SYSTEM: The system shall include a variable flow coolant system with 1000 psi capabilities.

4.11.17 LIGHT TOWER: The system shall include a 3-color light tower on the equipment.

4.12 Controls

4.12.1 CONSTRUCTION: The control shall be a solid state, soft wired, Electronic Industries Association, EIA RS-274D input format, computer numerically controlled (CNC) system utilizing large scale integrated (LSI) circuits for data processing and control. The control shall be a micro-processor-based hardware designed to support an operating system which shall allow loading and editing a program while another program is being executed, and shall be specifically designed for application to CNC. The control shall be a multi-blocked, buffering, contouring system capable of driving all axes simultaneously. Plug-in circuit boards shall be coded to facilitate identification and location in the control and shall be arranged as convenient plug-in elements of quick disconnect modules with minimum connectors. Built-in test points, test procedures and instructions shall be provided for isolation and identification of defective components and circuitry.

4.12.2 CABINET: The control shall comply with NEMA Standard 12 and shall be sealed against dust and shop environmental conditions that might adversely affect performance of the system. No outside air shall be blown through the control for cooling purposes. The control shall be equipped with an industrial type air conditioner, allowing it to operate satisfactorily in ambient temperatures of 50°F through 110°F and relative humidity of 5% through 90%.

4.12.3 INPUT METHODS: The control shall be designed to operate from memory loaded from USB Port (no less than 2-ports); from Manual Data Input (MDI) using the keyboard

4.12.3.1 KEYPAD: The control shall be provided with one alphanumeric keypad that shall generate the 128 International character set and shall be constructed with an oil-tight switch panel. The keyboard shall be provided with tactile and/or audio acknowledgement for entry verification unless individual key responses are immediately displayed on the color display.

All keys, dials, and switches shall be functionally grouped.

4.12.3.2 ETHERNET PORT: The Ethernet port shall be capable of connection of a laptop style PC when necessary for troubleshooting and for loading of software and CNC programs.

This connection will not be made while the system is connected to the DNC network.

4.12.3.3 USB PORTS: The system shall include no less than (2) USB data ports. These ports shall be capable of being used to load CNC programs into the machine control or for connection of a printer to the machine control.

4.12.4 DISPLAY HARDWARE: The control station shall be provided with one color display measuring a minimum of 19-in diagonally across the visible screen.

4.12.5 STORAGE MEMORY: The control shall be provided with a minimum of 20-gigabytes of usable part program storage. Control memory shall be non-volatile (unaffected by power failures).

4.12.6 PROGRAM MEMORY: The control shall be provided with a secondary active storage device with a minimum capacity of 32-MB of user NC part programs and associated data. This is the memory used to hold the program being executed and simultaneously holding a program to be edited.

4.12.7 POWER LOSS RECOVERY: The control shall recover from power outages. Upon power resumption, the control shall automatically reload/reboot the executive and bring itself back, by operator initiation, to a state where the operator can initiate part program load and restart. For safety purposes, this recovery shall only begin after operator initiation.

4.12.8 MODES: Provision shall be made to allow operation in automatic, single block, Manual Data Input (MDI) and manual modes.

4.12.9 STEP MODE: It shall be possible to MDI in symbolic RS 274D data format and execute the statement in a record by record mode of operation, that is, one line at a time. If the MDI mode interrupts an automatic or single block mode, provision shall be made to re-enter at the point of interruption.

4.12.10 DIAGNOSTIC: The control shall include a diagnostic system for monitoring the control during operation and for locating malfunctions when troubleshooting. It shall bring the machine to a controlled stop should a malfunction occur during operation. The system shall give fault data in understandable code or message form on the color display, which shall identify a problem at board level in the control and identify program errors.

4.12.11 ALARM: The control shall display a visible alarm in the event of a system failure. The control shall also maintain an alarm history log to allow viewing after the alarm is corrected and cleared.

4.12.12 FAULT INTERUPT: The control shall ensure that the machine functions occur in the proper order and shall initiate protective action should a faulty condition develop. Typical action resulting from incompatible commands could be ABORT or Pause, with warning output to the display.