B08 ATTACHMENT 0001 REVISED RIPD E4000-19-1-01 - ID Hone Revised 4-8-21.docx

HORIZONTAL HONE MACHINE REVISED 4-6-21

GENERAL SYSTEM DESCRIPTION

The purpose of this purchase description is to define salient characteristics and other deliverables required for the acquisition of two (2) Horizontal Internal Diameter Hone Machines. The hone machines are required for Army mission requirements for material removal and fine surface finishing and polishing work. This project entails the provision of the base machine as well as tooling and auxiliary equipment to create a turn-key solution for the Rock Island Arsenal Joint Manufacturing Center (RIA-JMTC).

STANDARDS AND PUBLICATIONS

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.

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.

Occupational Safety and Health Act of 1970 (OSHA).

American Society of Testing and Materials (ASTM).

American Society of Mechanical Engineers (ASME).

American National Standards Institute (ANSI).

National Electrical Manufacturers Association Standards (NEMA).

Electronic Industries Association (EIA).

Institute of Electrical and Electronics Engineers (IEEE).

American Code for Information Exchange (ASCII).

American Welding Society (AWS).

American Gear Manufacturers Association (AGMA).

National Fire Protection Association (NFPA).

1.1.1.1 NFPA-70 National Electrical Code

1.1.1.2 NFPA-79 Electrical Standard for Industrial Machinery.

International Standards Organization (ISO).

DESIGN

Ownership 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.

General Design Standards 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.

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.

IDENTIFICATION 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 Duns 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).

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.

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://pieetraining.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.

UTILITY CONNECTION: Equipment supplied to the RIA-JMTC 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 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.

UTILITY CONNECTION LABOR: RIA-JMTC 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.

UTILITIES AVAILABLE: RIA-JMTC shall be responsible for providing the following:

1.1.1.3 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.

1.1.1.4 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.

1.1.1.5 Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. This is necessary to maintain IEPA compliance.

1.1.1.6 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.

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

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

1.1.1.8 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)

1.1.1.9 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.

1.1.1.9.1 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.

1.1.1.9.2 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.

1.1.1.9.3 All filters shall be either cleanable or replaceable.

1.1.1.9.4 All pumps shall be self-priming.

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.

1.1.1.10 Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

1.1.1.11 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.

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.

1.1.1.12 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.

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

1.1.1.14 Protection shall be provided to prevent damage to components.

1.1.1.15 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.

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

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

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

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

1.1.1.20 All pumps shall be self-priming.

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.

1.1.1.21 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.

1.1.1.22 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.

1.1.1.23 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.

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.

1.1.1.24 The unit shall be of watertight construction.

1.1.1.25 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.

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

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

1.1.1.28 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.

1.1.1.29 As a minimum, the chip removal unit shall be provided with an on/off switch or buttons, stop button, and reversing switch. The units shall be provided with adequate swarf removal from the work-piece and removal from coolant before coolant re-enters the reservoir.

MOTORS:

1.1.1.30 All motors shall be rated for continuous duty.

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

1.1.1.32 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.

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

1.1.1.34 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.

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.

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.

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

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.

Safety, Security and Environmental SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. At all times during the execution of the contract, the contractor will maintain adequate plant protection devices 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. 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.

1.1.1.35 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.

1.1.1.35.1 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.

1.1.1.35.2 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.

1.1.1.35.3 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.

1.1.1.35.4 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 Contracting Officer’s Representative (COR), or paced in a drop box at a RIA-JMTC access point.

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

1.1.1.36.1 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.

1.1.1.36.2 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.

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.

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.

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.

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

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

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.

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.

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.

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

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

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.

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.

CONTROL GUARDS: Controls shall be guarded against accidental operation.

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.

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.

Responsibilities 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.

SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system. Examples would include, but are not limited to, buried sewer lines, standing water, and so forth. The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

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. The equipment shall consist of, but is not limited to the following described principal components, attachments and accessories necessary to meet the operational and performance requirements specified herein. The honing machine(s) requested shall have the ability to hone multiple materials. Materials used at Rock Island Arsenal include Steel, Stainless, Aluminum, Bronze among others:

Machine:

BED: The bed shall be a rigid, heavily ribbed, close grained, ferrous, casting of iron or iron alloy or a non-tubular, stress relieved, welded, steel fabrication ribbed and braced to prevent any distortion, deflection and maintain accuracy within the normal operating and load capacities for which the machine is designed. Bed segments shall be precision machined on their mating surfaces and properly matched and labeled to insure the accurate alignment and connection of bed sections, slide ways, spindle carriage, work holding system, drive gear racks, and any other connecting components without the use of shims, gaskets, spacers, or fillers. Bed segments shall be secured to each other by a sufficient number, size, and strength of fasteners, as well as, dowels and/or keys to insure maximum strength, rigidity and alignment of the bed sections. Slide way design and construction shall be as specified in 4.1.3.

SPINDLE CARRAIGE: A spindle carriage shall be provided. The carriage shall be a rigid, heavily ribbed, close grained, ferrous casting of gray iron or iron alloy or a stress relieved, welded, steel fabrication ribbed and braced to prevent any distortion, deflection, or loss of accuracy within the normal operating and load capacities for which the machine is designed. The carriage shall form the foundation for a spindle, and carriage feed drive assembly. The carriage shall be designed to mount on two widely spaced bed ways, which allow the carriage to traverse along its full rated travel. The carriage bearing length, width, and distance between slide ways shall be sized and proportioned to insure maximum rigidity and distribution of forces generated within the design limits of the machine. The carriage shall be machined to accept replaceable or insert type precision way bearings that will insure close and permanent accuracy over the length of their mated slide ways. Way bearings shall be of a design and material having low friction characteristics that will prevent sticking, overshoot and excessive wear to the slide ways and way bearings. Antifriction re-circulating, precision, roller way bearings are acceptable provided they are used in conjunction with precision ground and hardened replaceable slide ways or slide way inserts having a surface hardness not less than Rockwell C-58. All way bearings shall be pressure lubricated. Gibs, guides, or bearings shall be provided to maintain accuracy and alignment of the carriage to the ways and adjust for wear. All carriage way bearings shall be protected from contamination by way wipers.

SLIDE WAYS: The spindle carriage and work holding system shall each be supported on their individual, widely spaced, pairs of slide ways. Each slide way shall be of sufficient length to support its respective slide without excessive overhang, over the entire travel of the slide. Slide ways shall insure close and permanent accuracies and alignments of the slides. Slide ways shall be hardened and ground replaceable type slide ways. All slide ways shall have a surface hardness not less than Rockwell C-58. Hardened and ground, precision, replaceable slide ways shall be fastened to their foundations by a sufficient number, size, and strength of fasteners suitable for the application. Dowels, keys, or body bolts shall be utilized to maintain slide way alignment. Counter bores machined in the slide way surfaces to facilitate fastener heads and alignment hardware shall be plugged flush with the way surface with a material that will protect way surfaces and way bearings from contaminates that could collect in counter bores. Segmented slide ways shall be precision matched between segments forming one continuous slide way without the use of shims, gaskets, or fillers between segments. Slide way configuration and design shall insure the slides cannot be lifted from their ways under any load or operation within the operating capacity of the machine. Rockwell C-58 requirement applies only to spindle carriage ways.

WAY WIPERS: Way wipers shall be provided on all linear axes, minimizing the entrance of dirt, debris and swarf to the guide-ways and slide-way bearing surfaces. The wipers shall also provide sufficient sealing capability as to minimize the amount of machining coolant reaching these areas.

SPINDLE DRIVE SYSTEM: The spindle shall have a servo powered drive system of no less than 30 kW.

SPINDLE DRIVE SHAFT: The spindle drive shaft shall be able to support tooling to cover the inside diameter listed in 4.1.17. It shall be attached to the spindle drive system by bolts and a minimum of 2 keyways. It shall attach to the tool body by a universal joint of the manufacturers standard design. It shall have an internal expansion rod used to expand the tool body. The internal expansion rod shall be supported by the drive shaft, and sealed to prevent contaminants from entering the system.

RECIPROCATION DRIVE SYSTEM – a reciprocation drive system shall be provided. The reciprocation drive system shall be equipped with a servo drive with an output of not less than 11 kW . The drive system unit shall be designed to achieve infinitely variable reciprocation rates from 1-100 FPM, with a minimum number of drive components, as practicable, to eliminate sources of mechanical-lost motion. Reciprocation rates shall be controlled from the operator console. The reciprocation drive system shall be equipped with a positioning encoder direct coupled to the head shaft for monitoring carriage positioning and velocity. Reciprocation shall be chain-type, with #140 single chain and sprockets.

MACHINE GUARDING: Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts. Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of "OSHA Safety and Health Standards (29 CFR 1910), General Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other paragraphs of this specification.

SAFETY FEATURES: The systems shall include appropriate fencing and light curtains where necessary in order to be compliant with the identified safety standards in Section 2 of this RIPD.

TOOL EXPANSION SYSTEM: The tool expansion shall be accomplished via an electric servo motor actuator and be equipped with position and load sensing capability. The tool expansion system shall accommodate rotary/Linear expansion and provide input for stone ware monitoring and compensation. Feed rate and expansion force shall be controlled from the operator console. The control shall have a feature for automatic tool expansion.

WORK PIECE HOLDING DEVICES: The hone shall be supplied with not less than two (2) separate work piece holding devices that make up the work piece holding system. The work piece holding apparatus shall consist of universal chain-type part holding fixturing. utilizing 60-6 chain and clamps. The work piece holding device shall be supported on air slide ways. All work piece holding devices shall support at a minimum half of the entire weight of the maximum capacity specified herein. The work piece holding devices shall allow for vertical crane loading of work pieces. The work piece holding devices shall provide for a positive means of locking or clamping the work piece and not damage, distort or mar the external finish of the work piece. This clamping system shall be in accordance with OSHA regulations. The work-piece holding device shall be capable of allowing cylinders to rotate both clockwise and counter clockwise while honing. A means to position and lock\unlock the work piece holding system along the slide ways shall be provided. It shall be the manufacturer’s standard design. The system shall be provided with an auto centering system.

POWER TRACKS: All flexible power lines, cables, conduits, and hoses necessary to connect the linear sliding, powered, assemblies to stationary utilities and controls shall be contained within a flexible power track arrangement. The power track shall be the manufacturers standard. Conductors located on the power track shall be adequately cradled or secured at regular intervals and in an orderly manner. Power track design shall insure that flexible conductors are not stretched, crimped, pinched, or scraped over the full travel of the track. A guide arrangement shall be provided to insure straight motion of the track, parallel to carriage motion, without twist or binding. The power track shall be located in a position that will allow access and egress to the operator and control panel without interference as well as afford the best possible protection of the conductors. All conductors shall be of sufficient length to allow full travel of the spindle carriage and shall be connected at both ends to junction boxes and manifolds in proximity to the track ends to facilitate replacement of conductors. All conductors shall be labeled at both ends. Installation of the power tracks in the overhead position is not allowed.

POSITION FEEDBACK: All motion devices shall be equipped with position feedback devices wired to a control system as part of a closed loop system to indicate true position of the slides. The feedback devices shall be the manufacturer's standard. The devices shall be fully protected from contaminants such as dirt, dust, swarf, and coolant by protective covers.

OVER-TRAVEL PROTECTION: All linear slides shall be protected from over-travel or collision with other machine components at both extremes of slide travel. Electrical limit switches shall be utilized to disable the individual feed drives before slide and feed drive components can be damaged from an over travel condition. Limit switches shall not reduce the travel range of the individual slides. When the mass of the slide and its traverse rate create inertia that may cause slide over travel past the limit switch, a slowdown limit shall be provided. Slow down limits shall be hardwired switches or programmed in the control. Slow down limits shall be located ahead of the over travel limits as close as practical. Slow down limits when actuated shall decelerate the feed drive of the slide to a level that will insure the stopping of slide motion when the over travel limit is actuated. Mechanical stops shall be provided as a final over travel protection device in the event the electrical limits fail.

FLOOD COOLANT AND FILTRATION SYSTEM: The machine shall be provided with a flood coolant system. Each machine shall have its own system. The system shall be complete with all necessary pumps, motors, filters, reservoirs, valves, piping, and flow controls. The coolant filtration system reservoir shall have a capacity of not less than 1000 gallons be of adequate size to perform effectively with the machine and be of double wall construction to eliminate condensation. The reservoir and system shall be protected from contamination with filters, screens, baffles, clean out plates, and other features needed to keep the system clean, operational, and facilitate maintenance. Coolant shall be agitated to prevent thermal stratification. The clean coolant delivery pump shall be not less than 2 HP. Coolant shall be controlled by an on/off switch. A means shall be provided to allow the operator to direct and control the coolant flow. The system shall have adequate capacity for all types of honing operations for which the machine is designed. A means of spent coolant recovery to the reservoir shall be provided, with the dirty coolant return pump being rated for not less than 2 HP. The coolant recovery system shall be equipped with a high intensity magnetic pre-filter assembly with double-reduction drive and components. Splash guards shall be provided to contain coolant used during honing operations. The coolant system shall separate swarf from coolant. The coolant filtration system shall be equipped with a deep-bed paper filter with float advance and end-of-roll signal on the operator’s panel. Waste swarf shall have no free liquids. The system will be provided with an integral chiller.

CONTROL SYSTEM: The control shall be a PLC based system or equivalent, and it shall have as a minimum, the following features:

1.1.1.37 CONTROL SYSTEM FEATURES:

1.1.1.37.1 Color touch screen HMI 15” LCD monitor

1.1.1.37.2 Menu screens with diagnostic, trouble shooting and alarm codes mounted in a pendant operator control panel.

1.1.1.37.3 Part program storage and recall capability

1.1.1.37.4 Full control of all machine functions from operator control panel

1.1.1.37.5 The control unit shall be mounted on a swing pendant which is attached to the machine base

1.1.1.37.6 Cycle start/stop

1.1.1.37.7 Coolant on/off

1.1.1.37.8 Auto compensation as pressure changes are detected during the honing process.

1.1.1.37.9 Manage the minimum control operations such as stroke positions, motion control, stone feed, spindle speed, and cutting pressure

1.1.1.37.10 Ability to indicate high and low spots during processing and automatically correct the geometry with appropriate short strokes without operator intervention

1.1.1.37.11 Spindle jog, short stroke function

1.1.1.37.12 Store all process parameters and reset all machine parameters. The intent is to have “NC Reset” functionality, i.e., reset settings to system defaults.

1.1.1.37.13 Storage for a minimum of 999 distinct part programs

1.1.1.37.14 Machine spark out functions

1.1.1.37.15 Dwell and oscillation functions

1.1.1.37.16 New part operations in a step by step user interface format

1.1.1.37.17 Tool overload protection function to ensure optimal stock removal and protection of the tool during processing

1.1.1.37.18 Carriage overstroke protection

1.1.1.37.19 Digital stroke position indicator

1.1.1.37.20 Digital RPM readout for the spindle

1.1.1.37.21 Digital speed indicator

1.1.1.37.22 Automatic home functions

1.1.1.37.23 Center height of the monitor above finished floor shall be no more than 65”

1.1.1.37.24 Emergency stop cable for the entire length of the machine.

1.1.1.37.25 Programmable stroke positioning and tool settings TOOLING: One (1) tooling range featuring tandem length tooling with guides, stone holders, driveshaft assemblies, and related components including abrasive stones. Tooling shall be capable of processing the inclusive range: 1inch through 15 inches shall include the following components:

1.1.1.38 1.00” diameter tool/ integral driveshaft: Tool range between 0.99”-1.19” at a minimum or equivalent. Integral driveshaft of length appropriate to the machines stroke capacity. Shall include stoneholders

1.1.1.39 1.25” diameter tool: Tool range 1.19”-1.43” at a minimum or equivalent. Appropriate diameter driveshank. Shall include stoneholders.

1.1.1.40 1.50” diameter tool: Tool range 1.43”-1.93” at a minimum or equivalent. Shall include appropriate driveshank and stoneholders.

1.1.1.41 2.00” diameter tool: Tool range 1.93”-2.44” at a minimum or equivalent. Shall include appropriate driveshank and stoneholders.

1.1.1.42 2.50” diameter tool: Tool range 2.44”-2.93” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.43 3.00” diameter tool: Tool range 2.93”-3.43” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.44 3.50” diameter tool: Tool range 3.43”-4.09” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.45 4.00” diameter tool: Tool range 3.88”-5.00” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.46 5.00” diameter tool: Tool range 4.88”-6.13” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.47 6.00” diameter tool: Tool range 5.76”-7.06” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.48 7.00” diameter tool: Tool range 6.76”-8.06” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.49 8.00” diameter tool: Tool range 7.76”-9.06” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.50 9.00” diameter tool: Tool range 8.76”-10.06” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.51 10/11” diameter tool: Tool range 9.63”-12.25” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.52 12/13” diameter tool: Tool range 11.63”-14.25” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.53 14/15” diameter tool: Tool range 13.63”-16.25” at a minimum or equivalent. Shall include appropriate diameter driveshank, guides, and stoneholders. The guides shall accommodate the range of the tool.

1.1.1.54 To be considered equivalent, the tooling components must encompass the full working range of the equipment.

DRIVESHAFTS: The contractor shall be responsible for the provision of any driveshafts that may be required to encompass the range of tooling required. This shall include any wipers, support bushings, and drive adapters used to couple the driveshafts.

PERFORMANCE: The machine supplied under the requirements of this specification shall meet the requirements of the following performance tests in AISI 4130 or AISI 4340 steel of 6” ID, 36” work-piece length as well as Bronze. The Bronze piece shall be 2” ID with a 48 in length. The following performance capabilities shall be the standard accuracies for the equipment:

Final bore tolerance ± 0.0002” Roundness ± 0.0002” Surface finish 4 RMS (with paper allowed) Driveshaft curvature 0.015” over length of part Drive shaft TIR 0.015” over length of part

SIZES AND CAPACITIES: The equipment supplied under the requirements of this specification shall conform to the dimensions, sizes, and capacities stated below.