Revised_B_SOW_09-11-2018_CNC_Crank_Cylindrical_Grinding_Machine.pdf

DESCRIPTION/WORK STATEMENT/SPECIFICATION

5/31/2018 REV A

09/11/2018 REV B

1.0 Scope: This purchase specification provides the minimum requirements for 1 each CNC Crankshaft Grinding Machine.

2.0 Applicable Documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of request for proposal shall apply:

U.S. Department of Labor

CFR Title 29, Chapter XVII, Part 1910 – Occupational Safety and Health Regulations

(Applications for copies shall be made to the Superintendent of Documents, Government Printing Office, Washington, DC 20402)

Electronic Industries Alliance

J-STD-001C – Requirements for Soldered Electrical and Electronic Assemblies

(Application for copies shall be made to the Institute for Interconnecting and Packaging Electronic Circuits, 2215 Sanders Road, Northbrook, Illinois 60062-6135)

National Fire Protection Association (NFPA)

NFPA - 70 The National Electrical Code, 1996

NFPA - 79 Electrical Standard for Industrial Machinery, 1997

(Application for copies should be made to the National Fire Protection Association, One Batterymarch Park, P.O. Box 9101, Quincy, Massachusetts 02269- 9101)

Underwriters Laboratories Inc.

UL 508 Standard for Safety for Industrial Control Equipment

(Application for copies should be made to Underwriters Laboratories, Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096

The American Society of Mechanical Engineers

ANSI B11.6 Safety Requirements for Lathes with or without Automatic Control

ANSI B93.114M Pneumatic Fluid Power Systems, Standard for Industrial Equipment and Machine Tool Applications. 1987

(Application for copies should be made to The America Society of Mechanical Engineers, 345 East 47th Street, New York 17, N.Y.

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA ICS 1 Industrial Controls and Systems 1993 (DoD Adopted) NEMA ICS 3 Industrial Systems 1993 (DoD Adopted) NEMA MG 1 Motors and Generators 1993 (DoD Adopted)

NEMA MG 7 Motion/position Control Motors and Controls 1993 (DoD Adopted)

(Applications for copies should be addressed to the National Electrical Manufacturers Association, 2101 L Street, N.W. Washington DC, 20037-1580)

ELECTRONICS INDUSTRIES ASSOCIATION (EIA)

EIA. SP-3761 Interface Between Data Terminal Equipment and Data Circuit Terminating Equipment Employing Serial Binary Data Interchange. 1997

EIA RS-267 Axis and Motion Nomenclature for Numerically Controlled Machines

1990 (DOD adopted)

EIA RS-274D Interchangeable Variable Block Data Format for Positioning and Contouring/Positioning Numerically Controlled Machines, 1980 (DOD adopted)

GEIA-491 Interface Between Numerical Control Unit/Peripheral Equipment-

Binary Data.

(Application for copies should be addressed to the Electronic Industries Association, 2001 I Street, N.W., Washington DC, 20006-1899) (Non-Government standards and other publications are normally available from the organizations that prepare or distribute the documents. These documents also may be obtained in or through libraries or other informational services.)

2.1 Order of Precedence. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence.

3.0 Salient Characteristics:

3.1 General Requirements: The CNC Crankshaft Grinding Machine shall be new and one of the manufacturer’s current models capable of operation in accordance with the requirements herein. The CNC Crankshaft Grinding Machine shall have a precision spindle capable of precision grinding. The CNC Crankshaft Grinding Machine shall be capable of performing the operations of O.D. grinding for crankshafts. The CNC Crankshaft Grinding Machine shall be capable operation either manually, semi automatic, auto cycle, full ISO programming of computer numerical control (CNC) to include all required software and hardware necessary to program and operate the CNC Crankshaft Grinding Machine from the machine’s control device. The CNC Crankshaft Grinding Machine shall have a precision way system, precision bearings, automatic lubrication system, coolant system, full enclosure, work light, parts and instruction manuals, standard set of wrenches and keys for the CNC Crankshaft Grinding Machine and it’s accessories. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1. Machine Capacity. The requirements for the machine capacity shall be as follows:

Swing Over Table Ø 18” Grinding Diameter (maximum) Ø 14” Distance Between centers (minimum) 70” Load Between Centers (minimum) 800 lbs.

Steady Rest Positioning, programmable 60” Steady Rest Capacity, automatic 2” – 6” DIA

3.1.2. Wheel Head. The minimum requirements for the wheel head shall be as follows:

Wheel Size (OD x ID) Ø 30” X 12”

Wheel Width 1.25” MAX Wheel Surface Speed 8,500 SFPM Move Increment (on diameter) 0.000010” Wheelhead Rapid Feed (on diameter) 394 IPM Wheelhead Configuration 90˚

3.1.3. Table. The minimum requirements for the Table shall be as follows:

Type Traversing Table Stroke 70.0” Slide Linear Roller Guides Move Increment 0.000010” Table Rapid Feed 394 IPM

3.1.4. Workhead. The minimum requirements for the Workhead shall be as follows:

Type Live/Dead Workhead Spindle with Swiveling Base Spindle Nose A2-5 U.S. Standard Workhead Spindle Taper MT #5 Work Speed (Variable) 21 to 500 RPM

3.1.5. Footstock. The minimum requirements for the Footstock shall be as follows:

Type Positionable body by program command or jog Foot Stock Center MT #4 Center Retraction .98”, Programmable

3.1.6. Dresser. The minimum requirements for the Dresser shall be as follows:

Type Stationary Diamond Holder Location Behind the workhead

Type Formed Diamond Dressing Tool or Single point type

3.1.7. Motors. The minimum horsepower requirements for the motors shall be as follows:

Wheel Drive Motor 15 Kw Work Drive Motor (Brushless AC Servomotor) 4 Kw Wheelhead Feed Drive Motor (Brushless AC Servomotor) 2 Kw Table Feed Drive Motor (Brushless AC Servomotor) 2 Kw Hydraulic Pump Motor .75 Kw Wheel Spindle Lubrication Motor 0.33 Kw Fan Cooler Motor for Spindle Oil 0.75 Kw Coolant Pump Motor, Flood 0.75 Kw Bed Coolant Flush Pump Motor 0.75 Kw

3.1.8. Wheel Hub Mount. The CNC Crankshaft Grinding Machine shall include as a minimum 2 wheel hub mounts as follows:

1 each Standard Wheel Hub Mount and Flange Assembly - Wheel Width of 1.3” to 2.00” 1 each Narrow Wheel Hub Mount and Flange Assembly - Wheel Width of .50” to 2.00”

3.1.8.1 Balancing Arbor. The CNC Crankshaft Grinding Machine shall include as a minimum one Balancing Arbor for static balancing of the grinding wheel.

3.1.9. Fluid Capacities. The minimum requirements for the Fluid Capacities shall be as follows:

Spindle Lubrication Tank 4 Gal.

Hydraulic/Lubrication Tank 5 Gal.

Coolant Tank 105 Gal.

3.1.10. Power Requirement. The minimum requirements for the Power Requirement shall be as follows:

Main Machine Power 480 Volt 3 Phase 60 Hz.

All of the machines accessories shall operate from the single source voltage supplied for the machine power.

(Note a Transformer must be furnished to meet this requirement if machine power requirement is other than the power specified)

3.1.11. Coolant System. The CNC Crankshaft Grinding Machine shall include a coolant system that as a minimum consist of the following:

Holding capacity for 105 US gallons 20 gal/min paper and magnetic coolant filter One (1) coolant pump One (1) bed wash pump Low Level Detection

3.1.12. Mist Collection System. The CNC Crankshaft Grinding Machine shall include a mist collection system that is designed to control coolant mist to the acceptable permissive limits prescribed by CFR Title 29, Chapter XVII, Part 1910 – Occupational Safety and Health Regulations within the machines recommended operating area.

3.1.13. Machine Control. The CNC Crankshaft Grinding Machine shall have a machine control that features simplified servo control and I/O connectivity and utilizes G-Code part programming, conversational programming from floor. The machine control shall as a minimum provide the following.

Axis Control:

• 2 Simultaneously Controllable Axes

• Inch/Metric Conversion

• Emergency Stop

• Least Input Increment of 0.0001mm, 0.00001inch, 0.0001deg

Operation:

• Auto Operation

• MDI Operation

• Single Block Mode

• Manual Feed Mode (Jog)

• Manual Handle Feed

• Incremental Feed

Feed Function:

• Rapid Traverse

• Rapid Traverse Feedrate Override (preset value, 25%, 50%, 100% settings)

• Feed per Minute

• Feedrate Override

• Jog Override

• Override Cancel

Part Program Storage & Editing:

• 5120m Part Program Storage

• 200 Stored Part Programs

• Part Program Editing

• Part Program Protection

Data Input/Output and Communications:

• Reader/Punch Interface 1 (RS-232)

• USB

Extended Requirements:

• CNC 3 Axis

• Embedded Ethernet

• High Speed Serial Buss (HSSB)

• Pentium III 866MHz

• 256 MB Ram

• Separate FA Full keyboard

Display Requirements:

• Status Display

• Clock Function

• Current Position Display

• Program Display

• Parameter Setting Display

• Self Diagnosis

• Alarm Display

• Alarm History Display

• Help Function

• Servo Adjustment Screen

• System Configuration Display

• Data Protection Key

• Custom Screens for ease of operator interface

• 10.4 inch TFT LCD Touch Screen Display

Auxiliary and Spindle Functions:

• Spindle Override 3-axis CNC unit, with movable pendent type operation panel with keyboard type manual data input, manual pulse generator, including these features:

• Grinding cycles:

1. Plunge grinding

2. Non-round grinding(ABILITY TO GRIND CRANKSHAFT PIN DIAMETERS)

3. Traverse Grinding

4. Face Grinding

5. Radius Generation

6. Taper Grinding

• Mode selection:

1. Auto

2. MDI

3. Manual

4. Handle (pulse generator)/Jog

5. Test cycle

6. Single Block

7. Program search

• 10.4" color LCD touch screen

• Multiple-part program storage memory each up to 30 steps with a selector switch

• Automatic determination of feeds, speeds, dwell time, traverse speed, rpm

• Programmable dressing cycle with automatic compensation

• Programmable jump on timing for the in-process gauge

• Programmable flagging cycle

• Jog feed axis selector.

• Grinding feed override switch from 0 to 150% in 10% steps

• Dressing feed override switch from 0 to 150% in 10% steps

• Rapid feed override switch from 0, 10, 50 & 100% settings

• Feed hold switch

• Wheel spindle on/off

• Emergency return

• Emergency stop

• Program number display

• USB Port and Memory Stick

• Ability to support measuring gauges out of the machine while measured on centers with the ability to provide automatic offset adjustment. Use of a separate PC is acceptable.

3.1.14. Jib Crane. The CNC Crankshaft Grinding Machine shall include a machine mounted Jib crane for use in mounting and removal of grinding wheel assemblies.

3.1.15. Wheel Load Assist. The CNC Crankshaft Grinding Machine shall be supplied with a mechanism to aid the operator in loading heavy grinding wheels.

3.1.16. Gap Sensor. The CNC Crankshaft Grinding Machine shall as a minimum be equipped with a gap sensing devise to indicate contact between the grinding wheel and the part.

3.1.17. Compressed Air Dryer. The CNC Crankshaft Grinding Machine shall be supplied with an electrically powered, condensing type compressed air dryer that includes a particulate filter mounted before the dryer to catch any particles that could clog the dryer. Compressed air dryer shall be furnished with an all stainless steel heat exchanger, is thermally protected and uses CFC free R-134a refrigerant. The Compressed air dryer shall be wired into the main control circuitry and will have a drain line designed for low maintenance.

3.2 System of Units. The equipment shall display all units of measure in the U.S.

Customary System of Units (first) and be capable of displaying both U.S. Customary System of Units and Scientific Units (second) where applicable.

3.3 Equipment Location. The CNC Crankshaft Grinding Machine will be located in a typical machine shop area. The space available for this equipment is 18’ X 30’ including its attachments and operator’s area. There is paved access to all entrances; door access provided is 12’ minimum, aisle ways are 6’ wide minimum.

3.4 Electrical Power Requirements. The CNC Crankshaft Grinding Machine shall be designed to operate on 480 VAC, 3 phase, 60-hertz electrical power. The electrical system shall conform to National Fire Protection Association (NFPA) 79. All electrical wiring and components shall be sized for 460 VAC / 460 VAC operation.

3.4.1 Electrical Noise. The electrical power at ANAD is subject to noise. If the CNC Crankshaft Grinding Machine requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the CNC Crankshaft Grinding Machine. If the CNC Crankshaft Grinding Machine is subject to interference from adjacent machinery, the CNC Crankshaft Grinding Machine shall include the proper shielding to prevent malfunctions.

3.5 Safety and Health Requirements. The CNC Crankshaft Grinding Machine shall be designed and manufactured in accordance with ANSI B11.6. The manufacturer shall ensure that the CNC Crankshaft Grinding Machine and all equipment and accessories used on the machine shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910. If a conflict arises between the ANSI B11.6 and the OSHA standards, the more stringent standard shall apply.

3.5.1 Noise Level. Noise emitted by the CNC Crankshaft Grinding Machine shall be no greater than 80 decibels as measured per ANSI S12.23-1989. The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the equipment into conformance with this requirement shall not interfere with visibility needed for safe operation of the CNC Crankshaft Grinding Machine. Operators shall be able to use this equipment without the need for hearing protection.

3.5.2 Ergonomics The equipment shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

3.6 Maintainability. The CNC Crankshaft Grinding Machine shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. The contractor shall provide evidence that repair parts and service for the CNC Crankshaft Grinding Machine are readily available. The contractor shall also provide information on the normal maintenance actions required for the CNC Crankshaft Grinding Machine including type of maintenance, required interval, mean time to perform maintenance and number and skill of people required to perform the maintenance actions. The CNC Crankshaft Grinding Machines maintainability will be a factor in the past performance evaluation of the contractor's proposal.

3.6.1 Construction. The CNC Crankshaft Grinding Machine, equipment and accessories shall be constructed of quality material to the maximum extent possible.

3.6.2 Components The components used to manufacture this CNC Crankshaft Grinding Machine shall be the manufacturer’s latest make and model. The contractor shall only use components that will be readily available for a minimum of 10 years after installation or can be easily replaced with newer components of the same type. This includes not only contractor-manufactured items but also those supplied by sub-contractors.

3.7. Warranty: The CNC Crankshaft Grinding Machine shall be covered by the manufacturer’s standard commercial warranty for this type of equipment and/or shall be extendable up to a period of no less than three years. The warranty shall be written in the Anniston Army Depot’s name. During the warranty period, the contractor shall be responsible for the repair of any defects in equipment parts or workmanship. The contractor shall respond to request within 48 hours after the request.

3.8 Nameplate. A nameplate shall be attached to the CNC Crankshaft Grinding Machine and shall contain, as a minimum, the following information:

a. Nomenclature.

b. Manufacturer’s name.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Short-circuit/over current rating.

g. Contract number or purchase order number.

h. National stock number (if applicable).

i. Date of manufacture.

3.9 Lubrication Plate or Chart. A lubrication plate or chart shall be attached to the CNC Crankshaft Grinding Machine. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of lubricant(s) with SAE number or lubricant identifier.

3.10 Environmental Compliance The CNC Crankshaft Grinding Machine provided under this contract shall meet all applicable Environmental Protection Agency (EPA) restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user’s health and shall be adhered to during the manufacture, service, transportation, storage and operation of the CNC Crankshaft Grinding Machine.

3.10.1 Recovered Materials The offerer/contractor is encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

4.0 Acceptance Testing & Verification

4.1 Conformance. The CNC Crankshaft Grinding Machine shall meet the requirements of this specification and conform to the manufacturer’s own drawings, specifications, standards, and quality assurance practices. The Government reserves the right to, at any time during the contract period, require proof of such conformance or to inspect the CNC Crankshaft Grinding Machine to determine compliance with the requirements of this specification.

4.1.1 Test Setup and conditions. Unless otherwise specified the manufacturer shall be responsible for supplying all tooling and material (s) and shall conduct all test required by the Government. The manufacturer shall provide test instruments and equipment with calibration traceable to the National Institute of Standards and Technology (NIST) and shall provide certification of calibration as specified.

4.2 Operational Test. Upon completion of the CNC Crankshaft Grinding Machine installation, the CNC Crankshaft Grinding Machine shall be operated in accordance with the Manufacturer’s standard operating procedure for a period of one (1) hour. During these tests, the contractor shall demonstrate proper operation of all CNC Crankshaft Grinding Machine controls, functions and features. The government will provide the materials necessary to perform the tests. All tests must be witnessed by the ANAD Contracting Officer or Contracting Officer's Representative. The proper operation of all controls and features shall be verified during this test period. Should a malfunction occur during any test, the contractor will correct the problem and repeat the entire test from the beginning.

4.3 Performance Test. Unless otherwise specified the performance test shall consist of the tests listed in ASME B5.16. The Government reserves the right to specify any or all the test listed in these standards.

4.4 Acceptance The Government will accept the CNC Crankshaft Grinding Machine only after the contractor successfully completes the requirements of paragraphs 4.1, 4.1.1, 4.2 and 4.3 herein. Final acceptance will be at Anniston Army Depot. Failure of the CNC Crankshaft Grinding Machine to meet the performance requirements specified shall be cause for rejection.

5.0 Installation and Delivery

5.1 Delivery The contractor shall complete the installation of all equipment within (365) calendar days after award of contract. The CNC Crankshaft Grinding Machine shall be delivered to Anniston Army Depot, Building 474, 7 Frankford Ave, Anniston, AL 36201- 4199.

5.1.1 Shipping, Handling, and Storage: The contractor shall be responsible for all shipping, storage, and handling of the CNC Crankshaft Grinding Machine and all materials. The Government shall not be responsible for furnishing any labor, equipment, or warehouse space for the loading, unloading, and storing of any materials.

The Government will make available if possible, space for a contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area. Should the contractor not wish to furnish a trailer for equipment storage, then the contractor shall coordinate with the Contracting Officer, a date at which time the contractor may deliver his equipment to the building.

5.2 Installation The contractor shall be responsible for installing the CNC Crankshaft Grinding Machine to include all labor and materials required. The contractor shall be responsible for insuring that the installation is compatible with existing facilities. The contractor will provide along with the bid, all of the installation requirements for the proposed offering, in this case a (CNC Crankshaft Grinding Machine). This documentation is to include as a minimum, the following:

a. Floor plan drawing of the CNC Crankshaft Grinding Machine showing the floor space requirements.

b. Space required around the machine after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate weight of the machine with accessories and attachments.

f. All utility requirements, including capacities of required utilities and approximate locations of utility connections to the machine.

g. Minimum doorway opening required to bring the machine into the building where it is to be installed.

h. Industrial waste disposal requirements, if any.

i. Ventilation requirements, if any.

A site layout for the equipment is included with this specification for reference.

Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours. The area near where the equipment is to be installed is in operation. The contractor shall not interfere with ongoing Government operations and production unless authorized by the Contracting Officer. Installation shall be completed and the equipment operational within 365 calendar days after award of contract.

5.2.1 Site Visit: A site visit is recommended to insure that the proposed equipment will be compatible with existing facilities.

5.2.2 Electrical: All electrical work shall comply with American National Standards Institute (ANSI) Publication C2 – National Electric Safety Code and with National Fire Prevention Association (NFPA) Publication No. 70 – National Electric Code. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings.

Workmanship shall be in accordance with standard commercial practices. Runs shall be installed perpendicular and parallel to existing facilities and the equipment to be installed. When equipment is installed near existing power lines, equipment shall be located for proper clearances in accordance with ANSI C2. New equipment shall not be connected to Government power without prior approval of the Contracting Officer. No high voltage work will be accomplished without prior approval of the Contracting Officer.

All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

5.2.5 Trades: Coordination of trades installing the equipment shall be the responsibility of the contractor.

5.2.6 Foundation Hardware: All foundation hardware shall be furnished by the contractor and included in the bid price.

5.2.7 Utilities: The Government will provide utilities within 20 feet of the equipment installation site. The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor in the installation manual noted above. What the Government provides at the job site is limited to the following:

5.2.7.1 Electrical: The Government will connect power to contractor furnished fused disconnect devise. The contractor shall furnish and install a main fused disconnect devise separate from the equipment. The fused disconnect devise shall be the correct size and type required the equipment voltage and comply with the requirements of paragraph 5.2.2. The Government will furnish only one voltage to the site.

5.2.8 Equipment Protection: The contractor shall protect surrounding equipment and shop area from damage due to dust, debris etc., during the installation.

5.2.9 Site Cleanup: The contractor shall remove all debris, scrap material, trash, etc.

from the job site daily. The depot will furnish a dumpster for all trash and construction materials at the job site, and will be responsible for emptying said dumpster. ANAD will provide an outdoor location for the cleanup of contaminated material if requested by the contractor. No equipment will be provided by the Government to perform any of the work performed by the contractor.

6.0 Documentation The contractor shall provide documentation to the government as listed below. Three copies each of the following technical data shall be provided as specified on the attached DD Form 1423 with the CNC Crankshaft Grinding Machine.

The contractor shall also provide three CDs that each contains copies of the delivered documentation.

6.1 Content The manuals shall include electrical, hydraulic, and pneumatic schematics, as applicable; parts lists, trouble shooting procedures, preventive maintenance requirements, lubrication schedules, calibration procedures, etc. Catalogs shall fully describe optional tooling, fixtures, and attachments available for the equipment furnished. In addition, any other technical data normally furnished with the equipment shall be provided. All technical data shall be furnished in the English language and be IAW with the following data item descriptors (DIDs)

Operator' Manual CDRL A01 DI-TMSS-80527A Engineering Support Manuals CDRL A02 DI-TMSS-80527A Engineering Drawings CDRL A04 DI-SESS-81003B Equipment Manuals CDRL A05 DI-TMSS-80527A

7.0 Training The contractor shall provide training to the following type of personnel:

Operators – 10 days which includes programs per part #’s (235004732)(5103264)(12254249)(2715658) and programs with changeover.

Maintenance Personnel – 3 days

Engineering Personnel – 3 days

Training shall be provided for the operation, programming and maintenance of the equipment. Training shall be conducted at Anniston Army Depot during normal depot working hours. All training costs shall be included in the total bid price.