Attachment_1_Statement_of_Work_B145_CNC_Milling_Machines.pdf

April 24, 2018 Rev A

DESCRIPTION/WORK STATEMENT/SPECIFICATION

April 24,2018

1.0 Scope: This purchase specification provides the minimum requirements for 2 CNC

VERTICAL MACHINING CENTERS.

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 Standards 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) or the most current version of the International Electric Code IEC 60204-1

Underwriters Laboratories Inc.

UL 508 Standards for Safety for Industrial Control Equipment

(Application for copies should be made to Underwriters Laboratories, Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096 or the most current version of the International Electric Code IEC 60204-1.

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 VERTICAL MACHINING CENTER shall be new and one of the manufacturer’s current models capable of operation in accordance with the requirements herein. The machine will be a cast or molded frame (not a welded steel frame). The CNC mill shall be capable of operation in manual, semi-automatic, or fully automatic cycle. The machining center shall use standard ISO programming format for computer numerical controlled machine tools. It will include all required software and hardware necessary to program and operate the CNC MILL from the machine’s control panel. The control will include basic level Question and Answer with Graphics conversational assist programming for basic machining. The CNC control will accept programs from an off-line programming system. The CNC MILL shall have precision linear guide ways, precision spindle bearings, flood coolant system, through spindle coolant system, work light, full enclosure, spare parts list, maintenance and instruction manuals, standard set of wrenches and keys for the CNC Mill and its accessories. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Controlled Axes. The CNC MILL shall have as a minimum of three (3) controlled axes that can be run in both simultaneous linear and simultaneous contouring modes (3-axes simultaneous contouring). Axes shall be defined as X,Y,Z and shall be programmable in increments as small as .0001 inches shall be capable of contouring.

There must be an integral torque limiting system which electronically senses axis overload which will shut down the machine to an E-stop condition. The ball screws need to have absolute position encoders or equivalent that divides the rotation of ball screws to a minimum of 1,200,000 divisions. The position of all axes is to be known by the controller at all times including times of power loss, crashes or E-stop. The VMC will not require batteries to support the absolute position encoders. The VMC will not require to return to a home position at any time. The control shall be capable of adding a 4th axis interface and drive as a field retrofit.

3.1.2 Travel. The minimum requirements for axis travels are: X-axis travel minimum

58.00 inches, Y-axis minimum 25 inches, Z-axis minimum of 25.00 inches.

3.1.3 Table. The minimum table work surface will for the machine is 60 inches in X-axis, 25 inches in Y-axis and table work load of at least 3,000 lbs.

3.1.4 Spindle. It shall be a 40 taper spindle with CT retention knobs and will be a dual contact type. The dual contact spindle will accept both single contact type tool holders as well as dual contact tool holders. The spindle will be an integral motor type with no belts or pulleys in the drive train.

3.1.5 Spindle Speed / Horsepower. Minimum horsepower will be 25hp intermittent duty with continuous duty of 20hp. Range of speeds shall be from 50 rpm to 11,000 rpm.

3.1.6 Frame Construction. The frame shall be a double column bridge type which fully supports the table at extremes of travel. The material for the frame shall be a high tensile cast iron alloy of at least 38,000# tensile strength. Located in both the spindle and the frame, there shall be sensors for REAL TIME axis compensation for changes in the work zone environment.

3.1.7 ATC. The ATC (automatic tool changer) shall have a minimum of 30 tool storage positions and shall be a double arm type.

a. There will be a next tool ready station.

b. The ATC will accommodate both CT 40 taper tools including both dual contact tool holders and single contact tool holders.

c. The ATC shall hold tools of at least 30 lbs. in weight.

d. The ATC will handle tools 3.75 inches in diameter with adjacent tool stations filled and 5.75 inches diameter tools with adjacent tool stations empty.

e. Tools up to 15 inches long shall be accommodated.

f. Rotation of the ATC shall be driven by a servo motor with absolute position encoder feedback. Step-tracking for individual steps of the tool change sequence process is required.

g. Tool exchange time will be 2.8 seconds maximum, Tool to Tool. Tool Change will average less than 5.5 seconds, Chip to Chip. There will also be a spindle air blast during tool exchange.

3.1.8. Ball Screws. The ball screws shall be direct coupled to the axis motors with zero backlash couplings with absolute precision encoders for each linear axis.

a. The ball screw bracket housings shall be integral to the machine casting. The bracket housing will provide 360 degree ball screw support.

b. Cutting federate shall be as a minimum from 0.050 inches per minute to 1000 inches per minute for all linear axes.

c. The X and Y axes shall have rapid traverse rates of at least 1,500 inches per minute. Z-axis rapid traverse shall be at least 1,200 inches per minute.

3.1.9 Accuracy and Alignment. The CNC Mill shall have positioning accuracy with ball screw pitch error compensation on X-axis to 0.0008”, Y-axis and Z-axis 0.0005” full-stroke. Repeatability shall be for X-axis 0.00039” and Y-axis and Z-axis 0.00027”.

Alignment of each ballscrew within its housing and bracket shall be within 0.0002 inches or less over the full length of the X, Y and Z axes travels.

3.1.10 Cooling Systems. A closed, dual input system for spindle cooling unit will be provided to cool the Main Spindle Bearing Housing. A heat exchanger will be used to cool the Main Electrical Control Enclosure. There will be an air gap between the electrical cabinet and the frame of the machine.

3.1.11 Lubrication There shall be an Auto Lube system for the ways.

3.1.12 Coolant Supply. There shall be a flood coolant system with a roll-away coolant holding tank of at least 55 gallons.

a. A splash gun is required.

b. All coolant supply systems must be capable of using oil, synthetic, semi-synthetic, or water based coolants.

c. The mill shall be prepped to receive coolant through the spindle for a minimum pressure of 800 psi.

d. The mill shall be prepped to receive a mist collector.

3.1.13. CNC Control System. The CNC Mill shall have as a minimum of 120 GB program storage, two (2) USB Ports, a RS232C Port, and Ethernet interface. The CNC Mill shall be fully programmable from the machine’s controller as well as accepting off-line ISO G-code programming. It will include the necessary software and memory to accept programs generated as described in the previous sentence. The CNC Mill shall have as a minimum the following features:

a. 15 inch min color LCD monitor with two (2)USB ports.

b. 120 GB memory with 100 Gigabytes of program storage.

c. Hard Disk Drive with Ethernet Interface for hardwired and wireless types.

d. Rigid Tapping.

e. Helical Milling.

f. Any Angle Chamfering.

g. Auto-Assist at the machine programming software.

h. Portable Remote Jog Handle.

i. Spindle Orientation.

j. Rapid Traverse Override Switch.

k. Auto Z-Zero Offset Function via tool setting device with tool breakage detection.

l. Solid 3-D graphics and 2-D graphics display, operator switchable.

m. The control shall have a visual display tooling library and shall be capable of importing drawings of tools from tool manufacturers. The tool drawings will remain resident in the CNC control.

n. The control system must have auto gauging (part probing).

o. The control system must have a spindle probe for part location and feature measurement.

p. The control system shall have resident G-code and M-code definitions and explanations for their use resident in the CNC control. Additionally, there will be two hardcopies of the same information.

q. The CNC control will accept all standard Windows based protocol formats such as, but not limited to: .pdf, .doc, .xls, .txt, .wmv, .avi, .jpg, and .tif. All formats listed shall be able to display work instruction documents, safety and training videos and job related memos through the CNC control display panel without the need for a secondary PC station.

r. The CPU (main processor) for the CNC control shall be upgradeable at any time to the most current processor technology available – ie, WINDOWS and CPU.

s. There will be at least two (2) USB Ports and one (1) RS232C Port as well as the capability of Ethernet.

t. At least two (2) Gigabytes of RAM memory in the CNC control.

u. Software License to allow user-written or third party written user software programs for peripheral devices. ie, bar code readers, cameras, etc.

v. Serial Communication at a minimum of 9mb transfer speed per second.

w. ACC/DECC performance based on torque and speed values of the motor to calculate acceleration and deceleration automatically.

x. Servo performance on command permits maximum feed rates while assuring shape conformance. Program commands CNC to observe specific shape error and adjust feedrate as necessary.

y. Touch-Screen performance, QWERTY keyboard and soft key control panel data entry.

z. Work geometry conversion (mirror image) by either a soft key or switch on the operation panel.

aa. Ball screw pitch error compensation.

bb. Tool Life Management. Will calculate tool wear based on the number of parts machined or linear inches cut. When programmed, the software will direct the VMC to change to a redundant tool. When redundant tools have been exchanged, the information shall be displayed on the CNC control screen.

cc. Work Coordinates, 200 Sets.

dd. Tool Offsets, 300 Sets.

ee. Auto-assist programming software to generate basic shapes and tool paths.

ff. Message function – written into the program to advise operator of specific tasks associated with the current process.

gg. Mid-block restart – function allowing re-start in the middle of a block.

3.1.14 Chip Conveyor. The CNC Mill shall have coil augers within the enclosure to direct chips to the lift up type conveyer system. The conveyor to remove chips from the machine enclosure shall have a discharge height of at least 39”.

3.1.15 Work Light. The CNC Mill shall be equipped with a work light inside the enclosure of the work area.

3.1.16 Voltage. The CNC Mill shall be supplied configured to operate on 480 Volts, 3 phase, 60-hertz electrical power. (Note: the use of an external transformer to match the machine’s power requirements is acceptable.)

3.1.17 Tooling Package. 32 pull studs with coolant-thru capability. Mill spindle provided shall be compatible with both single and dual contact tool holders, #40 taper.

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 Mill will be located in a typical machine shop environment. The space available for this equipment is: Machine-1 13’ x 15’, Machine- 2, 13’ x 15’, including its attachments and operator’s area for each machine. There is paved access to all entrances; door access provided is 12’ opening. When machine is placed it must be kept 3 feet from walls. Aisle ways are 6’ wide minimum.

3.4 Electrical Power Requirements. The CNC mill shall be designed to operate on 230 or 460 VAC, 3 phase, 60-hertz electrical power. The electrical system shall conform to National Fire Protection Association (NFPA) 79 or to International Electrical Standard IEC 60204-1. All electrical wiring and components shall be sized for 230 / 460 VAC operations. Use of a multi-tap transformer is acceptable.

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

3.5 Safety and Health Requirements. The CNC Mill shall be designed and manufactured in accordance with ANSI B11.6 or International Machine Tool Standards ISO 230-2. The manufacturer shall ensure that the CNC Mill 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 Mill 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 Mill. 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 Reliability. Evidence of the reliability of the proposed CNC Mills shall be included with the contractor's proposal. The contractor shall cite at least 5 similar CNC Mills sold over the last 10 years and include the following information for each CNC mill: customer, contract or purchase order number, and customer point of contact information (phone number, e-mail, etc.). The reliability of the CNC Mill cited will be a factor in the past performance evaluation of the contractor's proposal.

3.7 Maintainability. The CNC Mill 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 Mill are readily available. The contractor shall also provide information on the normal maintenance actions required for the CNC Mill 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 Mill maintainability will be a factor in the past performance evaluation of the contractor's proposal.

3.7.1 Construction. The CNC Mill, equipment and accessories shall be constructed of quality material to the maximum extent possible.

3.7.2 Components The components used to manufacture this CNC Mill 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.

3.7.3 Warranty: The CNC Mill shall be covered by the manufacturer’s standard commercial warranty for a period of three years – parts and labor. The warranty shall be written in the name of the Anniston Army Depot. 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 requests for service within 48-hours after the request.

3.8 Nameplate. A nameplate shall be attached to the CNC Mill 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 Mill. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

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

3.10 Environmental Compliance The CNC Mill 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 Vertical Machining Centers.

3.10.1 Recovered Materials The offeror / 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 mill 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 mill to determine compliance with the requirements of this specification.

4.1.1 Test Setup and conditions. Unless otherwise specified, ANAD shall supply all tooling and material(s) as outlined in 4.2 and 4.3. The contractor shall conduct all tests required by the Government. The government 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 mill installation, the CNC Mill 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 Mills 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 test(s).

4.3 Performance Test. Unless otherwise specified, the performance test shall consist of the tests listed in ASME B5.57. The Government reserves the right to specify any or the entire test listed in these standards.

4.4 Acceptance. The Government will accept the CNC mill 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 mill 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 and acceptance made within two-hundred (200 days) calendar days after award of the contract.

5.1.1 Shipping, Handling, and Storage. The contractor shall be responsible for all shipping, storage, and handling of the CNC mill 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 Mill 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 mill). This documentation is to include as a minimum, the following:

a. Floor plan drawing of the CNC Mill 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. Industrial waste disposal requirements, if any.

h. 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 an active working area. The contractor shall not interfere with on-going Government operations and production unless authorized by the Contracting Officer or the Contracting Officer’s Representative.

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 or the International Electric Code. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings or equivalent International Electrical Code Standards for Machine Tools. 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 or the Contracting Officer’s Representative [COR] assigned to the project. No high voltage work will be accomplished without prior approval of the Contracting Officer or the assigned COR. All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

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

5.2.4 Foundation / Hardware. All foundation hardware and foundation requirements as determined by the by the machine builder shall be furnished by the contractor and included in the bid price.

5.2.5 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.

5.2.6 Electrical. The Government will connect power to all contractor furnished fused disconnect device. The contractor shall furnish and install a main fused disconnect device separate from the equipment. The fused disconnect device 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.

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

5.2.8 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 all 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 Mill. 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 – On-Site. The contractor shall provide as a minimum training to the following type of personnel on-site at ANAD:

Operators –1 day per machine

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.