Attachment_1_Statement_of_Work.pdf

ATTACHMENT 1

DESCRIPTION/WORK STATEMENT/SPECIFICATION

Saddle Type Surface Grinding Machine

1.0 Scope: This purchase specification provides the minimum requirements for 1 each Saddle Type Surface 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) or

CE Conformite Europe

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 Saddle Type Surface Grinding Machine shall be new and one of the manufacturer’s current models capable of operation in accordance with the requirements herein. The Saddle Type Surface Grinding Machine shall have a precision spindle, programmable and manually operated three axis, capable of fully automatic functions. The programmable automatic cycles shall include: rough/fine grinding, programmable straight wheel dressing, programmable radiused and angled wheel shapes with automatic compensation. An electro-magnetic chuck with controls shall be included. The Saddle Type Surface Grinding Machine shall be capable operation in manual, semi-automatic and fully automatic cycles. All required software and hardware necessary to program and operate the Saddle Type Surface Grinding Machine from the machine’s control device will be included. The Saddle Type Surface Grinding Machine shall have, Double-Vee and ground precision ways, fluorocarbon lining (Turcite), precision bearings, an automatic lubrication system, flood coolant system with both paper and magnetic particle separation, work light, parts and instruction manuals, standard set of wrenches and keys for the Saddle Type Surface Grinding Machine and its accessories. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

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

Chuck working surface 12 inches x 22 inches L-R Table Movement 28 inches U-D New Wheel to table Distance 10 inches I-O Cross Movement 13 inches Table load Capacity with Magnetic 500 lbs.

Vertical feed .5 AC servo motor

3.1.2 Spindle and Wheel The minimum requirements for the Spindle and Wheel shall include supporting both CBN and Diamond wheels in addition to standard abrasive wheels.

Motor Horsepower 7.0 hp Spindle Drive Direct Drive Spindle Type Cartridge Bearing Type Angular Contact

RPM 1700 rpm Wheel Size 14” x 1-1/4” x 5” Wheel Flanges – extra 3 Grinding Wheels –extra for steel 3

3.1.3 Wheel Dresser The minimum requirements for the Wheel Dresser elements include the ability to dress forms into the wheel – straight, radius, angle - without the need for ISO programming format.

Dresser Location Table Mounted Outside chuck envelope Dressing Cycles, Automatic w/ Compensation Straight Angle Radius Diamond Dresser Holder Capable of holding three

Diamonds

3.1.4 Axis Motion The minimum requirements for the Axis Motion elements. The down feed shall be from .00005 to .00015 of an inch. There shall be a programmable home system that will allow the machine table to position itself toward the operator for easy placement of parts on magnetic chuck. There shall be a pulse handle that has movement of .001/.01/.100 of an inch for easy setup.

Drive, X-axis (L – R) AC Servo, Ballscrew Drive, Y-axis (U – D) AC Servo, Ballscrew Scale Feedback on Y-axis Drive, Z-axis (Cross) AC Servo, Ballscrew Manual HPG for each Axis

3.1.5 Grinding Cycles The minimum requirements for Grinding Cycles shall include:

Straight, Facing, Slotting, Vee-form slotting, Plunge, Multi-slot plunge, and Area grind.

All grinding cycles shall allow for dressing during the cycle with automatic compensation.

3.1.6 Electro-Magnetic Chuck The surface grinding machine shall include as a minimum one Electro-Magnetic (12x22 size) Chuck with Fine Division poles, variable holding power and a Demagnetizer Control.

3.1.7 Enclosure The surface grinding machine shall include as a minimum a full-enclosure of the grinding work zone. The enclosure shall include a mist collector.

3.1.8 Lubrication The surface grinding machine shall have an automatic re-circulating lubrication system, electronically monitored which will stop the grinder in the event of a lubrication failure.

3.1.9 Balancing Arbor The surface grinding machine shall include as a minimum one Balancing Arbor for static balancing of the grinding wheel off the grinder.

3.1.10. Coolant System. The coolant shall be a “Dry” base design that will allow coolant storage outside of the machine base. The coolant tank shall be separated in stages and shall be a combination paper/magnetic type.

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 Surface Grinding Machine will be located in a typical machine shop area. The space available for this equipment is 10’ X 14’ including its attachments and operator’s area. There is paved access to all entrances; door access provided is 12’ open, aisle ways are 10’ wide.

3.4 Electrical Power Requirements. The Surface Grinding Machine 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 CE. All electrical wiring and components shall be sized for 460 VAC / 460 VAC operations.

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

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

3.5 Safety and Health Requirements. The Surface Grinding Machine shall be designed and manufactured in accordance with ANSI B11.6. The manufacturer shall ensure that the Surface 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 Surface 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 Surface 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 Surface 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 Surface Grinding Machine are readily available. The contractor shall also provide information on the normal maintenance actions required for the Surface Grinding Machine including type of maintenance, required interval, and mean time to perform maintenance and number and skill of people required to perform the maintenance actions.

3.6.1 Construction. The Surface 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 Surface 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 7 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 Surface 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 not less than one year. 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 Surface 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 Surface 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 Surface 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 Surface 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 Surface 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 Surface 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 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 Surface Grinding Machine installation, the Surface 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 Surface Grinding Machine controls, functions and features. The contractor 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. Performance Test shall consist of the Surface Grinders ability to operate to the manufacturer’s own specifications and produce to the desired dimensional requirements, tolerances and finish required to produce complete grinding operations as required for acceptance of specific dimensions furnished by the government. The initial performance testing shall be accomplished at the manufacturers’ facility and serve to demonstrate the machines ability to meet the governments intended purpose for the machine.

4.4 Acceptance The Government will accept the Surface 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 Surface 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 (120) calendar days after award of contract. The Surface Grinding Machine shall be delivered to Anniston Army Depot, Building 147, 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 Surface 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 Surface 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 (Surface Grinding Machine). This documentation is to include as a minimum, the following:

a. Floor plan drawing of the Surface 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. 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 in operation. The contractor shall not interfere with ongoing Government operations and production unless authorized by the Contracting Officer

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 with the Surface 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 A03 DI-SESS-81003B Equipment Manuals CDRL A04 DI-TMSS-80527A

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

Operators Maintenance Personnel

Auto Cycle Programming Personnel

7.1 Training Time One (1) week of training shall be conducted at Anniston Army Depot in addition to the standard setup and support offered with during normal depot working hours. All training costs shall be included in the total bid price.