FY17_REV_II_RR_Guide_Bore_WV12177_Spec.pdf

U. S. Army Watervliet Arsenal Watervliet, NY Equip Engr. Spec# 18-17-3416 Date: 31 May 2017 Revision II

Rebuild/Retrofit Cincinnati Milacron WV12177 Guide Bore

Table of Contents

1. Scope

1.1 Abbreviated Description

2. Applicable Standards and Publications

3. Requirements

3.1 General Requirements

3.2 Specific Requirements

3.3 Controls/Control Systems

3.4 Requirements for Demonstration of Conformance

4. Quality Assurance Provisions

4.1 Responsibility for Inspection

4.2 Preliminary Acceptance Inspection

4.3 Government Participation

4.4 Reinspection Provisions

4.5 Post Inspection Procedures

4.6 Final Acceptance Inspection

4.7 Warranty

5. Preservation, Packaging and Delivery Instructions

6. Instructions for Preparing Technical Offers

Equip Engr. Spec #18-17-3416 Dated 21 January 2017

1. Scope:

1.1 Abbreviated Description. This specification defines the requirements for the complete machine rebuild and retrofit of one 1984 Cincinnati Milacron Guide Bore, Watervliet number WV12177, and S/N 4390-80-0008. This guide bore has controlled guidance that can follow the theoretical boring centerline of a large caliber canon tube. The control can drive the boring head to maintain bore center line to the outside diameter maintaining concentricity.

1.1.1. BORING HEAD: The guided boring head is mounted on the end of the bayonet to the front of the Hydrostatic bearings. Support is obtained by the use of hydrostatic bearings.

Each bearing has four pockets where hydraulic oil is supplied maintaining an oil film around the complete periphery of the bearing. This oil film is approximately .005" thick and will accommodate small variations in bore diameters. The cutting tools derive their position in the bore from the hydrostatic bearings. In the bore guidance head, the front and rear bearings must function independently from the rest of the boring bar to allow for correction of the head. Both hydrostatic bearing pockets are rigid and act with a fulcrum pin. It is from this position that the boring head guidance is derived. The front bearing pockets are variable and control changes in the direction of the head with respect to the rear bearing pockets which allows for corrective moves of the head and tools to the actual centerline. Both the front and rear bearing are able to withstand the cutting forces of the boring operation and provide a solid base for the machining action.

1.1.2. STARTING BUSHING; The fundamental purpose of the starting busing is to supply an accurate means of supporting the boring head until it has traveled sufficiently into the tube for the bore diameter to take over the support of the head. Eight pressure gages are used to check the pressure at each of the eight bearing pockets in the bayonet. These gages show bearing pocket pressures only when the boring head is located in the starting busing. The starting bushing is also used to check tool setting prior to boring by employing a readout gage and an LVDT (Linear Voltage Differential Transducer). The LVDT converts linear motion of the core of the transducer into an output voltage or signal which can be read on a meter to show the amount of movement (shift). The tool setting is checked by aligning the cutting tool closest to the operator, with the sensing button of the LVDT located within the Starting Bushing. This aligning cannot be visually observed, but the operator can perform the alignment by watching the readout which is electrically connected to the LVDT. The rear tool insert is offset approximately .003” in relation to the front insert to allow for head float to accommodate the change in cutter location as it traverses down the bore.

The front end of the starting bushing is equipped with a seal ring assembly which provides a seal between the tube face and the Starting Bushing. This seal is used to prevent pressure loss in the hydrostatic bearings as they pass into the tube. The clamping force between the Starting Bushing and the tube face is regulated by a pressure controlled limit switch located at the top of the starting bushing.

1.1.3. Detecting Runout: If a tube can be bored so as to follow the actual centerline of the machine, it will have a straight bore. If a tube is rotated within the confines of a machine centerline while the bore wanders into an eccentric position, the head producing the bore will be moving in an orbital pattern. A sensitive electronic device called an accelerometer is used to detect this orbital variation or motion. The sweep of the accelerometer depends on the amount of orbital path and the number of revolutions per minute of the headstock spindle. The accelerometer is basically a pendulum that the larger and more rapid the throw, the higher the pendulum will swing. The output of this device is a voltage commensurate with pendulum swing from 0 to 10V. The accelerometer is located in the bayonet between the hydrostatic bearings and will produce a voltage signal when it detects an eccentric path. An accelerometer has been used to detect runout on all bore guidance machines to date.

1.1.4. Hydraulic Guidance System: The hydraulic oil used in the guidance system is the same oil used in the machine as a coolant. Before the coolant oil can be used in the guidance system it must be thoroughly filtered and temperature regulated to insure a constant viscosity which is necessary to obtain predictable control at the hydrostatic bearings. The oil next passes through a variable volume supply pump which control the amount of oil supplied to the hydrostatic bearings. The volume of this pump is regulated by an adjustable swash plate. An independent hydraulic system provides the pilot pressure for a servo valve which regulates the swash plate. An assist pump is used to supply a constant hydraulic pressure against the swash plate to help control its location. The output of the variable volume main supply pump is passed on to the boring slide by means of the power track and piping through the boring bar. Once the oil reaches the boring slide it is directed into two paths. One path is to follow a 5/8" line into the boring bar and feeds all eight hydrostatic bearing pockets with a constant fluid pressure. The second path is used for actual control of the boring head. When following this path the oil first goes through an intensifier pump to increase the pressure. A pressure greater than the constant oil pressure in the bearing pockets is required for guiding the head. The oil is next passed through a 10 micron filter and on to a servo valve. This servo valve receives its signal through the electronics from the accelerometer in the Boring Head.

A servo valve regulates fluid to the right pocket of the front Hydrostatic bearing. The oil line which was originally to regulate the left pocket on the front bearing is now used to monitor the oil pressure at that pocket. The servo valve is continually receiving a signal from the accelerometer and there is constant control of the boring head by the servo valve. The servo valve is set up such that it can add high pressure controlled oil to the pocket or it can allow the static pressure which is supplied to the pocket to be drained to tank. Whichever is needed for correcting the Boring Head. When both control pockets are operating, one pocket is receiving the high pressure control oil while the other control pocket is having the static pressure drained off.

1.1.5. Monitoring the Guided boring operation: The boring of a tube is a blind operation. The operator cannot see the cutting taking place and therefore a means of monitoring certain aspects of the cutting have been built into the bore guidance system. Earlier bore guidance machines used LVDTS as a sensing device for monitoring. The latest boring head uses inductive sensors (proximity probes) instead of the LVDT’s. This type of sensor is designed to obtain its readings without touching the bore and in this case reads through an oil film. The operator's console is equipped with five readouts and a recorder which is used for monitoring and recording of bore diameter, offset, runout, and bearing pressure and thrust. Each readout has limit setting capabilities which can be set at the control panel. If any of the readouts exceed the limits which are set, the boring feed will automatically shut off.

1.1.6. Bore diameter: The monitoring of bore diameter is accomplished by using inductive sensors which are mounted on the boring head vertically and diametrically opposed just behind the vertical cutting plane of the cutting tools. When the Boring Head is completely within the tube the limits on the readout are set at +/ - .oo3". During the transition from the starting bushing to the tube it may be necessary to expand these limits.

1.1.7. Offset: Offset is a term used to describe the location of the boring head with respect to the bore in which it is riding. To measure offset inductive sensors are located in the Boring Head. Normally the offset will vary only .00075" which indicates that the correction is taking place. The maximum parameters of offset will range from + / - .005” shall be manually adjustable within that range.

1.1.8. Runout: The runout of the boring head is monitored by using the output signal from the accelerometer. The readout will be manually set to stop the boring feed if the run out exceeds + /- .025” from centerline of rotation. The maximum parameters for the runout will be adjustable by the operator.

1.1.9. Bearing Pressure: The 1/4" line from the left front bearing pocket is connected to a pressure transducer and is used for monitoring bearing pressure. The readout will be furnished with two scales. The first scale will be manually adjustable for initial start-up and range from 0 to 50 psi. The second scale will also be manually adjustable for normal boring, range from 100 to 250 psi. A two position switch or other means of changing ranges shall be console mounted. Normal bearing pressure for standard (on-size) boring operation is 150 psi.

1.1.10. Coolant and Hydrostatic Oil: The oil used in this machine as coolant is the same oil used in the guidance system. However to two are contained in two separate connecting tanks. Before the oil is used in the guidance system, it is filtered and temperature regulated to ensure a viscosity necessary to obtain proper control at the hydrostatic bearings. This is accomplished by 10 micron filters located at the output and return ports of the oil tank and refrigeration unit.

The oil used as a coolant in the boring operation is received from the coolant side of the tank. This oil is feed to the boring slide through the power track and is connected to the hollow boring bar. The oil is pumped through the boring bar and discharged through ports in the boring head located at the cutting tool. The coolant passes through the end of the boring head flushing the chips through the gun tube and the end of the headstock. Located at the end of the headstock is a conveyor which will transport the chips away from the machine. The oil will be discharged back into the dirty oil tank, through a 40 micron filter and cooled back to clean tank.

NOTE: The functions depicted above may have been change over the years from control upgrades.

2. Applicable Standards and Publications All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal, OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues to their latest revision. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

2.1 Watervliet Drawings: Will be provided at point of award for which a confidentiality clause shall be signed.

• General Assembly

• Hydraulic Diagrams

• Lubrication Diagrams

• Electrical Schematics

• Pneumatic Diagrams

• Drive Unit- Slide

• Machine Assemblies

Bed, ways and racks….Bar Clamp….Starter bushing assembly Slide travel L.S. Assembly….boring bar supports….boring Head assembly End cap….Auto Steady rest….Manual steady rest….Support puller Boring Bar….Boring Head

• Headstock

3. Requirements. All requirements are mandatory from the standpoint of intended function.

Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

3.1 General Requirements:

3.1.1 Design and Engineering. Work performed as part of the rebuild shall be in accordance with current standards recognized for this type and class of equipment. Modifications to manufacturer's original designs to achieve requirements specified herein are not permissible if they result in deviations from good design practice.

3.1.2 Materials. Materials incorporated in the rebuild of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability to the standards recognized for this type and class of equipment.

3.1.3 Construction. All replacement parts used as part of this rebuild shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to the machine’s maximum rated capacity. Distortion and deflection at maximum load shall be limited to a degree consistent with retention of alignments and tolerances, and the machine shall recover from distortions and deflections at no load. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.3.1 Construction of Major Components. All major machine components such as beds, saddles, columns, etc. are castings either of iron or semi-steel, or shall be constructed as mild steel weldments. Weldments if used shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be thermally stress relieved to preclude spontaneous distortion.

3.1.3.2 Alignment Retention. Non-integral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry, shall utilize pins, keys, square shoulders or other such positive means of retaining alignment and regaining it in the event of accidental dislocation. The rebuild shall meet or exceed existing methods of retention on the existing machine. Retention of alignment that depends solely upon bolt tension and/or adhesives will be unacceptable.

3.1.4. Slideway Design and Construction As part of this rebuild all way systems shall be re-ground as required to re-establish original geometrical characteristics. The existing OEM way systems on this machine are replicable ways. All ways shall have a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more. Certification of hardness after the rebuild will be required.

3.1.4.1 Replaceable Ways. The existing machine has replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.1.4.2 Way Wipers. All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. All way wipers shall be replaced as part of this rebuild.

3.1.5 Workmanship. Rebuild workmanship throughout the machine shall be of good quality and meet industry standards.

3.1.5.1 Shimming. A shim is herein defined as an unplanned insert whose presence, dimension and shape do not appear on the engineering drawings and which cannot, therefore, be reproduced from those drawings. Shims, as defined above, shall not be incorporated as part of this rebuild.

3.1.5.2 Other Unacceptable Repair Measures. Welding, brazing, soldering and other such techniques shall be used only where called for in the original machine's design. They shall not be used as part of this rebuild to repair machine components defective in material or in machining accuracy.

3.1.6 Maintainability. All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement or adjustment as applicable.

3.1.7 Interchangeability. All parts bearing the same part number shall be functionally interchangeable.

3.1.8 General Electrical Characteristics. The electrical system shall conform, in quality, safety and performance, to all industry electrical standards.

3.1.8.1 Applicable Power Source. The power source to which the machine will is connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. See Attachment C

3.1.8.2 Electrical Safety Devices. The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plug-in circuit breakers or current-limiting fuses are not acceptable.

3.1.8.3 Conversion Equipment. If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be furnished with the machine by the contractor.

3.1.8.4 Motors. All motors shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. Under normal operation of the machine throughout its specified range and capacity, no motor shall be operating at overload, and all motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service and shall be properly balanced. Each motor shall bear an identification plate containing the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency and frame or mounting. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 HP or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. This is a rebuild/retrofit project then replacement motors shall as a minimum meet original OEM specs in continuous HP and torque ratings without the use of additional gearboxes.

Note: All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

3.1.8.5 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum. Class "A" ground fault interrupt protection shall be provided.

3.1.8.6 Utility Outlet. The machine shall be provided with a dual-receptacle 3-wire utility outlet fully wired and equipped to deliver 120-volt single-phase AC power at up to 20 amperes, based upon 480-volt 3-phase input. This outlet shall be protected by a ground-fault interrupter and shall be externally mounted and easily accessible. An electrical "noise" suppression device shall be provided.

3.1.9 Safety and Environmental Features.

3.1.9.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent Arsenal, State, Federal, and local regulations.

3.1.9.2 Protection of the Machine. The proposed control system shall be fully equipped with the devices, software, etc. necessary to prevent self-damage in the event of malfunction and/or ordinary operator negligence in so far as practical.

3.1.9.3 Noise Levels. The government's preference is to achieve noise levels not in excess of 80 dba. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities. Noise levels in the vicinity of the machine, even if not meeting the desired 80 dba, shall, under no circumstances, exceed a maximum of 85 dba when measured by a properly calibrated sound level meter set for "A" weighting and slow response. "Vicinity of the Machine" is further defined as an imaginary line completely surrounding the machine at a distance not exceeding one meter from the nearest point on the machine. The maximum noise level limit shall apply at the operator's console, even if the console lies inside the one-meter envelope.

Techniques such as sound level averaging or exposure time weighting shall not be used in meeting this requirement. The rebuilder will not be required to provide any additional enclosures/baffles, etc. to meet this requirement other than what was originally provided by the OEM for this machine.

3.1.9.4 Ozone Depleting Substances Section 326 of Public Law 102-484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class 1 ozone-depleting substance within the government specification or standards set forth in the contract. Attachment #B is a list of the restricted Class I CFC's and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "Ozone-Depletion-Potential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: Ozone-Depletion-Potential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC-11, CFC-12 and CFC- 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

Order of Precedence: In the event of a conflict between the text of this paragraph and the references cited elsewhere in this specification the text of this paragraph shall take precedence. Nothing in this specification, however, shall supersede Section 326 of Public Law 102-484 unless a specific exemption has been obtained.

3.1.9.5 Asbestos and Mercury Free Certification. All materials utilized as part of this rebuild shall be certified as asbestos and mercury free. This certification shall be provided at the time of proposal submission.

3.1.9.6 Material Safety Data Sheets. The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of the submission of his proposal.

3.1.9.7 Lead-Free and Chromium-Free Paint Certification. All paints and primers applied as part of this rebuild shall be certified as lead free and chromium-free. Lead based paint is paint that contains more than six one-hundredths of one percent (0.06%) lead by weight. This certification shall be provided at the time of proposal submission.

3.1.9.8 PCB-Free Certification. The machine and its equipment shall be certified as PCB-free prior to being shipped back to Watervliet. PCB free is defined as a level of contamination which is undetectable using EPA approved methodologies.

3.1.9.9 Lockout/Tagout Procedures. The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. The rebuilder shall ensure this information be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.10 Identification Plate. A second corrosion-resistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear the information called for as follows, with space at the bottom for one additional line of information to be applied by the government. The original ID plate shall not be removed from the machine

Nomenclature Manufacturers/Rebuilders name Model Manufacturers/Rebuilders Serial Number Power Input (voltage, phase, frequency, and total amps) Government Contract Number Date of Rebuild

3.1.11 Lubrication. Existing automatic lubrication system is a Lincoln model 87418.

Spindle bearings, gearboxes and transmission are lubricated by a recirculating lubrication system.

Systems of the foregoing types are considered automatic systems and they shall be equipped to be fail safe to the maximum extent possible. Any sensors or other devices used to detect the presence (or absence) of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods (e.g. Grease fittings, oil cups etc.) are permissible for lubrication points not practically served by automatic systems. For non-recirculating automatic systems, the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems (such as pressure spray), easily cleanable or replaceable filtration devices shall be provided. Recirculating type systems shall be equipped with means to confirm proper oil level. Sight gages shall be of the external standing tube type rather than the flush-mounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.1.11.1 Lubrication Plate. A lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

3.1.11.2 Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor is requested to choose the required lubricants, hydraulic fluids, oils and coolants from Attachment “A”, enclosed or where designated (*see note) approved industry/commercial equivalents. If a substitute is required, the contractor shall provide justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.12 Hydraulic System. The hydraulic system consists of three reservoirs; main tank, clean oil tank and dirty tank. These tanks are all connected to each other by over flow pipes.

Main tank used for hydrostatic bearings, and steady rest clamps, clean tank is used for cutting and coolant oil during the boring operation.

A new hydraulic system shall be provided and appropriately sized and powered for the intended application and shall conform to industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. The duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 95 degrees f in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature below this level. The system shall be protected against overpressure as well as under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, anti-surge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing.

3.1.13 Painting. All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification.

Paint shall be chromium-free and lead-free. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semi-gloss" and shall closely match the existing colors. Danger areas shall be painted red and caution areas shall be painted yellow, warning signs, tags or emblems will be affixed to respective areas of the machine in accordance appropriate safety standards.

3.1.14 Machine Hold Down and Leveling. Existing machine hold down hardware shall be retained by contractor for re-installation.

3.1.15 Gears. All gears replaced as part of this rebuild shall meet or exceed OEM provided gears and shall also adhere to the industry standards recommended for the type and severity of service required.

3.1.16 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities and delivery dates below. The contractor shall provide full documentation in the form of (as-built) drawings and manuals. Drawings shall not be generic.

Drawings/schematics shall be provided, as indicated below, in hardcopy and in AutoCAD 2007 or earlier version on 3.5” disk(s) or CD. “On-line” technical data will not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

a. Foundation Drawings, Standard or Special. (See note) N/A

b. Machine and Equipment Floor Plan. N/A

c. Catalog of Standard Tooling and Accessories. N/A

d. Non-Standard (special) Tooling and Accessories. N/A

e. Installation Instructions and Drawings. N/A

f. Lubrication Diagram or Instruction. To be delivered to the technical POC at time of machine re-delivery. (Two Copies)

g. Operating Instructions. Machine and control system operating instructions shall be in provided in separate manuals from other technical data provided. These instructions/manuals shall include a clear description of the functions on the control system operator’s panel. To be delivered to the technical POC at time of machine re-delivery. (Four Hard and Two Electronic copies)

h. Maintenance and Troubleshooting Instructions for all machine and control systems. These instructions shall include assembly drawings. To be delivered to the technical POC at time of machine re-delivery. (Two hard copies and Two electronic copies)

i. Electrical and hydraulic schematics and lubrication Drawings. To be considered acceptable, these schematics must clearly portray all electrical and hydraulic and Lubrication ties to their respective main systems. To be delivered to the technical POC at time of machine re-delivery. (Two hard copies and Two electronic copies)

Note: If, during installation and testing, the actual electrical and/or hydraulic and lubrication systems are configured differently than depicted on the schematics, receipt of the revised "As-Built" schematics shall be a condition of final acceptance.

j. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger sub-assemblies. To be delivered to the technical POC at time of machine re-delivery. (Two copies)

k. Programming Manuals. CNC programming manuals shall be supplied. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented and usable on the system offered or specified. To be delivered to the technical POC at time of machine re-delivery. (Two hard copies and Two electronic copies)

l. Software Documentation. The offeror shall provide two paper hardcopies and Two electronic copies (CDs, and preferably a flash card if control is equipped) of all final system software and ladder logic developed to control and interface the new control/drives with the existing machine tool. Final revision software to be furnished to the technical POC not later than 30 calendar days after final acceptance of the rebuild/retrofit or at such time when all software revisions have been completed.

Note: All electronic copies of documentation shall be put on one CD with two copies required.

3.1.17 Training Required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal", and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Type of training Number of persons When required Training location

Machine operation 4 During or after machine performance testing

On site

Mechanical maintenance 2 During startup On site

Hydraulic maintenance (if applicable)

2 During startup On site

Electrical maintenance 2 During startup On site

Electronics (CNC) maintenance

2 During startup On Site

SCR drives (if applicable)

2 During startup On site

Programming training 2 During startup On site

Note: For all types of training, the associated technical data (see 3.1.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A training schedule showing the hours of training for each person under their assigned category, shall be sent in with proposals for review.

3.1.18 Pneumatic Requirements. Air is needed for machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 80 psi and if higher or lower pressure is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 80 psi supply pressure. The machine shall also be equipped with devices to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 80 psig.

3.1.19 Control of Cutting Fluids. The machine is equipped with a coolant system, the contractor shall ensure that upon completion of the rebuild the machine is still equipped to prevent coolant from escaping the confines of the machine or leaking to the floor when producing workpieces of a size within the machine's normal working range. The rebuilder will not be required to provide any additional enclosures that were not originally part of the machine provided by the OEM. If a portion of the enclosure or coolant guarding is missing when the rebuilder takes possession of the machine then the rebuilder shall fabricate a replacement as part of the rebuild project.

3.1.20 Site Conditions. The machine covered by this specification is installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 60 degrees f. To 95 degrees f. and relative humidity will range from 20% or less to 95%.

On any given day, the temperature in the machine shop may change as much as 4 degrees f. per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying whatever is required to meet the specified performance.

3.1.21 Heat Exchange Equipment. Existing unit is a Dunham- Bush chiller unit model ARPC-020TS0 S/N 70428101AA2. New Heat exchange equipment shall be furnished with the machine to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable. Furthermore, it is the Arsenal's preference to avoid heat exchange equipment making use of the refrigeration cycle, and refrigeration systems of any kind are not acceptable unless design or specified temperature limits cannot be achieved without them. If a refrigeration system is absolutely necessary, the contractor shall insure that it operates properly using a refrigerant having an ozone depletion potential of zero. The contractor shall be responsible for identifying and providing such a refrigerant and its material safety data sheet.

3.1.22 Chip Removal. The machine utilizes chain type conveyor at the spindle end for chip removal. A new automatic chip removal unit of the same size shall be fitted, and provided to convey chips from inside the machine work envelope to the existing discharge points. Unit shall be reversible to facilitate clearing of blockages. The unit drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The units shall operate successfully in a variety of machining environments including dry-cutting, machining with cutting oils. Automatic means shall be provided to return cutting fluids to the existing discharge point.

3.1.23 Elapsed Time Meter. The machine shall be fitted with a meter to measure operating time of the spindle drive. The time totalizing meter shall be of the non-resetting type and shall have a range of 0 to 99,999 hours in increments of 1 hour. 1-hour being the least significant digit. Upon reaching the maximum accumulative hours the meter readout shall automatically revert to zero and continue to totalize time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the equipment.

The meter shall be located as to be readily visible but not subject to abuse relative to the operating environment of the equipment. Time meters resident in the numerical control unit are unacceptable.

3.1.24 Filtration System. Hydromation Mini-Vac filter model MV-D S/N 6206 with hinged pan conveyor. This unit is a vacuum type, automatic liquid filter. The unit consists of 8 major components:

• 430 gallon filter tank and filter chamber (Vacuum Box)

• 250 gallon clean liquid tank

• flight conveyor and drive unit

• filter media

• filter pump and piping

• clean supply pump

• electrical control panel

• Hinged pan conveyor and tank

3.1.25 Machine Installation, Startup and Testing.

3.1.25.1 Work to be performed by the Arsenal. In preparation for machine shipment Watervliet personnel will disconnect main machine power and compressed air supplies.

Watervliet will also drain all fluids as much as possible. Any minimal fluid left in machine is the contractor’s responsibility to remove.

After re-delivery of the machine Watervliet personnel will re-connect main machine power, compressed air and re-charge the machine with the required fluids.

3.1.25.2 Work to be performed by the Contractor. This project shall be a turn-key operation with machine returning in like new condition and functionality or better with the contractor being fully responsible for all work, and providing all personnel and equipment necessary to perform the required scope of work. Unless otherwise specified, all components and/or systems replaced/rebuilt as part of this project shall meet or exceed the original equipment manufacturers (OEMs) specifications and Watervliet Arsenal. Where possible it shall be required that components and/or systems rebuilt/replaced as part of this project be commercially available standard parts/systems obtained from sources within the United States

Contractor personnel shall be solely responsible for costs associated with disconnection/reconnection, removal/reinstallation, rigging, skidding and shipment and return.

After all required work has been completed, and upon completion of paragraphs 4.2 and 4.5 the contractor shall ship the machine to Watervliet Arsenal.

Contractor personnel shall coordinate the return of the machine to Watervliet. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded. Outside rigging services should be advised that chain hoists are not permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Contractor personnel shall supervise the placement of the machine on the installation site by the rigging service. In most cases no Arsenal forklift services and/or Arsenal personnel will be available for the re-installation.

Operators of forklifts shall have and be able to produce valid forklift licenses. Arsenal overhead pendant cranes (within load capacities) can be used by the contractor/rigging service for the installation. The contractor shall provide written certification to the WVA representative that all contractor/rigger personnel are qualified, through either formal training or experience per OSHA, to operate pendant controlled overhead cranes. The contractor shall ensure they bring all equipment/material necessary for the reinstallation of the machine. Watervliet does not have the resources to provide such material.

The contractor shall install all systems and place the machine in operation and conduct the acceptance tests specified in section 4. The contractor, through their service personnel, shall be fully responsible for the complete interfacing, startup, debugging and testing of the machine.

The service personnel shall remain until the machine activation and all testing and training has been successfully completed. Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal business work days. Contractor work outside Watervliet’s normal business work days cannot be guaranteed. Watervliet is on a condensed work schedule.

Normal business work hours/days for this schedule are four 9-hour business workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

3.2 Machine Specific Requirements:

3.2.1 Machine Tool Description: This specification defines the requirements for the complete machine rebuild and retrofit of one 1984 Cincinnati Milacron Guide Bore Watervliet number WV12177, and S/N 4390-80-0008. This guide boring machine has controlled guidance that can follow the theoretical boring centerline of a large caliber canon tube. The control can drive the boring head to maintain bore center line to the outside diameter maintaining concentricity. The machine consists of a bed, headstock, boring slide, clamping slide, steady rest, boring bar supports and all the necessary hydraulics, filtration, lubrication, coolant and electric equipment.

3.2.2 Physical Characteristics. Misc. machine info is as follows:

Horse Power................................................................ 50 HP Machine Approximate bed length.................................. 76’ Counter-Boring ............................................................ 3/4” to 6” Feed Rate .................................................................... 2” to 9.9” IPM Rapid Rate ................................................................... 150” per MIN.

Chuck 3 jaw ................................................................ 18” Spindle RPM ............................................................... 50-400 Bore Length ................................................................. 24’.

Work Piece DIA. ......................................................... 6”-13” Flow rate ..................................................................... 275 GPM Range of Motion of Clamping Slide............................... 10’ or less 26” Max Piece Diameter OD .............................................. 13” Work Piece ID............................................................. 4-6.250” Work Piece Boring Length ........................................... 24’ Bed units 3 (each) ........................................................ 9,800 LBS Headstock bed............................................................. 11,000 LBS Headstock Housing only ............................................... 2,000 LBS Spindle......................................................................... 425 LBS Main Hydraulic tank ..................................................... 90 gallons Clean Tank .................................................................. 250 gallons Dirty tank ..................................................................... 430 gallons Max self-centering steady rest....................................... 12”

3.2.3 Performance Characteristics. The performance characteristics of the machine shall be as they were when the machine was new. Below is a sample of the accuracies required, the rebuild shall recapture all of the referenced characteristics.

Alignment and Accuracy Characteristics Test Acceptable Tolerance

Headstock Spindle Run Out .0005” TIR Spindle Axis NTE .0005” in 12” Head Spindle Camming (at 12” radius) .0008” TIR Headstock Spindle Misalignment with longitudinal bed ways Vertical .0005” per foot

Horizontal .0005” per foot Misalignment of Headstock and Boring Supports .001” True Center Line Steady Rest .001” True Center Line Misalignment of Headstock and Bushing Holder .001” True Center Line Flatness and parallelism of Bed ways .0005” per foot Straightness of work bed .001 per ft. Non Accumulative Finish on all ways 16 Micro-inches

3.2.4 Other Required Characteristics. It is understood that, at this time, bidders are not fully aware of the extent of the work required for this rebuild. However, each bidder should be cautioned that statements such as "Watervliet will be notified of additional costs" or "a separate quote will be issued" or any other similar statements that could result in additional expenses to Watervliet after contract award will not be acceptable. The only exception to this is pertaining to major castings of this machine. .

The following shall be basic minimum requirements of the rebuild and shall not be interpreted as being all-inclusive of the work required. All quotes shall reflect at least these requirements. The machine has been cannibalized of the guidance and control systems.

Those parts are obsolete and WVA has 3 other machines in which the parts were used. No mechanical parts have been taken off the machine to the best of WVA’S POC knowledge, that’s not to say there are no parts missing.

A SIGHT VISIT IS MANDATORY.

The Machine tool shall be rebuilt and retrofitted to like NEW condition. This shall include, and not limited to the following:

a.) The existing control system shall be replaced with an open face Fanuc control. See para. 3.3 b.) Base All ways to be ground to OEM tolerances see para. 3.1.4.

Rack sections to be inspected visually for ware and dimensionally tolerances.

Defective sections replaced and NDT (Non-destructive testing) for cracks. All slides (clamping slide, boring tube drive slide, steady rests, and boring tube support slides) to be hand scraped for OEM alignments and fit including gibs and keepers.

All lubrication systems to ways and racks to be replaced with OEM system. NDT certification required.

c.) Headstock Spindle

All seals and bearings replaced, all gears and shafts checked for wear and other defects. Dimensional testing to include pitch diameter and NDT magnetic particle exam. All defective parts replaced. NEW 3 jaw hydraulic chuck replaced. New Fanuc 60 HP drive motor continuous duty is the preferred, motor max torque between 50 and 400 RPM, belts and pulleys replaced. Covers, shields, coolant spouts and returns reworked to like new or replaced. The contractor will be responsible for any mounting adaptation that may be required. NDT certification required.

Spindle shall be dynamically balanced to hold vibration to a minimum.

Speed shall be constant not to exceed 1% VARIATION THROUGHOUT THE FULL SPEED RANGE, REGARDLESS OF LOAD, and UP TO FULL HP.

d.) Clamp Slide All hydrostatic lines, bearings, bushings, valves, pumps and hoses and tubing and gauges replaced. All coolant seals and face rings replaced. New A.C. servo system installed to feed the slide and apply clamping force. Interfaced with new control system.