EDM_SPEC_37-18-3419.pdf

Specification for One New 6 Axes

Wire EDM’S

Spec. #37-18-3419

Rev. I

Watervliet Arsenal

Watervliet, New York 12189 05 February 2018

Department of the Army

TACOM

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

1. Scope:

1.1 Abbreviated Description. This specification defines the requirements for One New 6-

AXES CNC Wire EDM with X/Y/U/V-AXIS having Linear Motors (machine). C- AXIS to be utilized by an optional bidirectional rotary table.

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. 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.

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. The machine shall be designed and engineered in accordance with latest standards recognized or adopted by the Association for Manufacturing

Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use.

3.1.2 Materials. Materials incorporated in the construction of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability.

3.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. 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 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 a positive means for retaining alignments and regaining them in the event of accidental dislocation.

3.1.4 Slideway Design and Construction. All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Please state in your proposal details of the way system being offered.

A. Integral cast iron ways shall be hardened to RC 50 to RC 54 to a depth of .100 inch or more.

B. Hardened and ground steel ways for mating with Turcite, Rulon or other such low friction forgiving materials shall be hardened within the range of RC 55 to RC 62. Actual hardness within this range shall not very more than 5 RC points.

C. Hardened and ground steel ways for use with anti-friction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more. Slideway systems other than the three (3) referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a

60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.1.4.1 Replaceable Ways. If the machine being offered is portrayed as having 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. Wipers shall also be easily removable and replaceable.

3.1.5 Workmanship. Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology.

3.1.5.1 Shimming. Shims that do not appear on the engineering drawings shall not be incorporated in the machine.

3.1.5.2 Spacing. Spacers that do appear on the engineering drawings are permissible.

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. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

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

3.1.8 Applicable Power Source. The power source to which the machine will be 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 and return with solicitation.

3.1.8.1 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.

3.1.8.2 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. Internal transformer is preferred.

3.1.8.3 Motors. All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. 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. Each motor shall bear an identification plate containing, as a minimum, 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. All polyphase AC motors rated at 1 Hp or greater shall be of the high efficiency type.

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.

3.1.8.4 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.1.8.5 Utility Outlet. The machine shall be provided with an operational 120-volt single-phase, 15-ampere dual-receptacle 3-wire utility outlet. This outlet shall be protected by a ground-fault interrupter and shall be externally mounted and easily accessible. A “noise" suppression device shall be provided.

3.1.9 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment D and comply as applicable.

3.1.9.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent state, federal, local laws and regulations.

3.1.9.2 Protection of the Machine. The machine shall be fully equipped with the devices necessary to prevent self-damage in the event of malfunction and/or ordinary operator negligence insofar as practical.

3.1.9.3 Noise Levels. The government's preference is to achieve noise levels not in excess of 80 dba and shall be accomplished at no additional expense to the Government. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities (see 3.4.1.2), and shall be measured at any or various times during this test at the discretion of the Technical POC or other appointed representatives. Noise levels at a distance not exceeding one meter from the nearest point on the machine 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. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the proper operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

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 I 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 substances or systems, that are approved for use by the Environmental Protection Agency (EPA) 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.

3.1.9.5 Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist.

This certification shall be provided prior to machine delivery.

3.1.9.6 Lead-Free and Chromium-Free Paint Certification. All paints and primers applied to the system 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 prior to machine delivery.

3.1.9.7 PCB-Free Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection (see section 3.4), these fluids shall not contain Polychlorinated Biphenyl’s

(PCB’s). The machine and its equipment shall be certified as PCB-free prior to being shipped.

3.1.9.8 Lockout/Tagout Procedures. The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall 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 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, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature

Manufacturer's name

Model

Manufacturer's Serial Number

Power Input (voltage, phase, frequency, and total amps)

Government Contract Number

Date of Manufacture

3.1.11 Lubrication. The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. 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 (such as slideway lubrication), 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. Sight gages, if used, 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, at time of machine delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.12 Hydraulic System. If applicable, hydraulic systems provided shall be sized and powered for the intended application and shall conform industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible sight gages to indicate fluid level. An appropriately sized refrigeration system shall be provided to ensure the hydraulic fluid does not exceed 120 degrees f in temperature. The hydraulic system shall be protected against overpressure as well as underpressure. 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 and shall be located at floor level. Pressure gages shall be liquid filled.

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 selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA

Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.1.14 Machine Hold Down and Leveling. The machine base shall be provided with sufficient and properly located holes for positive hold-down when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended hold-down and leveling hardware.

Note: All hold-down and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

3.1.15 Gears. All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.1.16 Handwheels. Where power feed and/or rapid traverse of a machine component is provided or specified, associated handwheels or cranks, if any, shall not rotate when power feed or rapid traverse is engaged.

3.1.17 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

a. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in

AutoCAD 2007 or later shall be provided on a CD. This plan shall contain the dimensioned bolt-hole pattern of the holddown bolts for the machines. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities

(electrical power, air, water, etc.) required to operate the machine. This data shall be furnished

60 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2007 or later.

Note: Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specifically-shaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc.

The soil (sub-straight) for a foundation is assumed to be medium dense gravel or medium dense gravel and sand with a minimum bearing capacity of 4,000 PSF. Should the contractor disturb the soil below the yet to be constructed concrete foundation then the contractor shall compact the disturbed soil to achieve at least 2,000 pounds per square foot (PSF) bearing capacity.

Important: See instruction par. 6.4

b. Catalog of Standard Tooling and Accessories shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (two copies)

c. Non-Standard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2007 or later.

d. Installation Instructions and Drawings containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished 60 days prior to scheduled delivery of the machine. Two reproducible hardcopy and two electronic copies on CD in AutoCAD Release

2007 or later.

e. Lubrication Diagram or Instruction. To be delivered at time of machine delivery. Two reproducible hardcopy and two electronic copies on CD in AutoCAD Release 2007 or later.

f. Operating Instructions. These instructions shall be in provided in separate manuals from other technical data provided. To be delivered upon machine delivery. Four copies minimum and 2 CD’s

g. Maintenance and Troubleshooting Instructions and Mechanical Assembly drawings for all machine systems. To be delivered at time of machine delivery. Two copies minimum of the

Maintenance and Troubleshooting Instructions and two electronic copies on CD in AutoCAD

Release 2007or later of the machines mechanical assembly drawings.

h. Electrical and hydraulic schematics to be furnished. To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. Two reproducible hardcopy and two electronic copies on CD in AutoCAD Release

2007 or later. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

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

i. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and original equipment manufacturers part numbers 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 furnished not later than 30 days prior to delivery of the machine. (two hard copies and two CD’s)

j. Programming Manuals. Where a CNC machine is offered or specified, 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. These manuals shall be delivered at machine delivery. (two hard copies and one CD)

k. Software Documentation. The offeror shall provide two hard copies of all system software and/or ladder logic developed to control and interface the new control/drives with the existing machine tool. One CD or flash card to be delivered to the technical POC before final acceptance of the machine.

l. Backup for control Ram required on smart card or USB

m. All required electronic information shall be put together on 2 CD’s

3.1.18 Training required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. All instructions and materials, oral or written, shall be in English.

"On-Site" means "At Watervliet Arsenal". If specialized formal “off-site” training is available specify on offer availability and price as an option. 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

During startup and after machine performance testing

On site

Hydraulic maintenance

(if applicable)

During startup and after machine performance testing

On site

Electrical maintenance 2

During startup and after machine performance testing

On site

Electronics (CNC) maintenance

After machine performance testing On site

Programming training 4 after machine performance testing 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.

3.1.19 Repair/Replacement Parts and Service. The offeror shall also agree to provide parts and/or service for the contracted equipment within 72 hrs of notification of a problem. The offeror further agrees, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and be sufficient in detail to permit successful acquisition of the parts and associated repair service. In the event of a national emergency the U.S. Government reserves the right to obtain the data and use it to support operation of the machine tool(s) purchased under this contract. The offeror shall supply a list of recommended spare machine parts as an option with the offer.

3.1.20 Pneumatic Requirements. If air is needed for any 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 (unknown volume) and if higher or lower pressure or a specific volume 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.

3.1.21 Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.1.22 Control of Cutting Fluids. The machine and dielectric solution system provided shall be designed to prevent dielectric solution 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.

3.1.23 Site Conditions. The machine covered by this specification will be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65 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. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.1.24 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine/control/drive systems wherever it is needed 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.

3.1.25 Machine Installation, Startup and Testing.

3.1.25.1 Work to be performed by the Arsenal. Upon receipt of the required installation drawings (see 3.1.17); Watervliet Arsenal will clear the intended installation site prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities to first points of connection. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon his arrival and continue under his guidance.

Note: If installation instructions, foundation drawings and electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.17), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

3.1.25.2 Work to be performed by the Contractor. The Contractor shall be solely responsible for costs associated with skidding and shipment, rigging, to include floor preparation for machine installation at WVA. The floor at WVA is wood block with 8-10” of concert underneath. The contractor shall also provide competent English-speaking service personnel to install the machine, rough and finish level the machine, startup, and conduct the acceptance tests specified in section 4. The contractor personnel shall remain until the machine activation and testing have 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. If the contractor chooses to request

Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the

Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from non-availability of

Arsenal personnel or Arsenal-furnished equipment.

Once requirements of paragraph 4.1 and 4.2 have been completed contractor personnel shall coordinate the shipment 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 only certified chain hoists are permitted to be used at the Arsenal and that all rigging slings must have manufacturer’s tag 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 installation. Only propane powered forklifts are permitted and must also be equipped with a roll cage. All forklifts must be operated by licensed operators. 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. Contractor personnel shall also adhere to the

WVA requirements to wear OSHA approved safety glasses and safety shoes while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine(s). Watervliet does not have the resources to provide such material. Crane capacity within building is limited (2 tons) and therefore if not adequate then the contractor will need to provide alternate means necessary for the installation.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour 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 One

New 6-AXIS CNC Wire EDM with X/Y/U/V-AXIS having Linear Motors. C-Axis to be utilized by an optional rotary bidirectional table.

Equipment/accessories required to make a complete system specified herein shall meet or exceed the following characteristics.

The machine shall be used by the Arsenal for a variety of components used in the manufacture of cannon. The materials to be machined could be 4340 alloy steel which has been hardened to Rc38-42 and high nickel strength steels as well as other type steel components and materials including non-ferrous.

3.2.1.1 Required Characteristics:

a.) Machine Tool:

Work tank size (W&D) ........................................49” x 38”

Dielectric capacity ............................................... 433 gallons

X-axis travel .........................................................29.5”

Y-axis travel .........................................................19.5”

Z-axis travel .........................................................24”

U-axis travel .........................................................30”

V-axis travel .........................................................20.5”

Wire Diameter .......................................................0.004” to 0.012”

Maximum weight of work piece ..........................3,307 lbs. or more

Drive Mechanism (X, Y, U, V) ............................Linear servo motors

The Z axis position will automatically set the dielectric fluid for the operator.

b.) Alignment Accuracies:

Parallelism with the X/U-axis movement .............010mm/120mm of travel

Straightness X/U- axis movement ........................010mm/120mm of travel

Parallelism with the Y/V-axis movement .............010mm/120mm of travel

Straightness Y/V-axis movement .........................010mm/120mm of travel

Squareness with the U/V-axis movement .............010mm/120mm of travel c.) Positioning Accuracy :

X/U-axis ................................................................003mm

Y/V-axis ................................................................003mm

C-axes ..................................................................30 seconds

X/Y/U/V Min. Resolution .....................................000004” d.) Positioning Repeatability:

X/Y/U/V- axis .......................................................001mm

C-axes ..................................................................15 seconds

3.2.2 Other Machine Requirements:

3.2.2.1 One Rotary Table for Simultaneous Movement, Rotary/Indexing Table for Wire EDM to include:

Rotary table useable both Horizontal and Vertical

Table Diameter .................................6”

Vertical use Weight ..........................88 LBS.

Horizontal use Weight ......................44 LBS.

Weight ..............................................44 LBS.

3.2.2.2 Machine options:

L-Cut Wire chopper

.004”, .006”, .008”, .010”, .012” Wire Guide sets upper, lower, and pre-guide

44 LBS Wire Spool Feeder

Addition D/I tank

36 spool wire holder.

3.2.2.3 Software and Hardware:

Taper Measurement Jig Fixture Software

Taper 45 & taper Guide set .010 and .008 diameter

Interface for Rotary table to Machine, 8 axis simultaneous control.

MT Connect Adapter port for streaming data to a third party, a monitoring and analytics platform

Esprit offline CAD/CAM software to include 4 axis programming, coreless machining, involute gear module and CAD and solid model compatibility.

3.2.2.4 Remote Operator’s Pendant. A remote operator’s pendant shall be provided. The machine shall be provided with a remote operator’s pendant with the following minimum functions. Communication with WVA operators will be necessary to determine functions desired.

a.) Inch/Metric Incremental Jog b.) Axis select c.) Axis +/- Jog d.) Cycle Start e.) Feed Hold f.) Machine Stop g.) Master Stop h.) Remote On/Off i.) Position Display

3.2.3 Compressor Unit and Refrigerated Air Dryer System. Reference par. 3.1.20.

The compressed air supply at Watervliet Arsenal is at best 85 psi, volume undetermined. If the machine offered requires more than 85 psi at a particular volume then an Air Booster unit and tank shall be provided with the machine. Please state in your proposal what the machine requirements will be and if a Booster will be required. Regardless if a separate air supply is required the machine shall be provided with an appropriately sized ZEKS or Ingersoll Rand refrigerated air dryer system complete with input and output filter cartridges. All installation shall be provided and included Power for the ZEKS or Ingersoll unit shall be 110 VAC. Units utilized on other machines at WVA is the Ingersoll Rand model D31NC or ZEKS unit model

18HSF both models in and out dual stage filters.

3.2.4 Required 3R tooling:

Reference element, WEDM P/N 3R-200.1

Reference stop, WEDM P/N 3R-225

Leveling adapter, Macro P/N 3R-262HP

Leveling adapter, WEDM P/N 3R-272HP

Unimacro adjusting pallet, Unimatic P/N C 950 470

User kit, Macro P/N 3R-242S-4

User Kit WEDM P/N 3R-242HP

V-holder, Macro P/N 3R-208.6

3.2.5 Required Performance on Workpieces. The contractor shall demonstrate both the machine’s conformance to all requirements elsewhere specified in section 3 of this specification. As part of this demonstration, the contractor shall furnish at least 30 days prior to conformance testing, a dimensioned and tolerance drawing of one or more workpieces exhibiting characteristics in section 3.2.1.1 representing the machine being offered for approval by the

Arsenal contracting officer. After approval the drawing shall be the basis for the conformance test required in 3.4.1.5.

3.3 Machine Control System. The desired control system provided as part of this project shall be a CNC Machine Tool Control. Capable of importing 3D solid models and be visually able to view. The control system will have a wide variety of applicable machining patterns to respond to various kinds of machining needs. The control shall have the capability of performing 8 axis simultaneous turn and burn.

3.3.1 Control System Requirements. Each offeror shall provide for review a complete detailed checklist of the control systems standard and optional features that are available for the control system being provided as part of the proposed system. This checklist shall indicate which features are intended to be active or provided with the new control. The control shall be provided with an Uninterrupted Power Supply (UPS) battery backup and power surge protection.

The UPS shall insure the retention of power to the CNC for a minimum of fifteen (15) minutes in the event that failure of the primary power occurs. If the power is not restored within fifteen minutes the CNC shall automatically, without human intervention, execute a power fail routine, to protect against data corruption or disk damage and terminate processing in an orderly fashion.

a.) The control system shall include a flash memory card reader. One spare blank

128mb flash card shall also be provided.

3.3.2 Operator Control Panel. The contractor shall provide an operator control panel to house the display screen, and all machine controls, including control knobs, buttons, and handwheels. The operator’s panel/mounting shall be designed to permit visible access to the work envelope. The operators control panel shall also include the following:

a.) Keyboard protected and sealed for use in an industrial environment.

b.) The desired display shall be a 15” color touchscreen with full screen display. The touch screen device shall be suitably protected for use in a machine shop manufacturing environment. The operator’s panel provided shall have at least one USB port and a flash card reader port.

c.) An emergency stop button shall also be located on the panel.

d.) A remote Hand held MPG unit with display shall also be provided with functions appropriate for setting up or inspection of workpieces inside the work envelope.

3.3.3 Enclosures. If enclosures are provided, they shall be NEMA-12 rated. In addition:

a.) If required, given shop environmental conditions as detailed in par. 3.1.23, new control system enclosures for electronic circuitry shall be air conditioned and air filtered to maintain constant temperature, to reduce humidity and to prevent contamination of control boards and other critical system components. Air conditioning units shall not utilize Ozone

Depleting substances.

3.3.4 Interconnecting Wiring. All wiring shall comply with accepted Joint Industry

Code (JIC), National Machine Tool Builders Association (NMTBA), and National Fire

Protection Association (NFPA) Standards.

3.3.5 Control/Operating System Software and Documentation. One copy of the touchscreen software if applicable, ladder logic, Licensed operating system if applicable, control manufacturers system software, interface software, etc. and all pertinent documentation are to be provided prior to final acceptance. If the control provided is equipped with a flash card reader then a flash card loaded with the final version of the system software shall be provided with the final documentation.

Also to be provided is a control system bill of materials for the control and drive systems detailing all control system standard features/options (with option part numbers) and axes/spindle drive motors and drive package identifying information.

Ladder logic documentation provided shall include a listing of logic error/alarm messages and a cross reference list of the full descriptive relay contact and coil names to the abbreviated names in the logic.

3.4 Requirements for Demonstration of Conformance.

3.4.1 Certification, Drawings and Tests Required. The contractor shall demonstrate both the machine’s conformance to all requirements elsewhere specified in section 3 of this specification. As part of this demonstration, the contractor shall furnish at least 30 days prior to conformance testing, a dimensioned and toleranced drawing of one or more workpieces exhibiting characteristics of 3.2.1.1 for approval by the Arsenal contracting officer. After approval the drawing shall be the basis for the conformance test required in 3.4.1.5. The contractor shall also, as a minimum, provide the following certification and perform the following specific tests:

3.4.1.1 Certification of Completeness. The contractor shall provide written certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements.

3.4.1.2 Test of Conformance to Specified Performance Characteristics. The machine shall be dry cycled at least 30 minutes, during which time the machine shall be tested for conformance to specified performance characteristics, including but not limited to, feeds, speeds and manual as well as automatic cycling.

3.4.1.3 Test of Conformance to Specified Alignments and Accuracies. The machine shall be tested for conformance to the accuracies specified in paragraph 3.2.1.1.

3.4.1.4 Test of Conformance to Specified Horsepower Characteristics. At the discretion of the WVA POC the machine may be tested for power and rigidity. The vendor shall provide a proposed test part of their choosing for this test. The test shall pull full load spindle horsepower for at least three minutes. The workpiece finish and machine rigidity will be evaluated.

3.4.1.5 Test of Conformance to Specified Performance on Workpieces. Paragraph

3.2.1.1 outlines the types of accuracies which the machine shall be capable of producing on actual workpieces. Paragraph 3.4.1 further requires the contractor to prepare and gain approval of a workpiece drawing which shall become the basis for the test. The suggested workpiece shall sufficiently demonstrate the capabilities and features of the machine. Workpieces shall be 4340 alloy steel pre-heat treated to Rc 38-42.

3.4.2 Provision of Materials and Equipment for Preliminary and Final Acceptance

Testing.

3.4.2.1 Material for Workpieces. All materials necessary to produce the workpieces required in paragraphs 3.4.1 shall be furnished by the contractor.

3.4.2.2 Tooling. Tooling for all testing shall be provided by the contractor.

3.4.2.3 Cutting Fluids. Any cutting fluids necessary to perform the tests specified in paragraphs 3.4 shall be furnished by the contractor during preliminary acceptance testing and by

Watervliet for the final acceptance.

3.4.2.4 Hydraulic Fluids and Lubricants. All hydraulic fluids and lubricants necessary to perform any of the required tests shall be furnished by the contractor during preliminary acceptance testing and by Watervliet for the final acceptance.

3.4.2.5 Testing and Measuring Equipment. All testing and measuring equipment

(laser equipment included) needed to perform any of the required tests and measure the results shall be furnished by the contractor and shall be properly calibrated to standards traceable to the

National Institute of Standards and Technology (NIST).

4. Quality Assurance Provisions.

4.1 Responsibility for Inspection. The contractor shall be responsible for performing all certifications and tests required in paragraph 3.4 and shall provide such materials, supplies and equipment as are specified in paragraph 3.4.2.

4.2 Preliminary Acceptance Inspection. Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in paragraph 3.4. However, prior to officially scheduling the preliminary acceptance inspection the contractor shall perform preliminary machine geometry alignments, laser accuracy tests and cut a test part. When these tests are completed successfully, the contractor shall provide no less than 14 calendar days notice to the Arsenal

Contracting Officer that the machine is ready for the preliminary acceptance inspection. This notification shall also include for review the test results of all preliminary tests performed. If acceptable, the Arsenal representatives will schedule an inspection and the contractor shall await the arrival of the Arsenal representatives before starting the official inspection.

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection.

4.3.1 Examination for Completeness. The contractor shall furnish the Arsenal's representatives with a certification of completeness (see par. 3.4.1.1). The Arsenal's representatives will reserve the right to examine the machine to ascertain the presence of all specified features, equipment, markings and safety devices.

4.3.2 Examination of Performance Characteristics. During the test of conformance to specified performance characteristics (see par. 3.4.1), the Arsenal's representatives will observe the machine and its equipment for proper operation. Also during this test, the Arsenal's representatives may perform independent measurements of sound levels for conformance to par.

3.1.9.3.

4.3.3 Examination of Alignments and Accuracies. During the test of conformance to specified alignments and accuracies (see par. 3.2.1.1) the Arsenal's representatives will observe the performance of the test and reserve the right to review the results obtained.

4.3.4 Examination of Power and Rigidity. During the test of conformance to specified power and rigidity (see par. 3.4.1.4) the Arsenal's representatives will observe the machine for rigidity of construction and achievement of full power for the specified time period, and reserve the right to examine the workpiece after the test.

4.3.5 Examination of Performance Testing. During the test of conformance to specified performance on workpieces (see par. 3.4.1.5), the Arsenal's representatives will observe the operation of the machine and its equipment and reserve the right to inspect the workpiece after completion of the test.

4.3.6 Supplementary Tests and Examinations. The Arsenal's representatives reserve the right to ask for demonstration of any specified feature or machine alignment characteristics not demonstrated during the tests conducted in accord with paragraphs 4.3.1 through 4.3.5.

4.4 Reinspection Provisions. If, during the course of preliminary acceptance inspection, deficiencies are disclosed which cannot be satisfactorily corrected during this visit, preliminary acceptance will be withheld and the contractor will be required to take corrective actions. In such cases, the Arsenal's Technical POC reserves the right to dispatch Arsenal representatives to observe a reinspection and to charge the contractor's account for the travel and per diem costs of such reinspections.

4.5 Post Inspection Procedures. The Arsenal's representatives will not grant authority to ship the machine following preliminary acceptance inspection, even in cases where there have been no apparent instances of non-conformance. Authority to ship will be granted only by the

Arsenal's Contracting Officer. In cases where it is determined that the machine and its equipment conform to specification, the Arsenal's Contracting Officer will grant shipping authority within (10) working days of completion of the preliminary acceptance inspection.