Exhibit_B_Horizontal_Broach_Machine_13_18_3412_Specifications.pdf

U. S. Army Watervliet Arsenal Watervliet, NY Equip Engr Spec #13-18-3412 Date: 1 June 2018

New Horizontal Broach Machine

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

5. Preservation, Packaging and Delivery Instructions

6. Instructions for Preparing Technical Offers

Dated 1 June 2018

1. Scope:

1.1 Abbreviated Description. This specification sets forth the requirements for the design and manufacture of a heavy duty horizontal broaching machine (machine) intended for use in producing finished broached surfaces on cannon components.

2. Applicable Standards and Publications. All work performed and procedures followed in association with this project shall meet or exceed all applicable and current, 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.

2.1 The Following Publication Apply to the latest Revision

• NAS 966

• ISO 1708 AND 230-2

• NFPA 79

• IEC 60204-1

• ANSI/ASME B5

• ANSI B11

• ANSI/ISO 12100

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 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. 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.

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.

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. Equivalent slideway systems other than the three (3) referred to above may be offered. 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.

In such cases, way protection is still required and a suitable alternative to covers shall be proposed for review and acceptance.

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 shall be of good quality and meet industry standards. For purposes of this specification, good quality workmanship is further defined as the completed machine's 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. No internal or external transformers will be acceptable to convert to lower supply voltage.

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.

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, 20-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 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. Appendix 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.

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 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 if applicable.

3.1.9.7 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.

3.1.9.8 PCB-Free Certification. To the extent that the machine may have been charged with lubrication and 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.

3.1.9.9 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. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon Inc. or equal. Gearboxes or transmission cases shall be lubricated by the wet-sump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. 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.) 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. Wet-sump type systems shall be equipped with means to confirm proper oil level. 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 Appendix “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. 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 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.

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 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. Foundation Drawings, Standard or Special (see note): Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award no later than 30 days after award. All drawings shall be dimensioned in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

If a special foundation (see note) is required and the vendor/contractor refuses to provide the detailed drawings required then this shall be grounds for disqualification from further consideration in the machine tool procurement. Vendor proposals submitted shall be clear in their response to this requirement.

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 one which requires a specific thickness, specifically-shaped excavations for example coolant housings, chip conveyors, electrical circuits and conductors.

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. 6.5

Foundation Drawings details shall include at least:

1) At least one drawing shall depict an over-lay top view of the machine foundation outline, machine general arrangement drawing (including all ancillary equipment) and the anchor bolt hole pattern.

2) The foundation drawings shall include 100% complete foundation details necessary for Watervliet Arsenal to directly hand over to a General Contractor for construction.

This detail shall include, but not be limited to, complete foundation dimensions, rebar locations, rebar size, rebar pattern, concrete PSI requirements, and load bearing specs.

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

AutoCAD 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) required to operate the machine. This data shall be furnished as soon as possible after contract award or at least within 60 days WITH APPENDIX C. One reproducible hardcopy and one electronic copy on CD in AutoCAD.

c. 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)

d. Non-Standard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and 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 2004 or later.

e. 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. This data shall be furnished as soon as possible after contract award or at least within 60 days. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2004 or later.

f. Lubrication Diagram or Instruction. To be delivered at time of machine delivery. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2004 or later.

g. 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.

h. Maintenance and Troubleshooting Instructions for all machine systems. This material shall also include the machines mechanical assembly drawings. To be delivered at time of machine delivery. Two copies minimum of the Maintenance and Troubleshooting Instructions.

Two reproducible hardcopies and one electronic copy on CD in AutoCAD Release 2004 or later or PDF of the machines mechanical assembly drawings.

i. 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 hardcopies and one electronic copy on CD in AutoCAD Release 2004 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 hydraulic 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 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 copies)

k. 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. One Fanuc CD-ROM Manual and two Operation and Fanuc Handbooks.

l. Software Documentation. The offeror shall provide four copies of all system software and ladder logic developed to control and interface the new control/drives with the existing machine tool. Two copies shall be on CD and two copies shall be paper (hard) copies. To be delivered to the technical POC 30 days after final acceptance of the machine.

m. Test Part Drawing. Dimensioned and toleranced drawings of the finished configuration of any contractor-designed and contractor furnished workpieces used for machine acceptance testing (see par. 3.4) shall be furnished to the arsenal 60 days prior to preliminary acceptance testing.

3.1.18 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 Installation On site

Spindle/Axes Drives (if applicable)

2 During Installation On site

Programming training 1 During Installation 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 service for the contracted equipment within 72 hrs of notification of a problem.

Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify Watervliet Arsenal’s POC within two business days and shall provide a delivery schedule to be approved by Watervliet Arsenal’s POC. 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.

Note: 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, and shut offs 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. An external compressor is not acceptable.

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. If the machine is equipped with a coolant system, the contractor shall insure that the machine is designed and 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. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leak-proof metallic or non-metallic liner.

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 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 Chip Removal. A powered chip removal system shall be provided and shall be designed to convey all broaching chips away from the cutting tool area to a convenient discharge point at the rear of the machine. Installed discharge height shall be 36 to 48 inches above floor level. The system shall be so designed and shall operate at such a speed as to permit maximum drainage of broaching oil from the chips prior to discharge and to return the oil to the coolant reservoir. The conveyor shall be equipped with a reverse run mode, overload protection, torque limiting couplings and removable panels to prevent and assist in freeing jams.

3.1.26 Machine Installation, Startup and Testing.

3.1.26.1 Work to be performed by the Arsenal. Upon receipt of the required installation and foundation drawings (see 3.1.17); Watervliet Arsenal will prepare the intended installation site prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities (power and air) 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 final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings, or schematics.

3.1.26.2 Work to be performed by the Contractor. This project will be turn-key with the contractor being responsible for all aspects of the project except as mentioned in par

3.1.26.1 above. If a special foundation is not required the Contractor is responsible for the removal of wood block flooring and existing concrete preparation. Grouting for machine hold downs shall be the contractor’s responsibility regardless of foundation type. The contractor shall provide competent English-speaking service personnel to install the machine, rough and finish level the machine place the machine in operation and conduct the acceptance tests specified in section 4. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, and the service 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.

Contractor personnel shall be solely responsible for costs associated with shipping, delivery, rigging, installation, and connection. 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 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 tagged and certified chain hoists are 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 Arsenal personnel will be available for the installation. Only propane powered forklifts are permitted and must also be equipped with a roll cage and operator license. 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 each building is limited (2, 5, 10 or 15 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. The machine tool covered by this specification shall be a heavy duty, hydraulically operated, floor mounted, single ram, manually and automatically controlled, horizontal internal broach machine. Which shall be furnished complete with motors, coolant system, chip removal system and other equipment features and characteristics specified herein. The machine shall employ a puller cylinder which shall be aligned on the broaching axis within the tolerance permitted by vertical adjustment (see para 3.2.2.1). The machine shall be used for broaching such materials as 4340 alloy steel with a hardness of Rc 38-42. The main component to be broached is the 155mm square rack slot. The machine shall be designed and sufficiently powered for machining this material.

3.2.2 Required Physical Characteristics. The following listed characteristics are the essential features of the machine required:

CHARACTERISTIC VALUE

NORMAL PULLING CAPACITY AT ----------------------- 60,000 LBS. MINIMUM

PULLING HEAD

PEAK PULLING CAPACITY AT ---------------------------- 90,000 LBS. MINIMUM

PULLING HEAD 45 TON

PULLING HEAD TRAVEL MAXIMUM TRAVEL ------ 96 INCHES

PULLING HEAD VERTICAL ADJUSTMENT ---------- 3 INCHES

ABOVE AND BELOW CENTER LINE

THICKNESS OF FACEPLATE ------------------------------ 4 INCHES

3.2.2.1 Performance Characteristics:

CUTTING SPEED ------------------------- ------------------------------- 0.0 FPM MINIMUM TO

(INFINITELY VARIABLE) 15.0 FPM OR MORE

RETURN SPEED ---------------------------------------------------------- 0.0 FPM MINIMUM

TO

(INFINITELY VARIABLE) 30.0 FPM OR MORE

HYDRAULIC PUMP MOTOR SIZE -----------------------------------50 HORSEPOWER OR

MORE

COOLANT PUMP MOTOR SIZE -------------------------------------- 1 HORSEPOWER OR

MORE

COOLANT SYSTEM FLUID CAPACITY --------------------------- 100 GALLONS OR MORE

HYDRAULIC SYSTEM FLUID CAPACITY ------------------------ 255 GALLONS OR MORE

3.2.2.2 Alignment and Accuracy Characteristics.

PULLING HEAD GUIDEWAYS PARALLEL ------------------------- 0.0003 INCHES PER FT

HORIZONTALLY AND VERTICALLY 0.001 INCHES OVERALL

(MEASURED AT NOT LESS THAN TEN

(10) INTERVALS)

PULLING HEAD GUIDEWAYS STRAIGHT -------------------------- 0.0002 INCHES PER FT

HORIZONTALLY AND VERTICALLY 0.001 INCHES OVERALL

(MEASURED AT NOT LESS THAN TEN

(10) INTERVALS)

PULLING HEAD TRAVEL STRAIGHT -------------------------------- 0.0005 INCHES PER FT

VERTICALLY RELATIVE TO GUIDEWAYS 0.001 INCH T.I.R.

PULLING HEAD TRAVEL STRAIGHT -------------------------------- 0.0005 INCHES PER FT

HORIZONTALLY TO GUIDEWAYS 0.001 INCH T.I.R.

SQUARENESS OF FACE PLATE TO PULLING HEAD GUIDEWAYS

HORIZONTALLY ------------------------------------------------ 0.0005 INCHES PER FT

0.001 INCH T.I.R.

VERTICALLY ---------------------------------------------------- 0.0005 INCHES PER FT

0.001 INCH T.I.R.

CENTRALITY OF PULLING HEAD HOLE -------------------------- 0.001 INCH T.I.R.

RELATIVE TO FACE PLATE HOLE

3.2.3 Other Required Characteristics.

3.2.3.1 Coolant system. The machine shall be equipped with a flood-type coolant system designed for use with cutting oil. This system shall be complete including all pumps, piping, reservoir, motors, and other components needed for proper and full operation. The system shall be designed to direct flood coolant to the broach cutting tool in use and shall permit manual redirection of coolant stream by the operator. A means shall be supplied to allow varying the rate of flow of coolant. Full flow of this system shall be designed to deliver adequate volume of coolant for the types of material to be machined. Screens or strainers shall be provided to protect the coolant pump and these shall be readily accessible for cleaning. 200 gallon minimum coolant capacity.

3.2.3.2 Required Tooling. The contractor shall furnish with the machine, one (1) fixture as depicted on the drawing (Attachment A PDF) and one complete sets of broaching tools necessary to perform the tests specified in paragraph 3.4.1.5. (Attachment B PDF) Upon successful completion of final acceptance inspection (see para 4.6) the contractor shall supply the Arsenal at least one reproducible drawing and CD of all fixtures and tooling to be supplied.

Pulling head shall be compatible to WVA existing tooling.

3.2.3.2.1 Inspection Bar. Precision machine line up bar for puller/retriever/nest alignment inspection and adjustment. The Bar shall have an accuracy certification.

3.2.3.3 Faceplate. A faceplate to accept work parts and work holding fixtures. The faceplate shall have an accurately machined circular hole for aligning and securing work and work fixtures.

3.2.3.4 Broach Cylinder Assembly. The hydraulic power system shall include a broach cylinder assembly. The broach cylinder assembly shall incorporate a precision bored and honed cylinder assembly, piston rings, ram and an efficient ram seal. The assembly shall be securely mounted to the main frame and aligned in a manner to assure direct pull on the pulling head. The ram shall be affixed to the piston at the cylinder end and to the pulling head at the other end. The broach cylinder assembly shall have a minimum bore diameter of 10 inches. The cylinder ram rod connecting the broach cylinder assembly to the pulling head shall be not less than 3.750 inches in diameter. The ram and crosshead reciprocation shall be actuated hydraulically and controlled through the main control panel. The assembly shall be capable of withstanding the broach pulling and return forces demanded by the nature of the work involved.

The ram and pulling head stroke speeds, stroke lengths and tons of pull shall be in accordance with requirements specified herein. The broach cylinder assembly shall be bolted and dowelled directly to the main frame to insure strength and alignment.

3.2.3.5 Pulling Head. The pulling head shall traverse horizontally on guideways of the mean frame, be positively affixed to the cylinder ram and aligned with the face plate hole centerlines. The pulling head movement shall be activated through the hydraulic system cylinder and ram assembly and controls. The pulling head travel shall be adjustable throughout the entire travel length. The front face of the pulling head shall be capable of approaching the front face of the faceplate (fixture side) to within a distance of 9 inches or less. The pulling head shall accept broach pullers through a means of a 2-8-N-3 threaded hole in the face of the pulling head. The threaded hole in the pulling head and the faceplate hole shall have the same centerlines. The pulling head hole shall be adjustable by not less than 2 inches above and below the horizontal centerline of the faceplate hole. The pulling head shall be capable of both manual and automatic movement. The crosshead shall stop automatically at the end of its preset stroke. There shall be a convenient means for adjusting the stroke length of the pulling head. The pulling head ways shall be automatically lubricated. The pulling head shall incorporate ways that are easily adjustable to compensate for wear. The pulling head shall be capable of pulling Watervliet’s present stick broaches in use.

3.2.3.6 TOOL STORAGE AND HANDLING UNIT. The tool storage unit shall be designed to contain, store and deliver, in sequence a quantity of eight (8) or more square or round internal pull broaches and dispense in sequence each broach tool to the cutting position as it is required to automatically be picked-up by the draw head coupling device and pulled through its cutting operation. Upon completion of the cut the tool shall returned to the starting position, shall be retrieved and stored by the tool magazine in proper sequence. This unit shall be of such a design to accommodate broaches which utilize the full stroke and less and may be up to two (2) inches wider and two (2) inches higher. The unit shall be heat stressed prior to finish machining.

The tool storage unit shall be self-standing or a supporting unit that will attach to the main machine frame at the faceplate end. There shall be a means for leveling provided around the periphery of the tool storage unit.

Note: The tool and handling unit shall also have the capability to allow the operator to randomly select any tool it has stored, position it and pull it through a workpiece at any time desired.

3.2.3.7 SHUTTLE TABLE. A shuttle table shall be provided and shall be structurally adequate to support and automatically and accurately position the workholding fixture as described on the drawing (Attachment A PDF). Positioning accuracy of the shuttle table shall be such that the workholding fixture shall be repeatedly positioned within .001 inch of nominal broaching position.

3.2.3.8 Floor Pan. Full machine floor pan, shall be provided to contain carry-off or dripped coolant cutting oil.

3.2.4 Required Performance on Workpiece. Watervliet will provide an actual production component (Attachment D PDF) for which the Rack Slot shall be broached which shall be used as a performance cutting tests. The machine shall meet the performance characteristics in section 3.2.2.1 and the alignment and accuracy characteristics in section

3.2.2.2. The machine shall also be required to achieve the following performance characteristics on workpieces. The workpieces are 4340 steel case hardened from RC 38 to RC 42. Rack Slot dimensions 1.437” +.003” BY 1.625” +.003” and the allowable tolerances shall also be the basis for the workpiece performance test (see 3.4.1.5).

CHARACTERISTIC ALLOWABLE TOLERANCE

SQUARENESS OF RACK SLOT ------------------- ±.001 INCH OR LESS

OVER ENTIRE PIECE

PARALLELISM OF RACK SLOT ------------------±.001 INCH OVERALL

(BOTH 1.437" DIMENSION AND

1.625" DIMENSION)

ALLOWABLE TAPER OF BOTH ----------------- ±.001 INCH OVERALL

RACK SLOT DIMENSIONS

SURFACE FINISH OF RACK SLOT -------------- 63 MICRO INCH OR

FINER

3.3 Machine Control System. The machine tool covered in this specification is not required to be equipped with a computer numerical control. However, the machine's control system is required to be of modern design and latest proven state-of-the-art. It shall contain but not be limited to coolant system, on-off switch, broach jog forward switch, broach jog reverse switch and machine master reset switch. It is therefore required that, with two permissible exceptions, all of the controls required to operate the machine throughout its full ranges and capacities shall be located at the operator's console (see 3.1.8). The two permissible exceptions are adjustment rate and adjustment to motion limits such as trip dogs or limit switches, although an operating console which includes these functions as well will be acceptable.

3.3.1 Control System Requirements. Each offeror shall provide for review a complete 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.

a.) The control system shall include a USB thumb drive.

b.) Digital readout, the machine shall be equipped with digital readout of the position and motion of each precisionaxis of tool or workpiece movement.

c.) Inch or Millimeter interchangeability resolution .001” and .01mm d.) Lifetime stroke meter.

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

a) The desired display is Allen-Bradley programmable controller and touch screen HMI, with advanced programming, fault diagnostics, and tool tracking. Backup program CD included. Or equal

b) The touch screen device shall be suitably protected for use in a machine shop manufacturing environment. The operator’s panels provided shall have at least one USB port.

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

3.3.3 Enclosures. All enclosures 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.

b.) New enclosures shall be painted with a color as close to the painted color of the original machine tools as possible.

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.

Control/Operating System Software and Documentation. One copy of the touchscreen software, ladder logic, control manufacturer software, interface software and licensing agreement documentation are to be provided prior to final acceptance.