WVA Eq Eng Specification 9-21-3415 External Cylindrical 7m OD Grinder.pdf

Specification for New External Cylindrical Grinder

Spec. # 09-21-3415

Manufacturing Engineering Work Group Watervliet Arsenal

Watervliet, New York 12189 03/24/21

Department of the Army

TACOM

9-21-3415

CONTENTS

PARAGRAPH PAGE

1 Scope

1.1 Abbreviated Description

2 Applicable Standards and Publications

2.1 Non-Government Publications

2.2 Clarification

3 Requirements

3.1 General Requirements

3.1.1 Design and Engineering

3.1.2 Materials and Components

3.1.3 Construction

3.1.3.1 Alignment Retention

3.1.4 Slideway Design and Construction

3.1.4.1 Replaceable Ways

3.1.4.2 Way Wipers

3.1.5 Workmanship

3.1.6 Maintainability

3.1.7 Interchangeability

3.1.8 Motors

3.1.8.1 Motor ID Plates

3.1.9 Operator Control Voltage

o Utility Outlet

3.1.11 Safety and Environmental Requirements

3.1.11.1 Protection of Machine Operator

3.1.11.2 Protection of Machine

3.1.11.3 Noise Levels

3.1.11.4 Ozone Depleting Substances

3.1.11.4.1 Ozone Depletion Potential (ODP) Definition

3.1.11.4.2 Prohibited Substances

3.1.11.5 Asbestos and Mercury Free Certification

3.1.11.6 Material Safety Data Sheets

3.1.11.7 Lead Free and Chromium Free Paint Certification

3.1.11.8 PCB Free Certification

3.1.11.9 Lockout-Tagout (LOTO) Procedures

3.1.12 Identification Plate

3.1.13 Data Plates

3.1.14 Utility Connections

3.1.15 Utility Connection Labor

3.1.16 Utility Requirements

3.1.16.1 Electrical

3.1.16.1.1 Electrical Conversion Equipment/Transformers

3.1.16.2 Pneumatics

3.1.16.2.1 Air Booster Unit

3.1.16.2.2 Air Dryers/Filtration

3.1.17 Lubrication

3.1.17.1 Lubrication Plate

3.1.17.2 Lubricants, Hydraulic Fluids, Oils and Coolants

3.1.18 Hydraulic System

3.1.19 Painting

3.1.20 Machine Hold Down and Leveling

3.1.21 Gears

3.1.22 Handwheels

3.1.23 Technical Data

3.1.23.1 Machine and Equipment Floor Plan

3.1.23.2 Catalog of Standard Tooling and Accessories

3.1.23.3 Non-Standard (Special) Tooling and Accessories

3.1.23.4 Installation Instructions and Drawings

3.1.23.5 Lubrication Diagram and Instructions

3.1.23.6 Operating Instructions

3.1.23.7 Maintenance and Troubleshooting Instructions

3.1.23.8 Electronic and Hydraulic Schematics

3.1.23.9 Repair Parts Catalog

3.1.23.10 Program Manuals

3.1.23.11 Software Documentation

3.1.24 Training Required

3.1.25 Repair/Replacement Parts and Service

3.1.26 Special Tools

3.1.27 Control of Cutting Fluids

3.1.28 Site Conditions

3.1.29 Machine Installation, Startup and Testing

3.1.29.1 Work to be performed by the Arsenal

3.1.29.1.1 Site Designation

3.1.29.1.2 Utilities

3.1.29.2 Work Performed by the Contractor

3.1.29.2.1 Site Preparation

3.1.29.2.2 Rigging

3.1.29.2.3 Installation

3.2 Machine Specific Requirements

3.2.1 Machine Tool Description

3.2.2 Required Characteristics

3.2.2.1 Performance Characteristics

3.2.3 Required Features, Options and/or Accessories

3.2.3.1 Coolant System

3.2.3.2 Refrigerated Heat Exchanger

3.2.3.3 Automatic Wheel Balancing

3.2.3.4 Truing Device

3.2.3.5 Head Stock

3.2.3.6 Tail Stock

3.2.3.8 Steady Rests

3.2.3.9 Grinding Wheels

3.3 Machine Tool Control System

3.3.1 Control System Requirements

3.3.1.1 Intuitive/Conversational Programming

3.3.1.2 Other Control Requirements

3.3.2 Operator Control Panel

3.3.3 Interconnecting Wiring

3.3.4 Control/Operating System Software and Documentation

3.3.5 Control Functions and Capacities

3.3.5.1 CNC Features/Programming Requirements

3.3.5.2 Man Machine Interface

3.4 Requirements for Demonstration of Conformance

3.4.1 Certification, Drawing and Test Required

3.4.1.1 Certification of Completeness

3.4.1.2 Test of Conformance to Specified Characteristics

3.4.1.3 Test of Conformance to Specified Alignments and Accuracies

3.4.1.4 Test of Conformance to Specified Horsepower Characteristics

3.4.1.5 Test of Conformance to Specified Performance on Workpiece

3.4.1.5.1 Test Workpiece

3.4.1.5.2 Bearing Surface Test

3.4.1.5.3 Wheelhead cross slide repeatability

3.4.1.5.4 Slide Zone Test

3.4.1.5.5 Grind M776 OD

3.4.2 Materials and Equipment for Preliminary and Final Acceptance Testing

3.4.2.1 Material for Workpieces

3.4.2.2 Tooling

3.4.2.3 Cutting Fluids

3.4.2.4 Hydraulic Fluids and Lubricants

3.4.2.5 Testing and Measuring Equipment

4 Quality Assurance Provisions

4.1 Responsibility for Inspection

4.2 Preliminary Acceptance Inspection

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection

4.3.1 Examination for Completeness

4.3.2 Examination of Performance Characteristics

4.3.3 Examination of Alignments and Accuracies

4.3.4 Examination of Power and Rigidity

4.3.5 Examination of Performance Testing

4.3.6 Supplementary Tests and Examinations

4.4 Re-inspection Provisions

4.5 Post Preliminary Inspection Procedures

4.6 Final Acceptance Inspection

4.7 Warranty

5 Preservation and Packaging

6 Instructions to Offerors

6.1 Contents of Proposals

6.2 Standard or Optional Equipment

6.3 Prior Customer List

6.4 Special Foundations

6.5 Standard or Optional Equipment

Appendix A Acceptable Lubricants, Hydraulic Fluids, Oils, and Coolants Appendix B Class I Ozone Depleting Substances Appendix C Electrical Survey Appendix D Environmental Requirements

1. Scope

1.1. Abbreviated Description. The machine tool covered by this specification shall be a programmable, horizontal, external, cylindrical grinding machine. This machine shall have a center to center continuous grinding capability of 7 meters with a minimum wheelhead cross slide travel of 15”. This cylindrical grinding machine shall be of the traveling head type with a weight capacity of 30,000 lbs. while utilizing steadies.

2. Applicable Standards and Publications. The documents listed in this section are referred to in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not they are listed in this section. The quality of all work performed and material provided in association with this specification shall meet or exceed the listed industry standards and engineering practices for this type of equipment and its intended function.

2.1. Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B11.24 2002 (R12) ........................Safety Requirements for Transfer Machines ANSI B11.TR1-2004 ...............................Ergonomic Guidelines for the Design, Installation Use of Machine Tools ANSI B11.TR2-1997 ...............................Mist Control Considerations for the Design, Installation, and Use of Machine Tools Using Metalworking Fluids ANSI B11.TR3-2000 ...............................Risk Assessment and Risk Reduction - A Guideline to Estimate, Evaluate, and Reduce Risks Associated with Machine Tools ANSI B11.TR4-2004 ...............................Selection of Programmable Electronic Systems (PES/PLC) for Machine Tools ANSI B11.TR5-2006 ...............................Sound Level Measurement Guidelines ANSI B11.TR6-2010 ...............................Safety Control Systems for Machines ANSI B11.TR7-2007 ...............................Designing for Safety and Lean Manufacturing - A guide on integrating safety and lean manufacturing principles in the use of machinery ANSI B11.23 2002 (R12) ........................Safety Requirements for Machining Centers and Automatic Numerically Controlled Milling, Drilling and Boring Machines ANSI B11.22-2002 (R12) ........................Safety Requirements for Turning Centers and Automatic Numerically Controlled Turning Machines ANSI B11.21-2006 (R12) ........................Safety Requirements for Machine Tools Using Lasers for Processing Materials ANSI B11.20 2004 (R15) ........................Safety Requirements for Integrated Manufacturing Systems ANSI B11.19-2010 ..................................Performance Requirements for Safeguarding

ANSI B11.18-2006 (R12) ........................Safety Requirements for Machines Processing or Slitting or Non-Coiled Metal ANSI B11.17 2004...................................(R15) Safety Requirements for Horizontal Hydraulic Extrusion Presses ANSI B11.16 2003 (R09) ........................Safety Requirements for Powder/Metal Compacting Presses ANSI B11.15 2001 (R12) ........................Safety Requirements for Pipe, Tube and Shape Bending Machines ANSI B11.13 1992 (R07) ........................Safety Requirements for Single and Multiple- Spindle Automatic Bar, and Chucking Machines ANSI B11.12 2005 (R2015) ....................Safety Requirements for Roll Forming & Roll Bending Machines ANSI B11.11 2001 (R12) ........................Safety Requirements for Gear and Spline Cutting Machines ANSI B11.10 2003 (R15) ........................Safety Requirements for Metal Sawing Machines ANSI B11.09-2010 (R2015) ....................Safety Requirements for Grinding Machines ANSI B11.08 2001 (R12) ........................Safety Requirements for Manual Milling, Drilling, & Boring Machines with or without Automatic Control ANSI B11.07 1995 (R2010) ....................Cold Headers Safety Requirements for Construction, Care, and Use ANSI B11.06 2001 (R12) ........................Safety Requirements for Manual Turning Machines with or without Automatic Control ANSI B11.05 1988 (R08) ........................Ironworkers - Safety Requirements for Construction, Care, and Use ANSI B11.04 2003 (R13) ........................Safety Requirements for Shears ANSI B11.03 2012...................................Safety Requirements for Power Press Brakes ANSI B11.02 – 2013................................Hydraulic and Pneumatic Power Presses - Safety Requirements for Construction, Care, and Use ANSI B11.01-2009 ..................................Safety Requirements for Mechanical Power Presses ANSI B11.0-2015 ....................................Safety of Machinery; General Requirements and Risk Assessment ANSI / ISO 12100 – 2012 ........................Safety of Machinery - Basic Concepts, General Principles for Design - Risk Assessment and Risk Reduction

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 79 ..................................................Electrical Standard for Industrial Machinery

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 230-2:2006 ........................................NC Positioning Standard Revised

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B5 Machine Tools ....................................Components, Elements, Performance, and Equipment

2.2. Clarification. If any ambiguities or discrepancies between this specification and the standards listed in Section 2.1 are discovered by the contractor during the review of this specification prior to submitting an offer, the ambiguities and discrepancies shall be reported to the contracting officer by the contractor before the close of bidding or receipt of proposal.

Submission of a proposal or a bid shall be construed as evidence that the examination of this specification has been made. Contractor claims for labor, material, equipment, or difficulties encountered, which could have been discovered during this examination, will be denied.

3. Requirements.

3.1. General Requirements. The equipment specified in this document shall be a standard product of the manufacturer and shall require either no design changes, or if required, minor design changes to meet the requirements of this specification. Therefore, ownership of the design shall remain with the manufacturer.

3.1.1. Design and Engineering. The equipment specified in this document shall be designed and engineered in accordance with the latest standards, recognized by the Association for Manufacturing Technology and as listed in Section 2.1.

3.1.2. Materials and Components. Materials and Components incorporated in the construction of the equipment specified in this document, shall be free from defects and shall conform to the specifications and standards listed in this document.

3.1.3. Construction. All parts of the equipment specified in this document shall be new, unused and shall be constructed to be capable of withstanding all forces encountered during operation to the equipment’s 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, 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. 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 a value between RC 50 and RC 54. This hardness value shall reach a depth of .100 inch at a minimum.

b. Hardened and ground steel ways for mating with Turcite, Rulon or other equal to, low friction materials shall be hardened to a value between RC 55 and RC 62. Actual hardness values within the hardened and ground steel ways shall not vary more than 5 RC points throughout the measured area.

c. Hardened and ground steel ways, for use with anti-friction roller bearings, shall be hardened to a value between RC 62 and RC 65. This hardness value shall reach a minimum depth of 1/8 inch.

NOTE: 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 function of the equipment.

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 the 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 shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall be easily removable and replaceable

3.1.4.3. Shims and Spacers. Shims that do not appear on engineering drawings shall not be incorporated in the machine. Spacers that do appear on engineering drawings are permissible.

3.1.5. Workmanship. Workmanship throughout the equipment specified in this document shall be free from irregularities or defects that could adversely affect performance or durability.

3.1.6. Maintainability. All equipment components offered that are subject to wear, distortion or failure and all parts which require periodic adjustment shall be accessible for replacement or adjustment. Instructions for the maintenance and adjustment of these parts shall be clear, concise and definitive.

3.1.7. Interchangeability. All parts offered that bear the same part number shall be interchangeable.

3.1.8. Motors. All motors provided shall be of the type and horsepower rating to meet the specified requirements based on the engineering practices and standards listed in Section 2.1. All motors shall be rated for continuous duty. Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with thermal overload protection. Motor starters and controls shall operate at 24 VDC. Motor starters shall provide drop out protection. This means that in the event of power loss, the equipment shall be re-energized only by deliberate action of the operator. Manual or mechanical motor starters are not acceptable.

All motors shall be housed in enclosures of the appropriate NEMA type for class and severity of service. All AC unidirectional motor housing shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 horsepower or greater shall be equipped with a “soft start” mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 horsepower or greater shall be tested per IEEE Standard 112- Method B and must meet Premium Efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 9IEC 60034-30:2008. All motors are to be permanently lubricated and sealed.

3.1.8.1. Motor I.D. Plates. Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

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

3.1.10. Utility Outlet. The machine shall be provided with a 120 volt, single phase, 20 ampere, dual receptacle, and 3 wire utility outlet. This outlet shall be protected by a ground fault interrupter and shall be externally mounted on the operator control panel. A noise suppression device for this circuit shall be provided.

3.1.11. Safety and Environmental Requirements. The contractor shall review the environmental requirements documented in Appendix D of this document and comply as required.

3.1.11.1. Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with the standards listed in Section 2.1.

3.1.11.2. Protection of the Machine. The machine shall be designed and equipped in accordance with the standards listed in Section 2.1 to prevent self-damage in the event of malfunction and ordinary operator negligence.

3.1.11.3. Noise Levels. 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 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 operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

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 CFCs and Halons. The equipment specified in this document shall utilize 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. Safety Data sheets (SDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal (CDRL A001).

1.1.1.1.1. Ozone Depletion Potential (ODP) Definition. 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.

1.1.1.1.2. Prohibited Substances. Offerors are responsible to obtain and adhere to the most current list of environmentally prohibited substances as of the date of the submission of bids or proposals.

1.1.1.2. 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 (CDRL A002).

1.1.1.3. Material Safety Data Sheets. The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of proposal submission (CDRL A001).

1.1.1.4. 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 nine thousandths of one percent (0.009%) lead by weight. This certification shall be provided prior to machine delivery (CDRL A003).

1.1.1.5. PCB Free Certification. To the extent that the machine is charged with lubricant or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCBs). The machine and its equipment shall be certified as PCB free and certification shall be provided prior to machine delivery (CDRL A004).

1.1.1.6. Lockout/Tagout Procedures. The manufacturer shall provide the 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 but is not limited to electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal energy.

1.1.2. Identification Plate. A corrosion resistant metal plate shall be securely attached to the machine in a location visible to the operator's workstation. This plate shall bear, as a minimum, the information called for below, with space at the bottom of the plate for the addition of one line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and full load amps) Government Contract Number Date of Manufacture

1.1.3. Data Plates. All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

1.1.4. Utility Connections. Equipment supplied to the Watervliet Arsenal will have a single point shut off for each utility supplied to the system. This will be referred to as the “point of first connection”. Each type of power source shall have only one point of first connection. Each point of first connection shall be clearly labeled on the system and shown in the safety Lockout/Tagout portion of the documentation package. These points shall be located on a stationary component and positioned so that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

1.1.5. Utility Connection Labor. Watervliet Arsenal shall only provide labor and materials to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

1.1.6. Utility Requirements.

1.1.6.1. Electrical. The WVA power source that the specified equipment will be connected to will be a nominal 480 volts, 3 phase, 60 Hz AC voltage. However, the machine shall be able to operate normally at source voltages ranging from 432 to 504 volts. The WVA power source does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

NOTE: Offeror is to state required power/electrical requirements for offered machine. See Appendix C and complete.

1.1.6.1.1. Electrical Conversion Equipment/Transformers. If DC or reduced AC voltage is required to meet any specified equipment requirement, the conversion and transformation equipment shall be furnished with the machine. All transformers must meet NEMA TP 1-2002 energy efficiency requirements. Equipment which requires a high quality constant power source shall be furnished with the proper isolation and power conditioning equipment for the power service designated in this description

1.1.6.2. Pneumatics/Air. If air is required for any machine operation or function, the machine shall be fully equipped with all required components, fully installed to the point of connection of WVA shop air. Shop air at the Arsenal is 85 psi with above normal moisture and contaminant levels. If higher or lower pressure is required at the machine or a different air flow rate is needed, the machine shall be fully equipped to modify the supply pressure and volume.

The machine shall also be equipped to remove the above normal moisture and contaminant levels. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig.

1.1.6.2.1. Air Booster Unit. If the equipment offered requires more than 85 psi at the volume for operation of the equipment, then an air booster unit shall be provided with the machine. If operation of the equipment requires an accumulator tank, it shall be provided with the booster. Please state in your proposal what the machine requirements shall be and if a booster and tank will be required. Installation shall be provided by the contractor. If the use of an air booster is not possible and an air compressor is required, the contractor must state this in their proposal and provide justification detailing CFM, psi, application, and duration of air usage.

1.1.6.2.2. Air Dryers/Filtration. If the offeror determines that on machine air dryers are required to maintain moisture levels the air dryers shall be capable of drying air down to 35° F pressure dew point, minimum, from air entering the equipment at 110° F. The air dryer shall supply air at the required standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically.

1.1.7. Lubrication. The machine shall be equipped to provide 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 or equal to.

Gearboxes and transmission cases shall be lubricated by the wet sump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Automatic lubrication systems shall be equipped to be fail safe to the maximum extent possible. All sensors and devices used to detect the presence or absence of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods 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, cleanable or replaceable filtration devices shall be provided. Wet sump type systems shall be equipped with a means to confirm proper oil level. Sight gages shall be of the external standing tube type rather than the flush mounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

1.1.7.1. Lubrication Plate. A lubrication plate 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.

1.1.7.2. Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal has established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor shall choose the required lubricants, hydraulic fluids, oils and coolants from Appendix “A”, enclosed or where there is a designated equivalent. If a substitute is required, the contractor shall provide at the time of machine delivery, a justification which shall include the manufacturer, type and specification number as well as the reason for the substitution (CDRL A005).

1.1.8. Hydraulic System. Hydraulic systems provided shall be sized and powered for the intended application conforming to the standards listed in Section 2.ff1. The systems shall incorporate cleanable or replaceable filtration devices to ensure fluid cleanliness. Reservoirs shall be equipped with visible gages to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120° F in temperature, a heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure and under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, anti-surge devices and circuits shall be incorporated to ensure uniformity of motion under all loads. These devices and circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

1.1.9. 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 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.

1.1.10. Machine Hold Down and Leveling. The machine base shall be provided with mounting holes in a quantity and location 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 recommended hold down and leveling hardware.

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

1.1.11. 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.

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

1.1.13. 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. The contractor shall provide full documentation in the form of “as built” drawings and manuals.

Drawings shall not be generic. A “hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2017, shall be of one-to-one scale, shall be dimensioned in English units, and shall not utilize the color yellow. “On-line” technical data will not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided.

1.1.13.1. Machine and Equipment Floor Plan. One digitized machine and equipment floor plan in AutoCAD .dwg or .dxf format shall be provided on a CD. This plan shall depict the complete machine space envelope including all ancillary equipment and the dimensioned bolt-hole pattern of the hold-down bolts for the machine. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power including the full load amperage requirements, air, water, etc.) required to operate the machine. This data shall be furnished as soon as possible after contract award no later than 30 days after award (CDRL A007). Also, if a foundation is required for the offered machine then this drawing shall also clearly depict the outline of the foundation and provide locating dimensions from a fixed point on the machine to at least one corner of the foundation. 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.

1.1.13.2. 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 and no later than 30 days after award (CDRL A006). 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 Office.

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/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

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.

1.1.13.3. Catalog of Standard Tooling and Accessories. Catalog shall be furnished 30 days after award of contract (CDRL A008). 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. (One hardcopies)

1.1.13.4. 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 to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery (CDRL A009). (One hardcopy and one AutoCAD electronic copy)

1.1.13.5. Installation Instructions and Drawings. Instructions containing all necessary information required to install the equipment 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 (CDRL A010). (One hardcopy and one AutoCAD electronic copy)

1.1.13.6. Lubrication Diagram and Instructions. To be delivered to the technical POC at time of machine delivery (CDRL A011). (One hardcopy and one AutoCAD electronic copy)

1.1.13.7. Operating Instructions. These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery (CDRL A012).

(Four hardcopies and one electronic copy)

1.1.13.8. Maintenance and Troubleshooting Instructions. To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly drawings. To be delivered at time of machine delivery (CDRL A013). (Two hard copies and two electronic copies)

1.1.13.9. Electronic and Hydraulic Schematics. To be considered acceptable, these schematics shall clearly portray all “as built” electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery (CDRL A014). (One hardcopy and one electronic copy)

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.

1.1.13.10. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include 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 subassemblies. To be delivered at time of machine delivery (CDRL A015).

(Two hardcopies and one electronic copy)

1.1.13.11. Program Manuals. Where a CNC machine is specified, programming manuals shall be supplied. These manuals shall include, a clear summary of the control functions actually implemented and usable on the system specified. To be delivered at time of machine delivery (CDRL A016). (One hardcopy and one electronic copy)

1.1.13.12. Software Documentation. The offeror shall provide documentation of all system software and ladder logic developed to control and interface with the control/drives with the machine tool. To be delivered 30 days after delivery of the machine (CDRL A017). (One hardcopy and one electronic copy) One copy of the system memory backup (S-Ram) shall be provided on compact flash drive at startup of machine.

1.1.14. Training Required. The contractor shall be responsible for providing training of WVA personnel. The type and extent of training shall depend upon whether the machine specified 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". 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

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 2 During Installation On site

NOTE: For all types of training, the associated technical data (see 3.1.23) 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.

1.1.15. 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.

Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major machine components. 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.

Note: The offeror shall supply a list of recommended spare machine parts as a replacement option with the offer.

1.1.16. 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.

1.1.17. Control of Cutting Fluids. If the machine is equipped with a coolant system, the contractor shall ensure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine and 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.

1.1.18. 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° F to 95° 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° 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 what 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.

1.1.19. Machine Installation, Startup and Testing.

1.1.19.1. Work to be performed by the Arsenal.

1.1.19.1.1. Site Designation. Upon receipt of the required installation and foundation drawings (see 3.1.23), Watervliet Arsenal will designate an installation site and outline a general machine location on the shop floor.

1.1.19.1.2. Utilities. Once the machine is installed, positioned and rough leveled by the contractor or their designated rigging crew, Watervliet personnel will run utilities (power and air) to first points of connection on the machine. Watervliet must be provided with sufficient time to accomplish these connections. Sufficient time may be up to 3 working days depending on Watervliet personnel availability. 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 their arrival and continue under their guidance.

NOTE: If installation instructions, electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.23), 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.

1.1.19.2. Work Performed by the Contractor. This project is classified as a “turn-key” system with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Contractor personnel shall adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields, to wear safety shoes, and to refrain from wearing loose clothing (i.e. “hoodies”) and jewelry while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine.

1.1.19.2.1. Site Preparation. Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall layout the machine. Please note that the majority of the Watervliet Arsenal’s shop floor is covered with 2.0” thick wood block. The contractor is responsible for the removal of wood block flooring and existing concrete preparation. Contractor shall also be responsible for securing wood block flooring and install any leveling pads necessary for installation.

1.1.19.2.2. Rigging. 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 to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services should be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Only propane powered forklifts are permitted and forklifts must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses. The contractor shall ensure they bring all equipment/material necessary for the rigging of the machine. If necessary, the Watervliet Arsenal can provide the contractor with information for local rigging companies.

1.1.19.2.3. Installation. Once the machine is positioned and rough leveled by the contractor the contractor, through his own service personnel, shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 and 4 and perform the required onsite training. The contractor 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 their 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.

NOTE: 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.

1.2. Machine Specific Requirements.

1.2.1. Machine Tool Description. The equipment covered by this specification shall be a programmable horizontal external cylindrical grinding machine. This machine shall have a center to center continuous grinding capability of 7 meters; with a minimum wheelhead cross-slide travel of 15”. The machine shall be of the traveling head type, and shall be capable of either straight or limited taper cylindrical grinding and shall be capable of performing plunge grind operations. All wheelhead motions and wheel truing cycles shall be controlled by CNC. This cylindrical grinding machine shall have a weight capacity of 30,000 lbs. while utilizing steadies.

1.2.2. Required Characteristics.

1.2.2.1. Performance Characteristics.

Minimum swing over Table .........................................................24” (610 mm) Max workpiece length ..................................................................7 meters Minimum weight between centers without steadies ....................10,000 lbs. (9071 kg) Minimum weight between headstock and steady ........................30,000 lbs. (13607 kg) Minimum cross slide travel (x axis) .............................................400 mm (15.75”) Cross slide feed speed ..................................................................0.5 to 5,000 mm/min (0.02 to

196.85 in/min) Cross slide servo torque x axis .....................................................1000 daNm (7,380 ftlbs) X axis feed speed .........................................................................0.5 to 5,000 mm/min (0.02 to

196.85 in/min) Saddle servo torque Z axis ..................