WVA_Equipment_Enginering_Specification.docx

Equip Engr Spec # 5-20-3416 Date: 13 May 2020

U. S. Army Watervliet Arsenal Watervliet, NY Equip Engr. Spec #5-20-3416 Date: 10/22/20

Two New 4-axis CNC Vertical Turning Centers

Table of Contents

1. Scope

1.1 Abbreviated Description 2

2. Applicable Standards and Publications 2

3. Requirements

4. Quality Assurance Provisions

5. Preservation, Packaging and Delivery Instructions 25

6. Instructions for Preparing Technical Offers 26 1.

Scope:

1.1 Abbreviated Description. This specification defines the requirements for two new Doosan Puma VTR1620M 4-axis CNC Vertical Turning Centers or equal. The machines shall include a Renishaw part and tool probe system, live spindle, through spindle coolant, C-axis rotary table, automatic tool changer, automatic pallet changer, 8-pallet pool station and remote pendants. 10 pallets with adjustable and removable 4-jaw chucks.

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

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

3.1 General Requirements.

3.1.1 Design and Engineering. The machine shall be designed and engineered in accordance with latest standards recognized or adopted by the Association for Manufacturing Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use.

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

3.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

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

3.1.3.2 Alignment Retention. Nonintegral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of accidental dislocation.

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

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

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

C. Hardened and ground steel ways for use with antifriction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more. Slideway systems other than the three (3) referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.1.4.1 Replaceable Ways. If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.1.4.2 Way Wipers. All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall also be easily removable and replaceable.

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

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

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

3.1.6 Maintainability. All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement or adjustment as applicable. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

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

3.1.8 Applicable Power Source. The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. No external transformers will be acceptable to convert to lower supply voltage. If an isolation transformer is required for a neutral application on a 3 wire three phase power configuration the offeror shall supply the transformer.

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

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

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 120volt singlephase, 20-ampere dualreceptacle 3wire utility outlet. This outlet shall be protected by a groundfault interrupter and shall be externally mounted and easily accessible. A “noise" suppression device shall be provided.

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

3.1.10 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. The machine manufacturer will provide WVA with platforms and guarding to provide adequate access and operator protection as defined in OSHA 29 CFR PART 1910, as it pertains to machine safety.

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

3.1.10.2 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 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.

3.1.10.3 Ozone Depleting Substances. Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozonedepleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. All substances or systems, that are approved for use by the Environmental Protection Agency (EPA) have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data sheets (SDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: OzoneDepletionPotential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC11, CFC12 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.

3.1.10.4 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.

3.1.10.5 LeadFree and ChromiumFree Paint Certification. All paints and primers applied to the system shall be certified as lead free and chromiumfree. Lead based paint is paint that contains more than nine one thousands of one percent (0.009%) lead by weight. This certification shall be provided prior to machine delivery.

3.1.10.6 PCBFree Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection (see section 3.4), these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and its equipment shall be certified as PCBfree prior to being shipped.

3.1.10.7 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.

3.1.11 Identification Plate. A corrosionresistant 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

3.1.12 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. Gearboxes or transmission cases shall be lubricated by the wetsump 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 etc.) are permissible for lubrication points not practically served by automatic systems. For nonrecirculating 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. Wetsump 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 flushmounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.1.12.1 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.

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

3.1.13 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 sight gages to indicate fluid level. An appropriately sized refrigeration system shall be provided to ensure the hydraulic fluid does not exceed 120 degrees f in temperature. The hydraulic system shall be protected against overpressure as well as underpressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, antisurge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level. Pressure gages shall be liquid filled.

3.1.14 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 chromiumfree and leadfree. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semigloss", 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.

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

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

3.1.16 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.

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

3.1.18 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): The primary goal of foundation drawings is to ensure that the machine tool accuracies are guaranteed. The machine tool contractor shall provide these drawings and shall be complete in all construction detail to permit pricing and construction by a general contractor. Drawings shall be furnished 30 DAYS AFTER CONTRACT 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/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. 6.5.

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, etc.) required to operate the machine. This data shall be furnished 30 days after receipt of contract WITH ATTACHMENT C. One reproducible hardcopy and one electronic copy on CD or in AutoCAD.

SEE ATTACHMENT C

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. NonStandard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010 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/hold down holes. To be furnished 60 days prior to scheduled delivery of the machine. One reproducible hardcopy and one electronic copy on CD in AutoCAD Release 2010 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 2010 or later.

g. Operating Instructions. These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery. Four Hard copies minimum.

h. Maintenance and Troubleshooting Instructions and Mechanical Assembly drawings for all machine systems. To be delivered at time of machine delivery. Two copies minimum of the Maintenance and Troubleshooting Instructions. Two reproducible hardcopies and one electronic copy on CD in AutoCAD 2010 or later 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 hardcopy and one electronic copy on CD or memory stick in AutoCAD Release 2010 or later. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

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

j. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. 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 2 Operation and Fanuc Handbooks.

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

3.1.19 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 at an authorized control system training site as determined and arranged for by the contractor". If specialized formal off-site or on-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:

Hydraulic maintenance (if applicable)

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.

3.1.20 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 an option with the offer.

3.1.21 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 80 to 85 psi (unknown volume) and if higher or lower pressure or a specific volume is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 80 psi supply pressure. The machine shall also be equipped with devices to remove the ABOVE Normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 80 psig.

3.1.22 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.

3.1.23 Control of Cutting Fluids. The machine and coolant system provided shall be designed 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 leakproof metallic or nonmetallic liner.

3.1.24 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.

3.1.25 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine/control/drive systems wherever it is needed to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable.

3.1.26 Chip Removal. An automatic chip removal unit(s) shall be provided to convey chips of any material from the machine to an external container without manual aid. The unit shall be reversible to facilitate clearing of blockages. Controls shall include Manual/Auto, Fwd/Rev and Stop. There shall be controls located at the conveyor as well as at the operator’s station. Minimum belt width shall be 7”. Chip discharge height should be no less than 43” from floor level. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The unit shall operate successfully in a variety of machining environments including drycutting, machining with cutting oils and machining with waterextendable oils. Automatic means shall be provided to return cutting fluids to the machine's coolant tank which shall be separate from the unit. The chip removal unit shall be engineered for the machine so that when fully installed in accord with instructions all points subject to periodic maintenance and lubrication shall be externally accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself.

3.1.27 Machine Installation, Startup and Testing.

3.1.27.1 Work to be Performed by the Arsenal. This project is classified as a turnkey with the contractor being responsible for all-work associated with the installation unless otherwise stated. Upon receipt of the required installation and special foundation drawings (see 3.1.17); Watervliet Arsenal will clear the intended installation site prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities to first points of connection. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon his arrival and continue under his guidance.

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

3.1.27.2 Work to be Performed by the Contractor. This project is classified as a turnkey with the contractor being responsible for all-work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for costs associated with skidding and shipment, rigging, installation including at WVA. 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. The contractor shall also provide competent Englishspeaking service personnel to install the machine, rough and finish level the machine, startup, and conduct the acceptance tests specified in section 4. The contractor personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenalfurnished equipment. The contractor shall remove from WVA and dispose of all wastes (other than hazardous wastes) generated from uncrating and unpacking the machine at a permitted off-post disposal facility, in accordance with Attachment D of this specification and the document "WATERVLIET ARSENAL (WVA) INFORMATION FOR CONTRACTORS" which is available on the Watervliet Arsenal website. Once requirements of paragraph 4.1 and 4.2 have been completed contractor personnel shall coordinate the shipment of the machine to Watervliet. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded. Outside rigging services should be advised that only certified chain hoists are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Contractor personnel shall supervise the placement of the machine on the installation site by the rigging service. In most cases no Arsenal forklift services and/or Arsenal personnel will be available for the installation. Only propane powered forklifts are permitted and must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses. Arsenal overhead pendant cranes (within load capacities) can be used by the contractor/rigging service for the installation. The contractor shall provide written certification to the WVA representative that all contractor/rigger personnel are qualified, through either formal training or experience per OSHA, to operate pendant controlled overhead cranes. 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 a bill of lading and address label or a return shipping label from carrier and coordinate with the Arsenal POC.

3.2 MachineSpecific Requirements.

3.2.1 Machine Tool Description. The machines desired are two new 4-axis CNC Vertical Turning Centers. The table assembly shall be comprised of a Contouring Rotary table, tool changer, Renishaw part and tool probe system, coolant system, through spindle coolant, chip removal system, pallet pool and other equipment required to make a complete system specified herein shall meet or exceed the following characteristics.

The machine shall be used by the arsenal for a variety of high speed milling, drilling, boring, and tapping operations on components used in the manufacture of a block. The materials to be machined could be 4340 alloy steel which has been hardened to Rc38-42 and high nickel strength steels as well as other type steel components and materials including non-ferrous. All machine systems and assemblies shall be designed for high speed machining operations of these materials. Operations will include contouring, milling, drilling, tapping and boring.

3.2.1.1 Required Characteristics.

a.) Travels: Indicate in your proposal the axes designations based on whether the machine being offered is a traveling column or traveling table design. Offered travels are to assume machining up to a 3’ cube.

X Axis 87” min Z Axis (up-down) w/Spindle in Vertical Position 59” min b.) C-Axis Rotary Contouring Table (round table only): (same as 3.2.2.3) Rotary Full 360; 360,000 positions Speed………………............................................400 RPM or more

c.) Spindle: Designed for materials stated in par. 3.2.1 and to achieve optimal torque and speed range.

Tool Holder Type……………………………… Big Plus CAT50 d.) Feedrates: (infinitely variable):

e.) Tool Changer: Shall include a remote tool changer control and shall include at least Manual Rotation Right/Left/Off. Tool change system shall also permit manual activation of the powered tool retention system to permit manual changing of tools in the event the automatic system is idled for any reason. Other requirements are:

f.) Alignment and Accuracy Characteristics:

X axis motion squareness with Work Table Surface, Trammed from Spindle .00025" per 12”

Z axis motion squareness with Work Table Surface, Trammed from Spindle .00025" per 12”

Rotary axis motion squareness with Work Table Surface, Trammed from Spindle .00025” overall

Runout of the Spindle Taper not to exceed .001” TIR at 10" from Spindle Face

Linear Bi-Repeatability (X, V, Z-Axis) +/- 0.0002"

Linear Positioning (X, V, Z-Axis) …………………………+/- 0.0004”

Rotary axis Positioning +/- 5 seconds

Rotary axis Repeatability +/- 2.5 seconds g.) Machine Power Required: 480 VAC, 3- phase; 60 Hz

3.2.2 Other Required Characteristics.

3.2.2.1 Through-Spindle Coolant (TSC). In addition to being equipped with a complete high pressure flood/mist type coolant system the machine shall also be provided with a TSC system providing a minimum of 300 psi at 1.5 gpm minimum flow rate. The flood and TSC systems shall be complete and provided with all necessary pumps, motors, filters, piping, valves, etc. Activation and control of coolant flow volume shall be possible by either program/MDI code or manually. The coolant systems shall have the capability for manual or automatic start stop control.

3.2.2.2 Live Spindle. The machine shall have a live spindle that can tap, mill, drill, bore and contour with an RPM of 3000 or more. With a 20 HP drive motor or more.

3.2.2.3 Automatic Shuttle System/Pallet Pool. Automates the loading and unloading of one or more pallets with workpieces from a central storage location. The workpieces travel on a straight rail, carried by a vehicle with additional axes of motion that enable it to move the work into a machine and onto its table and out again when finished. Operators set up jobs at a central station, not at the individual machines, and a central computer controls the distribution and execution of the work. An 8 pallet pool station shall be included, along with ten 4-jaw pallets provided. Pallets must be able to have jaws installed and removed.

3.2.2.4 Work Area Enclosure. The machine shall also be provided with a work envelope enclosure to confine chips and coolant to the machining area. The guarding shall include transparent panels to permit viewing of the machine operation. Access doors for the operator shall allow the operator full access to the work area. The enclosure design shall also permit loading parts from overhead. The enclosure shall include a minimum of 5 light fixtures suitable for the work area environment. On/Off controls for the lights should be at the operator’s station.

3.2.2.5 Rotary Contouring Table. The machine’s work table assembly shall include a rotary contouring work table as a C-Axis. It shall be a rotary contouring table that’s 49” in diameter (round table only). The control system shall come complete with all software necessary for contouring.

3.2.2.6 Auxiliary Coolant Filter System. The TSC system shall be equipped for through-spindle coolant and use a 25-micron filter.

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

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

3.2.2.8 Hydraulic System Chiller. If needed to maintain acceptable hydraulic oil temperatures and accuracies the machine shall be provided with an appropriately sized hydraulic chiller system. See par. 3.1.12.

3.2.2.9 Compressor Unit and Refrigerated Air Dryer System. Reference par. 3.1.20. The compressed air supply at Watervliet Arsenal is at best 85 psi, volume undetermined. If the machine offered requires more than 85 psi at a particular volume then an industrial grade compressor unit shall be provided with the machine. Please state in your proposal what the machine requirements will be and if a compressor will be required. Regardless if a separate air supply is required the machine shall be provided with an appropriately sized ZEKS refrigerated air dryer system complete with input and output filter cartridges. All installation shall be provided and included. Note that noise levels of the compressor shall not exceed 85 dbs. Power for the compressor shall be 480vac. Power for the ZEKS unit shall be 110 vac. A common compressor and ZEKS unit utilized on other machines at WVA are Ingersoll Rand model #D31NC and ZEKS unit model 18HSF with dual filter stages.

3.2.2.10 Part Probing Systems. The machine shall be provided with an OPM 60 or equal Renishaw part probe system. All software and probing devices shall be provided. Machine shall be provided with a calibration ring at a known location.

3.2.2.11 Tool Probing System. The machine shall be provided with a Renishaw HPMA (high precision motorized arm) and a RP3 probe head. One TS13 or equal machine interface unit, Two 50 mm cube styli with a maximum tool length to probe 700 mm (27.5 in). Also includes modular tool probe datum arbor.

3.2.2.12 Adaptive Feed Control. The offered machine/control system shall be provided and setup with a complete Adaptive Feed Control system.

3.2.2.13 Tooling.

All tooling must have ability for TSC. Must include all Lyndex Nikken tooling listed below or equal to.

3.2.3 Required Performance on Workpieces.

Workpiece Performance Characteristics Required Performance

Accuracy of Bored Holes in

Accuracy of Contoured Angles Resulting from Linear Interpolation +/- 30 seconds Accuracy of Contoured Radii Resulting from Circular Interpolation +/-.001" per foot of radius Trueness of Machined Diameters

hole Tapping Capability 1.250" diameter or more coarse thread Surface Milling Capability 118 in./min. with 4" cutter

3.3 Machine Control System.

3.3.1 Control System Requirements. Paragraphs 3.3.1 through 3.3.7 are the minimum standard and/or optional features/capabilities control system requirements for the CNC system being provided. 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. Minimum specifications for the CNC control system hardware shall include the following:

a.) Fanuc 31i-B High Performance CNC software or equal to.

b.) If possible a 3.5" 1.44 Mb floppy drive and CD-RW drive shall be provided. These drives shall be located/mounted internally at the operator’s station but allow for external access. Access to these drives for downloading and uploading part programs and other information shall be, as a minimum, setup through standard system operator-interface screens. Indicate in your proposal if these devices are not available with the offered control system.

The new control system shall be provided with the means to connect to and communicate with Watervliet’s internal network system. This communication shall be via RS232 with external DB9 connection with cover, to have the ability to navigate through a shared directory to download part programs. If mount on the outside of electrical cabinet the hardware used at Watervliet Arsenal at the present time is purchased from Automation Direct www.automationdirect.com 1-800-633-0405 the connector we use is part number ZP-PNA-06-100 9 pin Female DB9 or equal. Also there shall be spare Ethernet connection at the drive location shall be complete with MTConnect communication protocol to include MTConnect Adapter and Agent, to provide for future use by WVA to communicate with Watervliet’s internal network system.

c.) The control shall be provided with an Uninterrupted Power Supply (UPS) battery backup and power surge protection. The UPS shall insure the retention of power to the CNC for a minimum of five (5) minutes in the event that failure of the primary power occurs. If the power is not restored within five minutes the CNC shall automatically, without human intervention, execute a power fail routine, to protect against data corruption or disk damage and terminate processing in an orderly fashion.

d.) The control system…