One 5-Axis, Vertical Computer Numerically Controlled (CNC) Milling Machine

Description of requirements: The contractor shall provide One (1) 5-Axis, Vertical, Computer Numerically Controlled (CNC) Milling Machine with the following salient characteristics:

The Government requires one 5-Axis, Vertical CNC-Mill that meets the following characteristics:

• A 5th-Axis capability, with a trunnion table, or a rotary platter that is either removable or permanently mounted in place inside the mill.  The 5th-Axis capability shall be true “5-Axis”.  Required size and operating characteristics are as follows:

  • Work envelope:
    • X-Y Flat Table – 18” wide (min.) X 18” deep (min.) usable area.
      • Weight capacity – 2000 pounds
    • Rotary/Trunnion Turntable (removable) – 7.5” diameter (min.)
      • Weight capacity – 125 pounds
    • Rotary/Trunnion Turntable (integral) – 15” diameter (min.)
      • Weight capacity – 600 pounds
  • Rotary/Trunnion turntable movement range:
    • A/B-Axis rotation – 130 degrees range of motion minimum
    • C-Axis rotation – 360 degrees minimum
  • Positional accuracies:
    • Linear positioning accuracy – 0.0005 inches or less.
    • Repeatability – 0.0003 inches or less.
  • Feed Rates:
    • Rapid traverse – 750 inches per minute (IPM) or faster.
    • Cutting rate – 750 IPM or faster.
    • Jog rate – 300 IPM or faster.
• A vacuum dust collection system that is to be used exclusively in the “dry” state and primarily for graphite dust.  This mill will be used for the fabrication of graphite dies and tooling for our incoming Spark Plasma Sintering (SPS) system, and for the fabrication of electrodes for “Sinker” or “Plunge” Electro-Discharge Machining (EDM) in the future.   . 
• A full-enclosure surrounding the mill to completely contain coolant escape during “wet” operation as well as to mitigate the release of graphite dust into the local atmosphere during “dry” operation.
• A wireless probe for locating samples in the mill prior to machining.  These systems shall be used to “touch off” on surfaces of a component that is located in the mill to establish locations and axes.  This information shall have the ability to be captured by the mill controller and used to guide machining operations based on the numerical code programmed by the operator. 
• A tool-setting system that shall automatically detect and measure a cutting tool that is loaded into a tool-holder and save its spatial position into memory.  . 
• An automatic tool-holding/tool-changing system with a capacity to hold at least 30 tools. and meets the following:
• • Tool capacity – 30 tools minimum
  • Tool diameter:
    • When every tool slot filled – 2.75 inches or larger.
    • When every other slot is empty – 4.75 inches or larger.
  • Maximum tool length – 9.0 inches or longer.
  • Maximum tool weight – 17.0 lbs. or greater.
• A high-speed spindle with high rpm’s that meets the following:
  • Spindle speed – 15,000 rpm minimum.
• A high-torque spindle that meets the following:
  • Peak power – 29 HP or greater.

Detailed Specifications:

• General Footprint (Floor Dimensions): Maximum allowable size:
  • Width (largest dimension, or side to side) – 130 inches maximum
  • Depth (smallest dimension, or front to back) – 120 inches maximum
  • Height (top to bottom dimension) – 150 inches maximum
• Machine Weight – 19,000 lbs. maximum.
• Coolant System:
  • Reservoir Capacity – 40 gallons minimum
  • Directional nozzles to direct coolant toward work piece.
• Active spindle head cooling system.
• Automatic chip removal system.
• On-Site or Off-site training provided for up to 3 individuals.
• Installation and set-up
• Detailed layout of system including air, power, fluid requirements and specifications provided prior to contract award.
• Printed and electronic operations manuals.