Ref: RRCAT/ACDFS/Tech Spec/201 19Nov 2013
Technical Specification
for
Manufacturing, Supply, Installation, Commissioning and Testing of
CNC Vertical Machining Centre
Government of India
Department of Atomic Energy
Accelerator Component Design & Fabrication Section
Raja Ramanna Centre for Advanced Technology,
Indore-452013
INDEX
A.Scope of the specification
B.Qualification criteria of the bidder
C.Terms & Conditions
D.Scope of supply
E.Machine specifications
F.Pre-dispatch inspection of machine & acceptance
G.Training to our Personnel
H.Installation, commissioning & acceptance of the machine at purchaser’s site.
I.Warranty
J.Packing & dispatch
K.Documentation
L.Guaranteed / Compulsory Technical Particulars
M.Performance certificate to be produced on Customer’s Letter Head.
A.Scope of the specification
The technical specification describes the requirements for manufacturing, supply, installation, commissioning and testing of computerized numerically controlled (CNC) Vertical Machining Center.
B.Qualification criteria of the bidder
Only original manufacturers/Authorised agents of manufacturerof VerticalMachining Centreare eligible to bid. The bidder must meet thefollowing qualification criteria.
B.1 The OEM shall have well documented internal quality system like ISO 9001:2000 or equivalent national/international standard for manufacturing, testing and commissioning of machine tools.
B.2.The bidder/ OEM shall have experience and capacity in the field of manufacturing, testing, installation and commissioning of VerticalMachining Centre.
B.3 The bidder/ OEMshall have manufactured minimum three numbers of VerticalMachining Centres of similar design capacity (as in tender).
B.4Bidders shall give a list of their customers in India where their Vertical Machining Centresare installed. At least two such machines should be located in Government / PSU /Stock listed company in India working in satisfactory condition with proper service support from OEMgiving the proof & performance certificate given in article -M.
Bidder must submit documents in support of each of the above criterion.
B.5Bidders shall mention the name of the contact person /complete mailing address/email in the bid. These contact details will be used for mailing official enquiries about bids. Clarification / information asked by the purchaser should be provided in the set time limit, failing which the bid may be rejected.
B.6The bidder shall confirm his capability to support for the spares, maintenance, and calibration and after sales service of the complete system after erection & commissioning, during and after the warranty period, either directly or through authorized service representative positioned in India. The service support should be in existencein India for last two years. On-site service support must be available in India. The details of the service support agency including its name, contact details, thedetails of service personnel and infrastructure must be provided along with bid. The bidder /OEM shall also ensure support for a minimum period of 10 years of useful period of machine.
Note – Only those bidders who qualify in the above criteria, their quotation (Bid) will be considered.
C.Terms & Conditions
C.1. Documents to be submitted with Bid
Bidder is required to submit following documents with the technical bid failing which his offer is liable to be ignored.
- Sources and make of components,bought out items and spares to be utilized in assembly of VerticalMachining Centre.
- List of installations where similar machines have been installed.
- Guaranteed/Compulsory Technical Particulars in the format at (Article no. -L)
- Performance certificate from user on their Letter head in the formatat Article no. - M.
- Site conditions required for installation & commissioning of machine which includes foundation details, Power supply etc.
C.2.Technical discussions and presentation of offers:
Bidder can seek clarifications/ discuss technical requirements of Vertical Machining Center through an enquiry to purchase department (IRPU, DPS, RRCAT, Indore-452013 (India). The bidder shall agree to make formal presentation of his technical bid at RRCAT, Indore(India) during tender evaluation stage.
D.Scope of supply
The scope of supply under this specification includes supply, installation, commissioning and testing of VerticalMachining Centerat RRCAT, Indore as per this specificationare as follows:
- Vertical Machining Centerwith all attachments.
- Essential accessories for the machine (for ensuring full functionality).
- CNC control system with relevant software packages.
- Spares for two years of trouble free operation.
- A complete set of tools required for maintenance of the machine. The tool set should be provided in a tool chest.
- Supply of 3 sets of all relevant technical documentation, drawings, circuit diagrams, maintenance and operation manuals etc. in ENGLISH both hard copy as well as soft copy.
- Inspection, testing & acceptance of machine at Manufacturer’s works.
- Erection, commissioning & testing at RRCAT, Indore.
- Training of RRCAT personnel atmanufacturer’s works& RRCAT.
- Machining of trial components as a part of machine qualification process.
- Bidder should offer all other “Optional Accessories” separately. Purchaser will be free to include any or all of quoted optional accessories in the scope of supply during evaluation stage.
E.Machine specifications
1.0 Scope: VerticalMachining Center (Fixed column bed type)with specifications as given below with essential and optional accessories. -01 Set
2.0 Specifications of the Machine
2.1 /Working strokes
2.1.1
/ Longitudinal traverse(X) / 800 mm or more2.1.2
/ Transverse traverse(Y) / 500 mm or more2.1.3 / Vertical traverse(Z) / 500 mm or more
2.2 /
Table
2.2.1 / Table clamping surface: / 1000 (Length)X500 (Width) mm (or larger)2.2.2 / Numbers of T- slots: / 4 slots or more or latest applicable
2.2.3 / Safe Working load on table / 600 kg or more
2.3 / Machine accuracies / All accuracies should be in accordance to
JIS/ISO230 Part2 or Latest applicable standard
2.3.1 / Positional Accuracies for all linear axes / ≤0.010 mm
2.3.2 / Repeatability for all linear axes / ≤ 0.006mm
2.3.3 / Spindle run out: / 0.010mm or less at spindle taper nose
2.3.4 / Working accuracy shall be as per NAS-979/Latest applicablestandard work piece machining test.
2.3.5 / Geometrical alignment check as per supplier’stest chart confirming to ISO 10791Part – 2/latest applicable test code.
2.4 /
Feed drive-
AC servomotor with re-circulating ball screws (for X, Y, Z Axes).
2.4.1 / Cutting feed rate / 10 m/min or more2.4.2 / Infinite variable speed feed motor of Fanuc/ Siemens make
2.4.3 / Rapid traverse speed for all linear axes / 30 m/min or more
2.5 /
Spindle head
2.5.1 / Tool mounting / BT 40 /ISO -402.5.2 / Spindle Speed, rpm / 6000 or higher
2.5.3 / Drive-AC Continuous duty S1 type motor / 7.5 kW or more
2.6 /
Feedback system
2.6.1 / Feedback elements: / Rotary absolute optical measuring system3.0 CNC control system:
CNC control system from Siemens/Fanuc with their latest applicable features.
4.0 Coolant system- Coolant through spindle centre.
5.0 Tool Magazine (Automatic Tool Changer-ATC)
5.2 / Capacity / 20 pockets: BT- 40 /ISO-405.3 / Permissible tool diameter / 80mm or larger
5.4 / Permissible tool length / 250mm or larger
6.0 Essential accessories -- One set each
6.1 / Automatic centralized lubrication system. Preferable Make Cenlub.6.2 / Splash guard (closed cabin).
6.3 / Built in AC (refrigerated type) for electrical /electronic cabinet.
6.4 / Sliding door interlock.
6.5 / Machine light (minimum 2 nos. of lights).
6.6 / Spindle load meter.
6.7 / Set of maintenance tools.
6.8 / Installation accessories.
6.9 / Coolant system for coolant supply through the spindle centre including pump and filtration system. Provision for external coolant shall also be provided.
6.10 / Metallic Telescopic Covers of rust resistant material shall be provided with wipers for guide ways of all axes. Provision should be made to avoid mixing of coolant & hydraulic oil.
6.11 / Process completion lamp (3tiers lamp) or equivalent applicable.
6.12 / Hand held coolant gun.
6.13 / Flood coolant system around the spindle
6.14 / Manual pulse generator for all axes.
6.15 / Set of pull studs (20 Nos.)
6.16 / Voltage stabilizer & Isolation transformer suitable for machine -1no. each
Preferred Make: NEEL / DELTA / AEI / POWER AID
6.17 / A chip conveyor to carry both short and curly chips efficiently and effectively to the chip bin on the floor should be provided at the side of the machine. One chip bin of appropriate size of Indian make, with wheels and handle for movement, should also be supplied.-1 set
6.18 / General purpose cutting tools with suitable adopters. Supplier should submit list of tools. All supplied tool holders, Cutting Tools, adapters etc. shall have through coolant provision so that coolant is available directly on the cutting tip during all possible operations. Provision for external coolant shall also be provided.
7.0 Optional accessories of the machine (to be quoted separately)
7.1 / Spares for two years normal running of machine. / 1 set7.2 / Option for “Process monitoring in the production”- manual intervention with open doors of machining area and release after completed check list. / 1 set
7.3 / General purpose cutting tools with suitable adopters. Supplier should submit list of tools. All supplied tool holders, Cutting Tools, adapters etc. shall have through coolant provision so that coolant is available directly on the cutting tip during all possible operations (for coolant through spindle). / 1 set
8.0 Other features of the machine
8.1 / Machineandcontrol system should be capable of simultaneous interpolation of X,Y Z axes.8.2 /
Guide ways for all linear axes should be of roller type or latest applicable
8.3 / Individual drive for all axes. Stepper motors in lieu of digital AC servomotors will not be acceptable.8.4 / Machine bed, column & all major casting should be made of close grained CI of Grade FG260 or better. Stress relieved.
8.5 / The machine should be equippedwith roller guide ways & re-circulating ball screws of grade C5 or better accurate grade for all linear axes. Spindle should be life time lubricated. In case of low lubrication, it should give an alarm message on the screen and the machine should stop automatically after completion of the cycle.
8.6 / Machine should be equipped with straight line steel cover for longitudinal and vertical guide way with deflector for chip removal.
8.7 / Machine should have full protection cabin, sliding doors having transparent windows to view progress of machining. Easy accessibility of maintenance work & easy job loading with EOT Crane.
8.8 / During manufacturing, the machine undergoes several intermediate and final tests. A quality assurance plan should be submitted along with offer.
8.9 / Machine should have adequate and reliable safety interlocks or devices to avoid damage to the machine, work piece and the operator due to the malfunctioning or mistakes. Machine functions should be continuously monitored and alarm / warning indications through lights/ alarm number with messages (on CNC display and panels) should be available.
8.10 / All the rotating parts used on machine should be statically & dynamically balanced & give test certificate at the time of supply.
8.11 / Maximum noise level shall not exceed 85 dB(A) at normal load condition,
1 meter away from the machine & give test certificate at the time of supply.
Page 1 of 12
F.Pre-dispatch inspection of machine & acceptance
F.1 / The machine shall be inspected in presence of our engineers at machine manufacturer’s works by laser interferometer for its positional deviation& repeatability as per JIS/ISO230-part2/Latest Applicable Standard before dispatch. The laser interferometer shallhave to be arranged by the machine builder. Machine shall also be inspected for its geometrical accuracies before dispatch as per manufacturer’s test chart confirming to ISO10791 –part 2 or latest applicable code.F.2 / Manufacturer shall machine trial jobs on the machine to be supplied as per NAS-979 in presence of our engineer. Raw material and required tooling will be arranged by machine tool builder. Fully machined jobs should be inspected on CMM to assess accuracies as specified in the drawings.
F.3 / Machine shall be able to interface with latest CAD / CAM software through external programming facility. Supplier should demonstrate this facility at the time of inspection before dispatch.All parameters against specification mentioned in E 2.0 to 6 & 8 will be verified at the time of PDI.
G.Training to our Personnel
G.1 / Two stage training to RRCAT personal –Stage 1:- After commissioning of machine bidder shallprovide training to RRCAT staff for 10 working days (at manufacturer’s works) in the area of maintenance (mechanical, electrical & electronics), operation and CNC programming.
G.2 / Stage-2:- Bidder shall provide extra training to RRCAT staff for 10 working days (at RRCAT, Indore) in the area of maintenance (mechanical, electrical & electronics), operation and programming within one year of commissioning of the machine. Training should start within 15 days from the date of request letter issued by RRCAT.
H.Installation, commissioning & acceptance of the machine at purchaser’s site.
H.1 / The supplier shallinstall and commission the machine at RRCAT, Indore. The site will be prepared by RRCAT as per requirements projected by the supplier. The supplier must inform foundation lay out and logistic requirements at site required for installation of the equipment within two months from the placement of purchase order.H.2 / The machine shall be inspected at RRCAT using laser interferometer for its positional deviation & repeatability as per JIS/ISO230-part2/Latest applicablestandard. The laser interferometer will be arranged by RRCAT. Machine shall also be inspected for its geometrical accuracies as per manufacturer’s test chart confirming to ISO 10791 –part 2 or latest applicable code
H.3 / For acceptance of the machine, values of positional accuracies and its geometrical accuracy quoted and agreed by the manufacturer during subsequent technical discussions shall have to be proved at RRCAT/Manufacturer works.
H.4 / AT RRCAT: Trial job will be machined as per NAS-979. Raw material and toolingshall be provided. Machined jobs will be inspected.
I.Warranty
I.1 / Bidder/OEM shall provideComprehensive Warranty for ONE year for the entire system from the date of commissioning of the machine at RRCAT, Indore.J.Packing & dispatch
The supplier shall provide faultlessrigid packing of the goods as is required to prevent their damage or deterioration during transit to their final destination RRCAT, Indore. The packing shall be sufficient to withstand, without limitation, rough handling during transit and exposure to extreme temperatures, salt and precipitation during transit and open storage. Packing case size and weights shall take into consideration, where appropriate, the remoteness of the goods' final destination and the absence of heavy handling facilities at all points in transit
K.Documentation
The following documents (hard copy & CD) to be provided in English:
K.1 / Operations & Maintenance Manuala)Hard Copy-3 sets
b)CD (licensed)-1 set
Operation & Maintenance manual for process and maintenance procedure
Detailed Maintenance manual of machine with all drawings of machine assemblies/sub-assemblies/parts including Electrical / Pneumatic/ Coolant / Hydraulic circuit diagrams.
K.2 / Control System Administration & Maintenance Manual in English
a) Hard Copy -3 sets
b) CD (licensed) -1 set
Control System Administration & Maintenance Manual should explain the detailed system configuration (mechanical and electrical assemblies) and administration including control system, electrical wiring with the help of sketches. System manual should explain known possible errors and the solution for the same.
K.3 / Ladder diagram and Machine parameters in soft copy and hard copy (3 sets) should be supplied with machine. Also the backup disc comprising of machine parameters and ladder program should be provided.
K.4 / Spindle assembly with its front and rear bearing layout drawing should be provided along with machine.
K.5 / Listof all necessary mechanical, electrical and electronic sparesrequired for next five years is to be provided (supplies of these parts are not in the scope of tender). Supplier shall ensure availability of spares for next 10 years. In case of discontinuing the model of the machine, supplier shall inform to RRCAT well in advance. An undertaking shall be submitted by the bidder in this regard.
L.Guaranteed / Compulsory Technical Particulars
(Bidder / supplier must fill in the following chart and enclose with the tender)
Specifications of the CNC Vertical Machining Centre
Sl. No. / Description of item / Bidder’s specification / Documentary proof in tender (indicate page no.) / Deviation if any –justifications for deviationList of customers in India where Vertical Machining Centres are installed and used for precision jobs.
Performance certificate from user as per article no.M
Qualification of bidder as per qualification criteria(as per clause B)
Longitudinal traverse (X)
Transverse traverse (Y)
Vertical traverse (Z)
Table clamping surface
Safe load for table
Positionalaccuracies for all linear axes
Repeatability for all linear axes
Spindle run out
Cutting feed range
Rapid traverse feed rates all linear axes
Spindle Speed, rpm
Drive capacity
Feedback elements
CNC control make and model no. and no. of enabled axes, data transfer system etc.
Tool magazine (ATC) capacity
Automatic centralized lubrication system.
Splash guard (closed cabin).
Built in AC for feed drives for all axes and electrical cabinet.
Sliding door interlock.
Machine light (minimum 2 nos. of lights).
Spindle load meter(Yes /No)
Set of maintenance tools.
Installation accessories.
Coolant system for coolant supply through the spindle centre including pump. Provision for external coolant.
Slide way covers.
Process completion lamp (3tiers lamp) or latest applicable.
Hand held coolant gun.
Manual pulse generator for all axes.
Set of pull studs (20 Nos.)
List of optional accessories offered (Yes / No)
Type of drive motors for all axes
Grade of ball screws used for linear axes
Submission of quality assurance plan along with offer (Yes / No)
Industrial standards /codes used for acceptance criteria of geometrical accuracies.
Industrial standards /codes used for acceptance criteria of trial machining jobs.
Two stage training program ( Yes / No)
Installation & Commissioning at purchaser’s site (Yes / No)
Standard Warranty
M.Performance certificate to be produced on Customer’s Letter Head.
PERFORMANCE CERTIFICATE
1. Bidder of the machine2. Make & Model of the M/C
3. Month & Year of Commissioning
4. Application for which M/C is used
5 / a) Table Size
b) Table load Carrying Capacity
c) Max Job envelope
d) Spindle Power (cont. rating)
e) Spindle Taper
6. Performance of the Equipment
(Tick whichever is applicable) / Best in the market
Satisfactory
Good
Average
Not Satisfactory
7. Any Other remarks
Signature & Seal of the Authority
Date: Issuing the Performance Certificate
Page 1 of 12