5 Axis CNC Milling Equipment - ISRO · PDF file1 Request for Proposal (RFP) For Supply, Installation & Commissioning of 5 Axis CNC Milling Equipment 10th October 2017 Laboratory for

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Request for Proposal (RFP) For Supply, Installation & Commissioning

of

5 Axis CNC Milling Equipment

10th October 2017

Laboratory for Electro-optics Systems (LEOS) Indian Space Research Organisation (ISRO) 1st Cross, 1st Stage, Peenya Industrial Area

BANGALORE-560058 INDIA

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INDEX: Sl.No Description Page No 1.0 Introduction 04 2.0 Application 04 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0

Detailed Specifications of Equipment and its essential accessories Linear Axes (X,Y,Z) NC Rotary Table Swivel of Milling Head Spindle for rotation of tool Measuring probe for taking work offsets Mist extractor and oil mist separator Central lubrication system for all the axes Coolant circulation and reprocessing system for job & tool cooling Cooling system for spindle motor and axis lead screws Mini Hand Held Unit Safety features for operating personnel and equipment Spindle monitoring feature “3D data model” of equipment configuration CNC Control system Power distribution system Optional features suggested by Vendor Spares and accessories Tool Holders, Jigs and Fixtures Factory Acceptance Test (FAT) & Training Installation & Commissioning Site Acceptance Test (SAT) Training Deliverables Utilities Guarantee / Warranty Format of quotation Total Quality Control & Management Delivery Period Expertise & Heritage General Terms & Conditions

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06 08 09 10 11 12 12 12

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14 14

15 15 15 17 18 18 19 20 21 21 21 21 22 23 23 25 25 25 26

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Index for Figures / Drawings / Sketches: Pg.No Fig.1: Pocket milling 27 Fig.T1: Types of Milling Tools used for pocket milling 27 Fig.2: Pockets with under cuts 28 Fig.T2: Milling Tools for making pockets with undercuts 28 Fig.3: Trepanning 29 Fig.4: Edging 30 Fig.5: Slicing 31 Fig.T3: Slicing / cut off Wheel 31 Fig.6: Profile generation on surface 32 Fig.T4: Tool for generating profiles on surface 32 Fig.7: Profiling on the bottom of pockets 33 Fig.T5: Ball Nose Diamond Tool to generate profiles on bottom of pockets 33 Fig.8: Base plate 34 Fig.09: NAS Test Piece (AL-6061) 35 Fig.10: Acceptance Trial Job (ZERODUR) 36 Fig.11: Desirable Machine Configuration 37

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1. INTRODUCTION: Laboratory for Electro-Optics Systems (LEOS) is a research and development organization working in the area of Applied Optics programmes carrying out design and development of telescope optics systems for astronomical, weather observation and forecasting applications. LEOS invites proposals for supply, installation and commissioning of 5 Axis CNC Milling Equipment along with the required accessories & spares as given in specifications, on-site demonstration of equipment performance and training on the equipment at LEOS. 2. APPLICATION:

Specification Complied /

Not Complied

Vendor’s offer / Remarks

The equipment will be used for carrying out various mechanical operations such as pocket milling, milling pockets with undercuts, trepanning, edging, slicing, generating profiles on the surface & on the bottom of pockets, etc., on GLASS & GLASS CERMICS like Zerodur, ULE, Astrosital etc., using diamond impregnated tools. The components produced in the equipment are used in Indian communication & weather observation satellites. Typical Mechanical Properties of above materials from milling point of view are: Density: 2.53 gm/cc Knoop Hardness 0.1/20 (as per ISO9385) : 620 Poisson ratio:0.24 Youngs Modulus: 90.3 GPa

2.1. APPLICATION REQUIREMENTS IN DETAIL: For all the operations given in section 2.1, range of Job sizes shall be:

Specification Complied /

Not Complied


Diameter: Minimum 100mm to Maximum 1800mm

Thickness: Maximum Height of Job above the machine table including fixtures will be ~ 600mm

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Sl.No Process /

Application

Complied / Not

Complied Vendor’s offer / Remarks

2.1.1 Pocket Milling to generate pockets with various geometries with thin ribs between the pockets using diamond impregnated milling tools of size from Ø5X40mm long to Ø100X300mm Long as shown in Fig.T1 & Fig.1 Typical pocket milling requirements are: 2mm thick ribs for pockets upto 100mm depth 3mm thick ribs for pockets upto 150mm depth 4mm thick ribs for pockets upto 220mm depth.

2.1.2 Milling the pockets of various geometries with undercuts using suitable diamond impregnated tools of size from Ø25X5mm thick to Ø75X5mm thick & shanks of size from Ø10*100mm long to Ø20*220mm long, as shown in Fig.T2 & Fig.2 Typical requirement for this process are: Rib thickness between pockets as given in section 2.1.1 Flange Thickness: 4mm Undercut distance: 15mm

2.1.3 Trepanning to get smaller size circular blanks from large blanks, using suitable trepanning tools Please refer to Fig.3 for a typical trepanning application

2.1.4 Edging to reduce the outer diameter & boring to increase the inner diameter of Jobs, either by contour milling (circular interpolation) “or” by keeping the tool stationary and rotating the Job, using tools as given in section 2.1.1 Roundness achieved in the above process shall be: < 20 microns for Jobs upto Ø750mm < 30 microns for Jobs of size upto

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Ø1500mm < 40 microns for Jobs of size upto Ø1800mm Please refer to Fig.4 for a typical edging process

2.1.5 Slicing of blanks upto 200mm thick using cut off wheels ranging from size Ø250X1mm thick to Ø600X3mm thick as shown in Fig.T3 & Fig.5

2.1.6 Profile generation on surface of Jobs using suitable radius nose wheels of size from Ø50mm to Ø200mm “or” ball nose tools of size from Ø10X50mm Long to Ø25X150mm Long as shown in Fig. T4 & Fig.6 with following profile accuracies: Within 50 microns for Jobs upto Ø500mm Within 100 microns for Jobs upto Ø1000mm Within 150 microns for Jobs upto Ø1500mm Within 180 microns for Jobs upto Ø1800mm

2.1.7 Generating convex / concave profiles on the bottom of pockets to achieve uniform thickness of front surface in Jobs, using suitable diamond impregnated ball nose tools as shown in Fig.T5 & Fig.7

2.1.8 In each of the above operation, the equipment should produce components with high degree of surface finish with an average surface roughness less than or equal to 3 microns Ra

3.0 DETAILED SPECIFICATIONS OF THE EQUIPMENT & ITS ESSENTIAL ACCESSORIES The Five Axis CNC Milling Equipment to be supplied should consist of following: 3.1 Linear Axes (X,Y,Z) :

Sl.No Specification / Requirement Complied /

Not Complied


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3.1.1 Traverse X (longitudinal) axis: ³2000mm Y (transverse) axis: ³2000mm Z (vertical) axis: ³1000mm

3.1.2 Minimum incremental travel required in each axis £0.001mm

3.1.3 Minimum Feed rate ≤0.1mm/min Maximum Feed rate ≥20000mm/min

3.1.4 Rapid traverse ≥20000mm/min 3.1.5 Desirable to have digitally controlled

AC motor for the feed drive, with liquid cooling & directly linked with liquid cooled re-circulating ball screw

3.1.6 Feed power of drives and motors should be sufficient to meet the requirement of operations listed in section 2.1 at maximum feed speed of equipment with about 4000 kg load on center of NC rotary table and with about 1.0mm depth of cut on materials given in section 2.0

3.1.7 It is desirable to have roller guide ways for the linear axes

3.1.8 Position feed-back should be by direct & absolute linear path measuring systems, with temperature compensation

3.1.9 Path measuring systems should have resolution ≤0.0001mm

3.1.10 Bi-directional positioning accuracy in all the axes should be ≤0.01mm

3.1.11 Perpendicularity between X&Y / Y&Z / X&Z should be ≤0.02mm over 500mm traverse

3.1.12 Vendor should provide technical details of the equipment offered, for all the above specifications

3.1.13 Vendor should provide equipment layout diagram indicating all the axes and the clearance that is available at extreme positions of the tool with maximum size of work piece on the table.

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3.2 NC rotary table:


Not Complied


3.2.1 NC rotary table should be able to hold Jobs of size upto Ø1800mm with at least 100mm clearance all around for radial clamping

3.2.2 Rotational speed Min ≤ 0.1RPM Max ≥ 10RPM

3.2.3 Minimum incremental rotation of Rotary table should be £ 0.001 deg

3.2.4 Minimum Input & Display resolution should be ≤0.001 deg

3.2.5 Bi-directional positioning accuracy should be ≤10 arc sec

3.2.6 Should be able to carry Job loads upto 4000 kg when load is centered to table

3.2.7 It is desirable to have digitally controlled AC motor with liquid cooling for the drive

3.2.8 Drive and Motor should have sufficient power to rotate the table from minimum to maximum RPM with about 4000 kg load on it and carryout the operations listed in section 2.1

3.2.9 Rotary table should have sufficient number of T slots on the surface for clamping of the Jobs. Distance between T slots should be between 100 to 150mm. There should be a slot at the centre for the purpose of alignment.

3.2.10 Rotary table should have a bore at center, concentric to the axis of rotary table for checking the alignment

3.2.11 The flatness rotary table surface should ≤ 0.02mm when measured over entire area.

3.2.12 The wobble (tilting) of rotary table surface at a distance of 500mm from center for one full rotation should be ≤ 0.02mm

3.2.13 Run-out of the rotary table should be

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≤ 0.02mm 3.2.14 Vendor should provide following

details of the NC Rotary table Material of construction of the NC rotary table Maximum torque / Holding momentum of the NC rotary table Diagram of the NC rotary table showing the clamping surface Dimensions of the largest work piece that can be accommodated on the rotary table in terms of Job diameter and its height from the surface of rotary table

3.3 Swivel of Milling Head


Not Complied


3.3.1 The milling head should be a continuously positioning universal milling head

3.3.2 The milling head should have a swivel range to orient the spindle axis from vertical position to horizontal position, with an increment of 0.001 deg. It is desirable to have additional swivel of upto 10 deg in opposite direction

3.3.3 Input & Display resolution should be ≤0.001 deg

3.3.4 Feed rate Min ≤ 0.1RPM Max ≥ 10RPM

3.3.5 Bi-directional positioning accuracy should be ≤10 arc sec

3.3.6 It is desirable to have a digitally controlled AC motor with liquid cooling and liquid cooled gear box for the drive

3.3.7 Vendor should provide following details of milling head Type of mechanism for indexing Swivel momentum Holding momentum Repeatability at spindle nose and indexing accuracy

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3.4 Spindle for rotation of tool


Not Complied


3.4.1 The equipment should have a integrated spindle (with built in spindle motor), with liquid cooling arrangement for spindle motor

3.4.2 Rotational speed of Spindle should be Minimum £ 10 RPM Maximum ³ 8000 RPM

3.4.3 Spindle taper should be HSK-A100 3.4.4 Radial run-out of spindle should be

£0.005mm when measured near the spindle nose using test mandrel £0.01mm when measured at a distance of 300mm from the spindle nose using test mandrel

3.4.5 Axial run-out of spindle should be £0.005mm

3.4.6 It is preferable to have hydro mechanical type mechanism for tool clamp / unclamping

3.4.7 Tool clamping force generated in the equipment should be ³ the clamping force required to hold the tool while carrying out the operations listed out in section 2.1 while using maximum size of tools at maximum tool RPM, feed rate and depth of cut of ~ 1mm

3.4.8 Spindle should have adequate Torque to carry out the operations listed out in section 2.1 while using maximum size of tools at maximum tool RPM, feed rate and depth of cut of ~ 1mm. Vendor to provide spindle torque values @ 40% duty cycle and @ 100% duty cycle

3.4.9 Spindle drive capacity should be ³ the power required for carrying out the operations listed out in section 2.1 while using maximum size of tools at maximum tool RPM, feed rate and depth of cut of ~ 1mm

3.4.10 Spindle should have an Internal Coolant System for passage of

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coolant through the tool while milling.

3.4.11 Vendor should provide following details about spindle in the equipment offered Type of construction Diameter of spindle Make of the spindle Drive capacity RPM Vs Torque chart at 40% and 100% duty cycle Acceleration time & Deceleration time Tool clamping and unclamping mechanisms Details of the spindle bearing viz., size & type of bearings and their arrangement Details of Internal coolant system Maximum weight of the tool and maximum size of the tool (along with tool holder) that can be held in spindle at maximum RPM Balancing quality of tools that are required for stability of spindle at maximum RPM

3.5 Measuring probe for taking work-offsets


Not Complied


3.5.1 Vendor should offer a measuring probe which can be mounted in the spindle of equipment, to probe the Job for initial job setting and taking work offsets.

3.5.2 The probe should work along with an optical machine interface (OMI) mounted on milling head / any other stationary part near the milling head. The probe and OMI should not have physical connection between them.

3.5.3 It is preferable to have Renishaw or its equivalent make measuring probe along with OMI for this purpose.

3.5.4 Equipment should have in-built work piece measuring cycles to measure Inner and outer diameters of circular

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Jobs, Angle between different faces of Jobs, Height of the Job etc., & to update them in the work offsets automatically.

3.5.5 Vendor should provide all the technical details of measuring probe offered

3.6 Mist extractor and oil mist separator


Not Complied


3.6.1 The equipment should be provided with a mist extractor to extract the coolant mist from the working area. Provision should be there to operate this mist extractor in manual mode as well as in auto mode.

3.6.2 Vendor should provide all the technical details of mist extractor and oil mist separator offered.

3.7 Central lubrication system for all the axes


Not Complied


3.7.1 The equipment should have a centralized lubrication system for automatic lubrication of guide ways and lead screws of all axes at regular intervals. Provision for monitoring the lubricant level should be there.

3.7.2 Vendor should provide the technical details of the lubrication system being offered and the details of the lubricant to be used.

3.8 Coolant circulation and reprocessing system for Job & Tool cooling


Not Complied


3.8.1 Equipment should have provision for coolant flow through the spindle as well as a multi jet unit surrounding the milling head.

3.8.2 Provision should be there to switch

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from coolant to air in the multi jet unit.

3.8.3 The flow and pressure parameters for coolant flow through the spindle as well as for external coolant (multi jet unit) should be displayed in operator panel

3.8.4 Coolant re-processing system should have an intermediate settling tank, a centrifuge and a fine filter (of less than 20 microns mesh) to remove the glass powder from coolant at various stages

3.8.5 The coolant in the main tank should be maintained at an optimum temperature, typically within 20 to 25

C before pumping back to equipment

3.8.6 The through coolant system in the spindle & axis guide way covers should have proper sealing mechanism to avoid entry of coolant into bearings of spindle & guide ways.

3.8.7 There should be a large flow rate pump for external coolant & high pressure pump for through coolant

3.8.8 Flow rate and pressure of the through coolant as well as external coolant should be monitored & displayed on operator panel.

3.8.9 condition of the filters at various stages should be monitored and there should be an alarm when the filters are clogged beyond allowable value

3.8.10 coolant tank should have a capacity of at least 800 Litres

3.8.11 Material of tank and its paint should be compatible with water soluble cutting fluids.

3.9 Cooling system for spindle motor and axis lead screws


Not Complied


3.9.1 The equipment should have a chiller unit to cool the spindle motor and axes lead screws to avoid their

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excessive heating. 3.9.2 Temperature of spindle motor and

axes motors should be monitored & displayed on operator panel

3.9.3 Vendor should provide the technical details of cooling system offered

3.10 Mini Hand Held Unit


Not Complied


3.10.1 Equipment should have a mini hand held unit to move the axes in Jog mode

3.10.2 It should have provision to move axes in the steps of 0.001mm, 0.01mm, 0.1mm, 1.0mm (selectively) and also in continuous mode

3.10.3 It should have a emergency-off push button

3.11 Safety features for operating personnel and equipment


Not Complied


3.11.1 Working area of the equipment (spindle, linear and rotary axes) should be fully enclosed in a cabin, with sliding doors having large and transparent safety glass (toughened) windows for observing the working area.

3.11.2 Safety interlocks should be provided to restrict the working of equipment in auto mode & to stop coolant circulation while the cabin doors are open

3.11.3 Safety interlock should be provided to stop milling of Job if there is an interruption in flow of coolant to the Job

3.11.4 Guide-ways of the axes should be covered suitably to avoid the coolant from entering into the guide-ways.

3.11.5 Provision should be there for loading the Jobs of size upto Ø1800mm X

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500mm thick using the overhead crane from top directly onto the Rotary table

3.12 Spindle monitoring feature


Not Complied


3.12.1 Equipment should have provision to monitor the condition of spindle bearing, preferably by sensing vibration of spindle & stop milling process in case of any problem.

3.12.2 Provision should be there to monitor the torque on the spindle continuously. If the torque exceeds the set limits, milling process should stop with an alarm

3.13 “3D data model” of equipment configuration


Not Complied


3.13 Vendor should supply the 3D data model of the equipment configuration which will be integrated with CAM software for simulation of 5 axis milling programs in CAM software, before their actual execution in the equipment. The 3D data model should be preferably in “STEP” format

3.14 CNC Control System The 5 Axis CNC milling equipment should consist of a PLC based CNC system, preferably latest SIEMENS CNC control system or its equivalent, through which all the operations of the equipment , its power management & distribution, monitoring of different process parameters & their control, monitoring of equipment safety & their control is carried out. Vendor’s Offer / Remarks:……………………………………………………………………………………. The CNC control system should have following features

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Not Complied


3.14.1 Hardware of CNC control system should be a micro processor based CNC path control system with integrated PLC and digital drive technology

3.14.2 It should have a flat operating panel with large display, preferably of size ³ 19”.

3.14.3 Screen texts should be in English. 3.14.4 Error messages due to faults should

be displayed and logged in English

3.14.5 Clear arrangement of keys on operator panel with provision for panel lockout should be there.

3.14.6 It should be possible to carryout programming, editing and simulation during the operation of equipment.

3.14.7 All the 5 axes (3 linear & 2 rotary) and spindle should be simultaneously programmable

3.14.8 It should have a hard disk with at least 50GB memory, to store the machine data

3.14.9 Should be able to store at least 500 part programs and data of 500 tools in the memory

3.14.10 Tool length, radius and wear compensation features should be available

3.14.11 Provision for CNC Programming in ISO formats should be there.

3.14.12 Should be compatible for programming with mathematical operators and functions

3.14.13 Should be compatible for programming in Cartesian and Polar coordinates

3.14.14 Editing of program by copying, insert, exchanging and deletion of program blocks, program jumps should be possible

3.14.15 Should have in built basic cycles for milling of basic geometries and for drilling

3.14.16 Graphic simulation of milling process

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should be there with determination of program execution time.

3.14.17 3D representation of milling process should be there, with facility to zoom in and out and view the sections

3.14.18 The following over rides should be available Feed rate over ride 0 – 120% Rapid traverse over ride 0 – 120% Spindle speed override 0 – 120%

3.14.19 The following operating modes should be available Jog mode MDI (Manual Data Input) mode Auto mode Single block mode

3.14.20 Suitable software & hardware interlocks should be provided for avoiding over-travel of any axis

3.14.21 Suitable safety interlocks should be provided to safe guard the equipment and for safety of operating personnel as per international safety standards and protocols

3.14.22 Safety alarms should be provided for emergency situations

3.14.23 The control should check the directional changes in advance during execution of program and adjust feed speed to adapt to the dynamics of equipment

3.14.24 The following modes of transferring program to equipment should be available Ethernet interface USB interface RS232

3.15 Power distribution system


Not Complied


3.15.1 The equipment should be compatible for the following power supply 400V, 3 Phase, Neutral, Earthing, 50 Hz 230V, 1 Phase, Neutral, Earthing, 50

18

Hz Maximum Variation in the supply voltage ~ ±10% Maximum Variation in the supply frequency ~ ± 2 Hz

3.15.2 The power distribution bus should be provision to safeguard the various sub-systems and the equipment as a whole, against any power fluctuations & power hazards, as per the applicable standards and norms

3.15.3 There should be a dedicated AC unit for electrical control cabinet

3.16 In addition to above, vendors can offer for any other features, as options, which will improve performance of the equipment and which will improve the milling process for glass and glass-ceramics Vendor’s Offer / Remarks:………………………………………………………………….. 4.0: Spares & Accessories:


Not Complied


4.1 Along with the equipment, vendor should provide following spares that are essential for 1000 days of trouble free operation of equipment (@ 8 hours of working per day)

4.1.1 Spares for regular preventive maintenance like, filters for compressed air, hydraulic oil and coolant, LM guide way wipers, filter mats for the AC units, rotary unions for through coolant etc.,

4.1.2 Electrical spares like contactors, fuses, relays, MCBs, switches etc

4.1.3 Spares that are specific to the equipment offered and which can cause complete breakdown of equipment in case of non availability

4.1.4 one standard maintenance kit for the equipment offered

4.1.5 Vendor may suggest the spares that have to be maintained by LEOS in addition to above, for trouble free operating of equipment

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4.1.6 Information on Spares / Service support facilities available in India for the equipment offered should be provided. Information on the strength of sales / service team and their locations in India should be provided

5.0: Tool Holders, Jigs & Fixtures:


Not Complied


5.1 Vendor should quote for following Tool holders (3 Nos each) compatible with equipment offered

5.1.1 HSK-A100 Tool Holder with ER16 Taper, with locknut, spanner and through coolant tube




5.1.5 HSK-A100 Tool Holder with 20H7 shaft, with locknut, wrench and through coolant tube

5.1.6 HSK-A100 Tool Holder – shrink fit type

5.1.7 HSK-A100 Tool Holder – Hydro grip type, with through coolant tube

5.1.8 ER25 collets of diameter from 8 mm upto 16mm in steps of 2mm (1 No each)

5.1.9 ER32 collets of diameter from 8mm upto 20mm in steps of 2mm (1 No each)

5.2 Vendor should quote for an additional base plate of size 2000 X 2000 X 75mm thick as given in the Fig.8. This base plate should be fixed to NC Rotary Table by suitable means and supplied along with the equipment. Provision for easy removal & re-

20

fixing of the base plate at customer’s site should be incorporated in the base plate design. If the features and dimensions given in Fig.8 are met with the NC rotary table of the equipment that is offered, the vendor need not quote for this separate base plate.

5.3 Vendor should explicitly specify the list of any other tools, jigs and fixtures that are required for day to day operation of the equipment & quote for the same

6. Factory Acceptance Test (FAT) & Training:


Not Complied


6.1 Vendor has to demonstrate the performance of equipment and its accessories at vendor’s site as per mutually agreed test / evaluation protocol.

6.1.1

Factory Acceptance Test should consist of Demonstration of equipment accuracies by milling a Aluminium NAS test piece as per the Fig.9, with work piece located at center of table and at extreme position of the table

6.1.2 Demonstration of milling glass ceramics using diamond impregnated tools, by milling a Zerodur blank as per the drawing given in Fig.10

6.1.3 The necessary raw materials viz., Aluminium & Zerodur Material, Tools, Tool holders, Jigs & Fixtures that are required to carry out above factory acceptance test should be arranged by the vendor

6.1.4 After the completion of FAT, the Trial Jobs, Tools, Tool holders, Jigs and fixtures used should be handed over to LEOS.

6.1.5 Vendor should provide training to LEOS personnel on operation of equipment at vendor’s site

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7.0 Installation & Commissioning


Not Complied


7.1 Vendor should install and commission the equipment along with its accessories at LEOS

8.0 Site Acceptance Test (SAT)


Not Complied


8.1 Vendor should demonstrate the performance of equipment at LEOS, as per the protocol followed for Factory Acceptance Test given in sections 6.1.1 to 6.1.5. Raw Material for Site Acceptance Test will be provided by LEOS.

9.0 Training


Not Complied


9.1 Vendor has to provide training to LEOS personnel at LEOS on operation and maintenance of the equipment and its accessories, and also on features of control system.

10.0 Deliverables


Not Complied


10.1 Five Axis CNC Milling Equipment together with all its essential accessories as mentioned in Section 3.0

10.2 Spares and accessories for 1000 days of operation of equipment (@ 8 hours per day), as mentioned in section 4.0

10.3 Tool Holders & Collets, as mentioned in section 5.0

10.4 Additional base plate as described in

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section 5.0 10.5 Tools, Tool holders, Jigs and fixtures,

power cables & any other items that are required for installation, commissioning and conducting acceptance trials of the equipment on NAS Test Piece as well as on ZERODUR part, as mentioned in section 6.0, along with NAS Test Piece and ZERODUR trial part

10.6 All the technical documents (in English) for Installation, Operation, Maintenance and Servicing of equipment and a soft copy of the same in the form of DVD

10.7 Electrical, Pneumatic & Hydraulic circuit diagrams and mechanical drawings of critical sub assemblies (in English) and a soft copy of the same in the form of DVD

10.8 Manual for electrical, mechanical, hydraulic & pneumatic spare parts and a soft copy of the same in the form of DVD

10.9 Certificate of compliance conforming to the specifications of the equipment

10.10 Accuracies test chart & axis calibration certificates for the delivered equipment certified by QA of the vendor as per international standards such as ISO230-2 or VDI/DGQ 3441

10.11 Reports of Factory acceptance test (FAT) and site acceptance test (SAT)

10.12 Manuals of the all the OEM equipment used in milling equipment (in English)

10.13 Soft copy of PLC program / Machine data

11. Utilities:


Not Complied


11.1 Vendor should provide following information on facilities required at LEOS for operation & maintenance of equipment offered

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- Electricity connection - Compressed Air Supply - Water supply - Floor Space required - Special foundation required

11.2 Vendor should provide following information

- Total weight of equipment - Height of equipment - Height of building required

for installation & - Foot print and clearance space

required all around the equipment

12. Guarantee / Warranty:


Not Complied


12.1 Vendor is required to provide warranty on the CNC milling equipment and all its accessories for a minimum period of one year from the date of acceptance at LEOS

12.2 Vendor should quote separately for extended warranty of 2 years from the date of expiry of normal warranty/guarantee

12.3 Vendor has to provide information on their AMSC policy & charges after expiry of warranty period.

12.4 Vendor should provide the terms and conditions of the warranty / guarantee offered. The nature of maintenance / service work that will be provided during warranty period should be clearly mentioned

12.5 Vendor should provide information on preventive maintenance that has to be carried out periodically for smooth operation of equipment

13.0 Format of Quotation: Vendor has to submit the offer in two parts, namely “TECHNICAL BID” & “COMMERCIAL BID”. Please note that prices should not be mentioned in the Technical Bid.

24


Not Complied


13.1 Technical Bid should consist of 13.1.1 Technical details of the equipment

offered in the form of a compliance / non-compliance matrix as given in this RFP.

13.1.2 Technical data sheets of the equipment offered should be provided wherever necessary

13.2 Commercial Bid should consist of 13.2.1 Prices of 5 axis CNC Milling

equipment and its essential accessories as given in Section 3.0, with detailed break up for each item

13.2.2 Quotation for the Spares and accessories as given in Section 4.0

13.2.3 Quotation for Tool Holders, Collets, as given in Section 5.0

13.2.4 Quotation for Additional base plate as given in Section 5.0

13.2.5 Quotation for any other jigs and fixtures suggested by vendor as in Section 5.0

13.2.6 Quotation to carryout Factory Acceptance Test at Vendor’s site as given in Section 6.0

13.2.7 Quotation to provide training to LEOS personnel at Vendor’s site as given in Section 6.0

13.2.8 Quotation for Installation & Commissioning of Equipment & its accessories at LEOS, carrying out Site Acceptance Test and for providing training to LEOS personnel as given in Section 7.0 to Section 9.0

13.2.9 Quotation for extended warranty for 2 years beyond normal warranty period

13.2.10 Quotation for AMSC beyond warranty period

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14.0 Total Quality Control & Management


Not Complied


14.1 Vendor should provide information on the management structure for execution of the present contract, identifying the focal point

14.2 Vendor should provide the Quality Policy of the organization and the plan for Total Quality Management (TQM)

15.0 Delivery Period


Not Complied


15.1 The desirable delivery period shall be 12 months from the date of release of Purchase order

16.0 Expertise & Heritage


Not Complied


16.1 Vendor should provide information on the company’s expertise in building 5 Axis CNC Milling Equipment, particularly for the model offered

16.2 Vendor should provide information on the company’s heritage in supplying similar equipment for milling glass & glass-ceramics along with user’s feedback

16.3 Vendor should provide information on company’s profile covering various aspects viz., technical, commercial and the uniqueness of the organization in the specific sphere of building and supplying CNC Milling Equipment

16.4 Vendor should provide information on the status of their organization in India in terms of manufacturing

26

locations, sales, service and spares support details etc

17. General Terms & Conditions:

- It is mandatory for the vendor to provide the ‘Technical Compliance Matrix’ with

proper technical justification with documentary evidences and technical data sheets.

Simple duplication of the technical specifications (without support documents and

technical explanation) will lead to the rejection of the offer.

- All bids must be enclosed with firm commitments and approvals from regulatory

authorities (respective countries) to supply the equipments if the order is placed.

Fig.1 : Pocket Milling

Fig T1: Types of Milling Tools used for pocket milling

27

Fig.2 Pockets with undercuts

Fig.T2 Milling Tools used for making pockets with undercuts

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Trepanning ToolSmaller dia blank cut from larger size Job

Job

Job Mounting pads

Machine Table

Fig 3: Trepanning

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Fig 4: Edging

30

Slicing wheel

Job

Machine Table

Fig 5:Slicing

Fig T3: Slicing/cut off Wheel

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Fig T4: Tools used for profile generation on surface

Fig 4: Profile Generation on surface

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Fig 7: Profiling on the bottom of pockets T5: Ball Nose Diamond Tool to generate profile on the bottom of pockets 33

Fig 8: BASE PLATEMaterial: ALUMINIUM-6061 (ANODIZED)

All the linear dimensions are in mm and angular dimensions are in degrees unless other wise stated

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Fig 9: NAS Test PieceMaterial: AL-6061

All the linear dimensions are in mm and angular dimensions are in degrees unless other wise stated

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Fig 10: Acceptance Trial JobMaterial: ZERODUR

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Fig.11 Desirable Machine Configuration

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5 Axis CNC Milling Equipment - ISRO · PDF file1 Request for Proposal (RFP) For Supply, Installation & Commissioning of 5 Axis CNC Milling Equipment 10th October 2017 Laboratory for

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