INDIAN INSTITUTE OF TECHNOLOGY BOMBAY MATERIALS MANAGEMENT DIVISION Direct : (+91-22) 2576 8800 (DR) / 8803 (Local) / 8804 (Import) / 8805 (Enquiry & Bill tracking), 8802(Progress) Email : drmm@iitb.ac.in, bkganesh@iitb.ac.in Technical Specification for 5-AXIS CNC MACHINE SPECIFICATION REQUIREMENT of Purchase Requisition No. 1000000141 Sr. No. SPECIFICATION REQUIREMENTS 1 Machine Description CNC single spindle Universal Machining Centre for 5 Axes Simultaneous machining. The machine should be based upon FEM-optimized, rigid and ribbed cast iron components and a machine base should be made of vibration reducing meehanite cast iron. The axes configuration shall be X,Y,Z (Linear axes), A & C (Swiveling/Tilting and Rotary respectively). Axis A & C should be on work table. Axis A is meant for swiveling/ tilting of work piece supported on two sides & Axis C is meant for rotation of work piece. It should be of compact design based on modern machine concept as well as control design should ensure highest accuracy, surface finish and productivity standard guaranteeing highly efficient mfg. process. N.B.: Pl. note that the axes A & C should be on work table. 2 Quantity Required: 1 No. 3 Application Machining of precision Aircraft components like Compressor, Guide Vanes & Nozzle guide Vanes, etc, made of Steel, Titanium & Nickel alloys in the form of solid billets / envelope forgings. 4.0 Table Size Table dimensions : 800 x 650 mm with rotary table of ɸ 650 mm Table load carrying capacity: 600 kg or more. 5.1 Machine Axes Travel X Axis = 650 mm Y Axis = 650 mm Z Axis = 500 mm A Axis = +120 0 / -120 0 C Axis = 360 0 continuous 5.2 Torque (at 100% Duty Cycle) A Axis = 3400 Nm C Axis = 2000 Nm 5.3 Linear axis Rapid Traverse Speed X,Y, Z : 40 m/min or more Swivel Axis A : 20 rpm Rotary Axis C : 40 rpm 6 Positional Accuracy according to VDI/DGQ 3441 standard: Positional accuracies for axes X,Y,Z Positional accuracy (P) = Not more than 0.008 mm Positional repeatability (Ps) = Not more than 0.005 mm Page 1
Positional uncertainty for rotary axes A & C as per VDI/DGQ 3441 Positional uncertainty (P) = 10 arc seconds 7 Spindle Details: Machine should have direct motor spindle drive Spindle Taper: HSK A63, Spindle run out = 0.002 mm (maximum) Max. spindle rotational speed : 18000 RPM or more Max. spindle power: 20 kw at 100% duty cycle or more Max. spindle Torque: 85 Nm at 100% duty cycle or more Adequate spindle cooling to be provided. 8 Feed Max. Feed rate : 40,000 mm/min for X/Y/Z Axes or more. 9 Axes & Spindle drives All drives should be of AC digital type and to ensure smooth transmission with zero slippage. Guide ways and ball screws should be protected with telescopic covers. Adequate cooling required to meet the accuracy requirements. 10. CNC Control System Latest Siemens 840 D/ Heidenhain TNC 640 Control system CNC, NCU,PLC, PCU & Operating console should be of latest version. Electrical wired up panels to confirm to CE norms and AC panel cooler to be provided. Linear measuring system for axes. 5 axes simultaneous control. 10A Feed Back System The machine should be equipped with Direct Measuring system for sustained accuracy. The measuring systems should be encapsulated. Their good arrangement should guarantee high availability and protection against chips and coolant. 11 Programming & control features 19 colour monitor with key board & display in English language. Entry of data for each address to be XXXXX. XXX 2D & 3D graphic display & graphic simulation. Metric & inch input Spindle orientation Linear, circular, helical, spline interpolation & rigid tapping. Least input increment: 0.001mm Tool Radius and length off set and tool wear compensation. Absolute & incremental programming. ISO code programme format. Co-ordinate transformation,background editing and programming Pitch error & backlash compensation. Alarm error display, and diagnostic features. Software & hardware locking for machine & control. Page 2
Program repetition, Coordinate transformation, Rotation, Mirror, Canned Cycles (Drilling,Milling, Tapping & Boring) and Macro Programming, copying,scaling, parametric programming & program error indication. Tool monitoring system. DNC, External interface: Ethernet, USB port & PCMCIA interface, facilities. Multi program storage with programme identification. Automatic repositioning after cycle interruption. Block search & skip. Decimal point programming. Programme restart after interruption Display of remaining cycle during execution of repeatative cycle/subroutine Electronic Hand Wheel provision for machine setting. 12 Display features Machine position. Program under execution. Block no. Active command block. Spindle speed & feed rate- actual & programmed value. Absolute position. Distance to go. Tool no & off set no. Error message if any. Mode of operation. Tool under execution. Relative position In process measurement value with reference to part datum. Part program & tool file library. Tool data Work zero. Machine running time Display & Spindle load meter. Reset. Page 3
13 Operator panel Manual pulse generator with axes selector X1,X10,X100. (Detachable type) Manual ON/OFF for Control System, Coolant, Spindle Spindle neutral position for dialing. Reference point Manual tool indexing in ATC Manual tool loading to spindle. Feed hold Emergency stop. Machine lock & programme lock. Block search. Feed rate over ride: 0 120%. Spindle over ride : 50 120 %. Auto/single cycle, Jog, MDA, MDI, etc modes. Test run / dry run. Cycle start & stop. Part programme edit selector. Cycle error indication. 14 Air Pressure The machine should operate at minimum of 6 bar air pressure. 15 Lubrication Guide ways Central pulse lubrication. 16 Power Supply 415 V ± 15%, 3 Phase 50 Hz ± 6% 17 Automatic Tool Changer Automatic Tool Changer with tool magazine of 50 tools or more. 18 Working condition The machine and its accessories should be tropicalized. Permissible ambient temperature range: +15 C to +35 C 19 Warranty Entire machine inclusive of all systems/ accessories should be warranted for 24 months from the date of installation and commissioning against all design, material or manufacturing defects. 21 Machine protection control The machine must be equipped with a smart protection control system to detect and monitor abnormal events during machine operation, and take suitable preventive/corrective action to avoid mishaps. Page 4
22 Safety Working area of the machine should have safety enclosure with Plexi glass windows. The machine must be provided with all safety features necessary to protect the machine, control and the operator while in operation from possible damage/ injury. Automatic machine shutoff with warning in the event of lubrication and coolant failure, spindle off and axis over travel. 23 Installation & Commissioning Foundation kit like vibration mounting pads, bolts, etc required for foundation to be supplied. Detailed drawing of foundation indication necessary details to be supplied Requirements of water and compressed air lines to be specified. Special requirements like isolation,vibration criteria, Air conditioning, dust free atmosphere, power requirements and flooring to be specified. Laser Calibration of the machine after Installation. 24 Training 25 Documentation Machine Operation CNC Programming Mechanical Maintenance Electrical and CNC maintenance Training on Siemens/Heidenhein CNC control system Supplier has to provide required training to 3 engineers after installation of the machine in the following areas:- Three sets of the following documents in ENGLISH are to be supplied with the machine:- Operator manual Programming manual Spare parts list Maintenance manual Electrical wiring diagrams Preventive maintenance check list, trouble shooting charts and guidelines. Machine test charts Machine assembly drawings Documents of all the bought out items 26 Experience/ Clientele Supplier should have installed similar or better configuration machines in atleast 10 locations in India, and should provide their contact details. The OEM should ensure continued supply of spares throughout the useful life of the machine, but not less than 15 years. Page 5
27 Attachments and Accessories The supplier should mention all the standard accessories supplied along with machine Supplier should also quote separately for all the optional accessories. 28 Special Note The quotation should include specific answers strictly with respect to our tender specifications in point-wise manner and deviations if any, should be highlighted with clarifications. Otherwise, the quotation will not be taken into consideration. 11 Delivery Period: 5 to 6 months 12 Delivery Mode: DDP Shipment, Price Should be quoted in FOB/FCA IIT Bombay & also give breakup of cost of DDP Shipment amount in separate sheet. Machine optional add-ons: ( To be quote optional items in separate sheet ) 1 3D Model of the machine 3D Model of the machine in STEP format for simulation purpose. 2 Coolant Machine to be equipped with coolant through spindle with 40 bar pressure (80 bar pressure preferred) and paper band filtration. Coolant tank must be equipped with minimum 600 ltr capacity. Spray pistol with pump. There pistol should spray at a minimum pressure of 2 bar. 3 Chip Management System Suitable chip extraction system to be quoted along with the machine and the chip trolley to be quoted as an option. 4 On line inspection Workpiece set up & in- process gauging with Renishaw (or equivalent) probe. 5 Tool presetting device/tool measurement System Tool Presetting device should be quoted along with the machine. Automatic tool length & tool radius measurement (Laser) system on the machine 6 Extended warranty : An extended warranty for additional 3 years after expiry of the first 2 years of mandatory warranty. 7 Spares and Annual Maintenance Contract: Annual Maintenance Contract (AMC) for a period of 3 years from the date of after the expiry of the 2 year warranty period. A kit of spare parts with itemized cost for maintenance of the machine for a period of 5 years operation to be quoted. 8 Calibration tool for 4/5 rotational axis Tool kit for control and compensation of the kinematic accuracy of 4/5 axis machine configurations. 9 Energy Meter for monitoring energy consumption in real time 10 Higher positional accuracy and repeatability package Page 6
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