STATEMENT OF WORK (SOW)

FOR
CNC SHOT PEENING MACHINE

Ver. 2.0 Dated 25 June 2019

GENERAL AND COOPERATIVE SERVICES PROGRAMME (LB)

Projects Support Branch
TABLE OF CONTENTS

1 ABBREVIATIONS AND ACRONYMS ..........................................................................................

2 DEFINITONS ................................................................................................................................
3 SCOPE OF WORK.......................................................................................................................
4 REQUIREMENTS.........................................................................................................................
4.1 General Requirements ............................................................................................
4.2 Safety .......................................................................................................................
4.3 Instructions, Warnings, Gauges, Labels ................................................................
4.4 Technical Specifications .........................................................................................
4.5 Factory Assembly and Testing ..............................................................................
4.6 On-site Training .......................................................................................................
4.7 Documentation ........................................................................................................
4.8 Consumables/Spare Parts .....................................................................................
4.9 On-site Installation Requirements ..........................................................................
4.9.1 Pre-Installation Checklist ............................................................................................
4.9.2 Installation Plan ..........................................................................................................
4.10 On-Site Acceptance……………………………………………………………………….
4.11 Project Management and Reporting.......................................................................
4.11.1 Project POC and Project Management Plan .................................................................
4.11.2 Progress Report .........................................................................................................
4.12 Environmental Protection .......................................................................................
4.13 Quality Assurance ...................................................................................................
4.14 Summary of Deliverables ........................................................................................

Annex-A: CNC Shot Peening Machine Technical Specifications

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1 ABBREVIATIONS AND ACRONYMS

AC : Alternating Current
AFMD : Air Maintenance Factory Directorate
AMS : Aerospace Material Specifications
ATEX : Atmosphères Explosibles
CNC : Computer Numerical Control
CoC : Certificate of Conformity
COTS : Commercial Off-The-Shelf
CW : Cut Wire
Db : Decibel
GUI : Graphical User Interface
HRC : Hardness Range (Rockwell C)
IEC : International Electro technical Commission
LAN : Local Area Network
NEC : National Electrical Code
NEMA : National Electrical Manufacturers Association
NSN : National Stock Number
NSPA : NATO Support and Procurement Agency
OEM : Original Equipment Manufacturer
OD/ID : Outside Diameter/Inside Diameter
OSHA : Occupational Safety and Health Administration
P/N : Part Number
PoC : Point of Contact
SAE : Society of Automotive Engineers,
SOW : Statement of Work
STANAG: Standardization Agreement
TEM : Test and Measurement Equipment
TuAF : Turkish Air Force
VAC : Volts Alternating Current

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2 DEFINITONS

As used throughout this SOW, the following terms shall have the meaning set forth below.
Where "as shown", "as indicated", "as detailed", or words of similar import are used, it shall
be understood that reference is made to this specification and the drawings accompanying this
specification unless stated otherwise.
Where "as directed", "as required", "as permitted", "approval", "acceptance", or words of
similar import are used, it shall be understood that direction, requirement, permission,
approval, or acceptance of the NSPA relevant staff.
Adjust. To regulate, settle, bring to a more satisfactory state of normal operating condition.
Check. Examine, inspect, test, or verify by trial.
Component. Any part of any item or system, which is detachable or removable from the main
body, or main assembly of the item or system; a constituent part or an essential part necessary
to the performance of the system.
Contractor. The term Contractor as used herein refers to both the prime Contractor and any
subcontractors. The prime Contractor shall ensure that subcontractors comply with the
provisions of this SOW.
Customer. Turkish MND MFGD.
Control. A mechanism used to regulate or guide the operation of a machine, apparatus, or
system.
End User. Air Maintenance Factory Directorate
Facility. An establishment, structure, or assembly of units of equipment designated for a
specific function.
Inspect. To examine thoroughly, to view closely in critical appraisal.
Maintain. To keep in a state of repair and efficiency, to preserve from failure or decline.
Maintenance. Work, which is required to repair or maintain equipment systems in a safe,
operational condition, or to restore these systems to initial or usable condition by overcoming
the effects of wear and tear, disaster, damage, or deterioration. New construction or alteration
is not included.
Repair. Repair is the restoration of a piece of equipment, a system, or a facility to such
condition that it may be effectively utilized for its designated purposes. Repair may be
overhaul, reprocessing, or replacement of constituent parts or material.
Replace/Renew. To remove damaged, defective, or deteriorated materials or parts and install
new or used materials or parts as approved.
Required. Demanded as necessary or essential to the satisfactory operation of the equipment
or system.
Integrate. To prepare and submit the necessary documentation, and to interface, connect and
configure the systems/equipment for the operation as required.

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3 SCOPE OF THE WORK

This Statement of Work (SOW) defines the requirements for supply, delivery and installation of
a fully functional turnkey CNC Shot Peening Machine and the related materials/services as
specified in the SOW.

4 REQUIREMENTS

4.1 General Requirements;

1. The Contractor shall furnish the labour, material, transportation, engineering

management, and system integration requirements to deliver, install and test the equipment.
The Contractor shall also provide training, documentation and spare parts in accordance with
the requirements specified herein.
2. The contractor shall provide the machine as new, from current production of the
manufacturer and with Original Equipment Manufacturer (OEM) Certificate of Conformity CoC).
3. All deliveries and works shall meet, as a minimum, standards, specifications,
drawings of the products’ OEMs.
4. Each equipment/subassembly that requires calibration shall be delivered fully
calibrated together with their calibration certificates/labels.
5. All equipment shall have locally compliant supply voltage plugs, cables, and
adapters for use in Turkey.
6. All software and hardware (cables, interfaces, tools, fixtures, etc.) to operate the
equipment shall be provided.
7. Software updates made by OEM shall be provided via electronic media or OEM
web sites. All available software updates shall be provided during the warranty period.
8. The Contractor shall provide complete software backup in CD/DVD media and
recovery procedure of the whole system, including CNC and PC backups.
9. The Contractor shall provide a “Declaration of Conformity” asserting that the
system is compliant with the EU directives, including but not limited to the following Directives:
-European Machinery Directive 2006/42/EC
-European Electromagnetic Compatibility Directive 2004/108/EC
-European Low Voltage Directive 2006/95/EC
-European Pressure Equipment Directive 97/23/EC
4.2 Safety

1. Prominently displayed warning labels shall be installed on the equipment for

which personnel/equipment health and/or safety hazard exists.
2. The system shall have protection/warning mechanisms, such as audio/visual
warning systems, safety interlocks, electronic control systems, etc., against operator errors
and voltage irregularities for safe and effective operation to the maximum extent practicable.
4.3 Instructions, Warnings, Gauges, Labels

1. The Instruction labels shall be made of durable material to resist damage under
normal use.
2. One label with identification number including Part/Model and Serial Numbers,
Description, and, if available, NATO Stock Number (NSN) information shall be affixed to each

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equipment, its accessories and spare parts. Technical documentation shall refer to equipment,
at a minimum, by the identification information given in the labels.
3. The items, which do not have NSN codification, will be codified by the End User
after the contract award. The Contractor shall submit all necessary data/documents to End
User in three (3) months after the contract award for NSN assignment to the system, its
subassemblies, and spare parts/consumables. The request for NSN codification will be made
by the End User to the national codification authority.
4. All labels, instructions and warnings shall be pictorial and written in English.
5. All gauges shall be calibrated and display information in metric units.
4.4 Technical Specifications;

The technical specifications of the CNC Shot Peening machine are provided in Annex-A.
4.5 Factory Assembly and Testing

1. The machine units shall be assembled and tested in the manufacturer facilities
prior to being delivered to the End User.
2. The contractor shall provide NSPA the Factory Acceptance Test report (to
indicate the test results/data, checks/inspections made by OEM staff for factory testing).
4.6 On-site Training

1. The Contractor shall provide the on-site theoretical/practical training listed below
at the End User’s facility in Turkey.
-Ten (10) working days operator training for five (5) user personnel
-Five (5) working days preventive maintenance, calibration, user level troubleshooting
/repair training for five (5) personnel.
2. Training shall be conducted in English language.
3. Training documentation shall be provided in Turkish and English languages.
4. Training shall be given by certified service engineers and/or technicians.
5. Training shall include information on;
-How to select the proper parameters for blasting a wide variety of parts including the
ones that will be used during the acceptance tests.
-Nozzle selection, feed rates, coverage, intensity measurement, impingement angles,
and other critical variables affecting the blasting process
-Writing effective and productive programs to get the maximum performance from the
machine.
6. Training shall be given within thirty (30) days after the delivery of the machine.
7. The contractor shall be responsible for provision of all required training material.
However, the equipment provided can be used for certain aspects of the training if coordinated
and approved by the Customer. If maintenance training requires the removal and dismantling
of parts, the contractor shall provide the appropriate support. The contractor shall restore the
equipment and site, including all spares, to the initial state at the end of the training.
8. The Contractor shall provide the training program and documentation to NSPA
sixty (60) days prior to the training session for review/arrangements with the Customer.
9. The Contractor shall clearly identify the resources made available by the
Contractor and the support required from the Customer on site (draft schedule, course content,
material/equipment required, etc.).

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10. Maintenance training shall include the personnel familiarization with OEM
follow-on customer support services, such as on-line service assistance, parts ordering and
service request by e-mail, OEM company web site, etc.
11. The Contractor shall issue and sign training certificates to the successful
trainees after completion of the training.
12. Training program shall include a hands-on course to be conducted using the
aircraft parts and the processes as specified below;
- P/N: 2032M91G02, F110-GE-100C/129D compressor rotor, stages-1,2 spool dovetail
slots shot peening.
- P/N: 1559M93P04, F110-GE-100C/129D fan rotor, stage-3 disk dovetail slots shot
peening.
13. After shot-peening operation is completed, shot-peened surfaces shall be
inspected visually with a 10X magnifier to determine that the surface has been completely
covered (100 % coverage).
14. Parts shot-peening operations shall be performed in accordance with USAF
Technical Orders 2J-F110-3-6 and 2J-F129-13-6.
4.7 Documentation

1. The Contractor shall provide complete set of OEM documentation as stated

below:
-User manuals including operation, preventive maintenance and calibration procedures/
periods,
-As built drawings, including, but not limited to floor layout, electrical and mechanical
connections and wiring.
-Service manuals including floor layout, mechanical assembly prints, preventive
maintenance, troubleshooting/repair procedures, illustrated parts breakdown and spare parts
catalogue, diagrams/schematics/drawings showing the connections of mechanic, pneumatic,
hydraulic and electric/electronic units/components.
2. The documentation shall include the vendor data/information in case they are
required for operation/maintenance, calibration, and repair operations that should be done
according to the procedures given in the User/Service manuals.
3. The documentation shall include the Tooling Envelope and Machine Homing
drawings and procedure.
3.1 The Tooling envelope shall illustrate the gun manipulation (robot) and part
manipulation (turntable) ranges of motion, and their relationship to each other to make a quick
check to determine the feasibility of running different size parts.
3.2 The machine homing drawings and procedure shall document the proper
orientation and position of the different manipulators in their home positions that are set. The
Machine Homing Procedure print shall show these positions and the proper technique for
home position setup to reset home positions after maintenance.
4. The documentation shall be provided as three (3) hard copies and three (3)
electronic copies in Portable Document Format (PDF).
5. The Contractor shall provide the documentation in English language.

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4.8 Consumables/Spare Parts

1. The Contractor shall provide a 24-month Initial Set of spare parts/consumables

package with necessary tools for installation and maintenance, including, but not limited to the
materials listed below;
-Cut Wire 14; AMS 2431/3 Conditioned Carbon Steel Cut Wire Shot Regular Hardness
(45-52 HRC), (quantity: 500 kg)
-Cut Wire 28; AMS 2431/3 Conditioned Carbon Steel Cut Wire Shot Regular Hardness
(45-52 HRC), (quantity: 500 kg)
-Almen test strips; Almen strips as per AMS-S-13165 (SAE-1070 Cold Rolled Spring
Steel Finish Blue Temper. Uniformly hardened to 44-50 HRC. Flatness +/- 0,0015 inch),
(Almen A: 200 ea., Almen N: 100 ea.)
-Digital Almen gage; with min. 0,005 mm accuracy (over a range of 0-0, 600 mm),
-Calibrated step block kits; set of 5 block (metric) and their associated calibration
procedures.
-Rotary lance kit (including lance and collect);
3 ea. for lance size OD/ID: 0,188 inch/0,093 inch,
3 ea. for lance size OD/ID: 0,375 inch/0,250 inch,
2 ea. for lance size OD/ID: 0,087 inch/0,048 inch,
2 ea. for non-rotating lance OD/ID: 0,750 inch/0,406 inch.
-Blast nozzles (3 ea.)
-Consumable materials; such as filters, blast hoses, belts, ductworks, seals, wear
plates, etc. as specified in the Operation and Maintenance Manuals.
2. The Contractor shall provide a 10-year recommended spare parts/consumables
list.
4.9 On-site Installation

1. The Contractor shall assemble/install all equipment in accordance with

manufacturer specifications and deliver the equipment as ready-to-use at the location to be
allocated by the Customer.
2. For information, specifications of the installation area are given below;
-The machine shall be installed in a workshop located in 1st Air Maintenance Factory
Directorate, Eskisehir/TURKEY. The installation area has an epoxy covered concrete floor.
-In this area, available electric power is 380± 10% V, 50 ±3% Hz, 3 phase.
-Light level in the workshop area is approximately 500 lumens.
-The workshop area is not air-conditioned and there is no temperature and humidity
level control.
-In the workshop area, there is maximum 100-psi pressured air supply.
4.9.1 Pre-Installation Checklist

1. The Contractor shall prepare a pre-installation checklist and send it to NSPA for
coordination of the required site preparations with the Customer. The checklist shall:
1.1 Include queries to find out what resources are available at the installation
location, to collect sufficient information to prepare the existing customer facility for installation,

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calibration and user level maintenance of the machine, and to confirm that the location is
appropriate and ready for the machine installation and operation.
1.2 Identify storage requirements of the equipment, if the equipment is to be
shipped and stored in advance of installation.
1.3 Describe the tasks and/or site preparations that need to be done by the
Customer for material unloading and installation.
4.9.2 Installation Plan

1. The Contractor shall prepare and submit an installation plan to NSPA based on
the information provided by the Customer in the pre-installation checklist. The installation plan
shall:
1.1 Define site-specific deficiencies or missing resources that may prevent the
proper installation on site. NSPA shall in turn advise the Customer to take the necessary
measures in preparation of the on-site installation.
1.2 Clearly outline equipment footprints,
1.3 Floor layout and orientation,
1.4 Cabling and wiring to be provided by the Contractor and/or the Customer,
1.5 All supply lines and cable paths and their types (data, LAN, power,
communication, pressured air, water, gas, hydraulic, etc.),
1.6 Paths of AC power,
1.7 Uninterruptible Power Supplies (UPS), and associated circuit breakers and
power distribution panels,
1.8 Detail all steps to be conducted during the installation,
1.9 Duration of each step of the installation that is under complete control of the
contractor
1.10 Identify both the Contractor and Customer Furnished equipment/material to be
installed,
1.11 Specify de-installation of existing cable and equipment, and remove existing
equipment, if any;
1.12 In addition, any other site preparations and responsibilities of the Customer.
2. The Contractor shall submit the installation plan to NSPA maximum 30 days
after the receipt of the pre-installation checklist.
4.10 On-Site Acceptance

1. The Contractor shall prepare an Acceptance Plan including the on-site

inspections/tests to verify that the delivery is complete and the equipment is fully functional and
ready to use. The Acceptance Plan shall be submitted 30 days prior to the scheduled on-site
acceptance inspections/tests for NSPA and the Customer’s review/comments. The
Acceptance Plan shall:
1.1 Clearly outline the resources that should be allocated by the Customer to
conduct the inspection/testing,
1.2 Specify the Customer site requirements to prepare the existing customer facility
for the equipment operation, calibration and testing,
1.3 Detail all steps to be conducted during the inspection/testing,

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1.4 Identify both the Contractor and Customer furnished equipment,
hardware/software to be used,
1.5 Detail any cable, interface, accessory, equipment, power and consumable
material requirements to perform the inspection/testing.
1.6 Include pass/fail, completion criteria and acceptance test procedures
1.7 Include verification of the following;
-Proper physical installation and operational configuration
-Hardware/Software operational functions
-All accessories and the documentation including User/Service manuals, warranty
certificate, original copy of CoC and Declaration of Conformity for EU directives compliance,
copy of Quality Management Certificate (ISO or AQAP or equivalent).
2. The Contractor shall test all equipment in accordance with manufacturer
specifications and deliver the equipment as ready-to-use at the location to be allocated by the
Customer.
3. All kinds of TEM, hardware/software tools, kits, accessories, documentation,
and consumable material that are required for the installation/assembly, on-site
inspection/tests shall be provided by the Contractor, at no additional cost to NSPA, so that the
inspected/tested item will be returned to the original condition with full set of spare parts and
consumables.
4. All on-site inspection/tests shall be performed in the presence of qualified
contractor personnel. The Customer’s designated personnel will attend the inspection/tests.
5. On conclusion of the delivery acceptance, once the Contractor has completed
the inspection/testing activities as per the Acceptance Plan, the Contractor shall draft a final
acceptance certificate that will be signed by representatives of the Customer authorities and
the Contractor.
6. On-site inspection/tests shall be performed for the aircraft part, P/N:
2032M91G02, F110-GE-100C/129D compressor rotor stages 1,2 spool dovetail slots shot
peening. The shot-peening operation shall include Almen testing procedure.
7. The Customer will provide the related parts (i.e. Part holding Fixtures, Almen
Test Fixture, which may be scrap parts with Almen blocks mounted to surfaces and Scrap
Part) for the shot peening testing.
8. After shot-peen operation is completed, the shot-peened surfaces shall be
inspected visually with a 10X magnifier to determine that the surface has been completely
covered (100% coverage).

4.11 Project Management and Reporting

4.11.1 Project POC and Project Management Plan

The Contractor shall appoint a Project Manager as main POC. Project Manager shall be fluent
in English. The Contractor shall prepare a Project Management Plan and maintain a master
schedule of events planned throughout the contract period. No change shall be made after
contract award to the original schedule, other than symbols indicating actual performance,
without prior NSPA coordination/approval.
4.11.2 Progress Report

The Contractor shall provide a monthly progress report to NSPA. The report shall describe
tasks accomplished during the reporting period, problems or issues requiring action, any

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situations which may cause delays in program completion and responsible parties and
suspense dates for any necessary solutions/actions.

4.12 Environmental Protection

1. The contractor shall take all reasonable and practical measures to safeguard the
environment and apply the best practices available in that field.
2. The Contractor shall provide:
An Environmental Management Plan (EMP) covering the decision-making protocol in
terms of Environmental Protection, operating procedures and emergency preparedness and
response plan associated with required services
Licenses and permits issued by the relevant authorizing authorities
A copy of his environmental management system policy, which shall be relevant to the
scope of this SOW.
3. In the provision of the services and products that are subject to this SOW, the
Contractor shall ensure compliance with, as a minimum, the following legal requirements:
European Union (or equivalent from a non-EU NATO country) environmental protection
regulations and the national implementation references (i.e. law, regulation) pursuant to the
EU Directives;
Host Nations national, regional and local environmental laws and regulations, where
applicable;
4. The contractor shall fulfil all the regulatory compliance obligations and the
environmental protection requirements indicated above and supply an “Environment Protection
Declaration of Conformity” showing compliance to the requirements and applicable laws and
directives.
4.13 Quality Assurance

1. The Contractor shall maintain an ISO 9001:2015 Quality Management

System complying with such requirements in the scope of the deliverables of this contract and
make available a valid certificate upon request by the NSPA.

2. The contract shall conform to AQAP 2131, NATO Quality Assurance Requirements for
Final Inspection and Test.

4.14 Summary of Deliverables

Firm Requirements;
-Provision of one (1) CNC Shot Peening Machine as stated in Annex-A
-Provision of On-site training as stated in SOW 4.6
-Provision of Documentation as stated in SOW 4.7
-Provision of 24-month Initial set of spare parts/consumables as stated in SOW 4.8

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 ANNEX-A

CNC SHOT PEENING MACHINE TECHNICAL SPECIFICATIONS

1. CNC Shot Peening Machine;

The CNC Shot Peening machine shall be a robotic blasting system with horizontal shaft
rollers for shot peening and abrasive blast cleaning.

2. System Technical Requirements;

1. The system shall have the integrated major sub-systems below.

-Blast Cabinet Assembly

-Reclaim/Blast Assembly
-Control Assembly
2. The system shall have below features for processing different components.

-4-axis gantry robot

-Indexing and extending turntable
-Horizontal shaft rollers
-CNC

3. The system shall have the capability to select, control and monitor:

-Peening air pressure,

-Shot flow rate,
-Peen time, feed rates or cycles,
-Part and nozzle position, orientation and speed,
-Lance rotation speed.
4. The machine shall be capable of performing rotary lance shot peening of the
component types listed below;

-Deep holes in aircraft braking components

-Lugs bores in helicopter rotor components
-Dovetail slots in aircraft engine fan rotors
-Oil drain holes in aircraft engine shafts
-Deep slots and features in airframe components
5. The system shall automatically switch between Cut Wire and glass beads size 6 type
media in maximum five (5) minutes and shall switch between Cut Wire 14 and Cut Wire 28
type media with operator assistance in maximum one (1) hour.

6. The system shall have a design to handle different blast medias including, Cut Wire (14
and 28) and glass beads (MIL-PRF-9954, size 6).

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7. The machine’s gantry robot and indexing spindle shall be specifically designed for high
precision pneumatic blasting.

8. The machine shall have flexibility to blast parts with variety of geometries and with
max. 120 cm diameter and max. 90 cm height.

9. The machine shall have powered horizontal rollers to provide capability for processing
shafts with max. 200 cm length.

10. The gantry style robot shall provide large work envelope and allow part access.

11. The machine shall have a dust collector and media delivery system.

12. The turntable shall be mounted on rails so that after a cycle, a large swing door is
opened and the turntable advances out of the cabinet allowing easy part loading by hand or
with an overhead hoist.

13. Power requirement to operate the machine shall be max. 460 Volts, 3 Phase, 60 Hz,
estimated 60 Full Load Amperes (FLA).

14. The machine shall fit into the working area dimensions given below;

Width: max. 6 m
Length: max. 6 m
Height: max. 7,5 m
15. The machine shall contain the modules specified in the following sections.

3. Blast Cabinet Module

The Blast Cabinet module shall be composed of the units below;

1. The cabinet, in which the shot peening process occurs, shall be constructed of min. 12
mm hot-rolled steel plate.

2. There shall be a door opening for convenient part loading In front of the cabinet and
another door located on the cabinet to position the end stop roller when processing shafts.

3. The bottom of the cabinet shall be sturdy and shall allow the spent blast media to pass
through to the reclaim system.

4. The cabinet shall be lined to prevent abrasion of the cabinet structure.

5. The rubber lining shall extend into all door openings to prevent erosion of door seals.
The rubber lining shall allow absorbing the energy from the blast.

6. A replaceable blast wear plate shall be mounted on the cabinet wall directly behind the
turntable where it absorbs energy from overspray and ricochet.

7. The blast wear plate shall be constructed from a proper material bonded to a steel
support plate.

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8. The cabinet feet shall have a design eliminating the need for special foundations. Each
foot shall provide with a levelling bolt and locking nut.

9. The cabinet shall have a hinged work door providing operator access to the interior of
the cabinet. The door shall be constructed of high-strength material and have a resistant
coating on the inside to protect it from abuse.

10. The door shall have a slam action latching mechanism with a full-length handle for
ease of opening.

11. There shall be an integral urethane lip directing media back into the cabinet at the
bottom of the door. The lip shall prevent media from falling out of the cabinet when the door is
opened.

12. The door shall have a keyed limit switch verifying the door is securely closed.

13. The door shall have an electrical interlock, which stops all processing if the door is
opened during a cycle, and prevents a cycle from starting when the door is open.

14. The door shall have a viewing window. The window shall be protected from ricochet
blast media by a urethane slide plate, which shall be opened or closed with a lever on the
outside of the door panel.

15. The doorstop shall hold the work door in an open position with a magnet. A shock
absorber shall decelerate the door to minimize the impact.

16. The service door shall provide access to the side of the process cabinet to position the
end stop roller when processing shafts.

17. The service door shall be electrically interlocked to shut down the machine in the event
of accidental opening.

18. On the bottom the service door, there shall be an integral lip to direct media back into
the cabinet. The lip shall prevent media from falling out of the cabinet when the door opened.

19. The service door shall have a min.180º range of motion to provide maximum access.

20. There shall be fluorescent light fixture to provide illumination for the interior of the
cabinet. The fixture shall produce a well-lit cabinet interior with min. 860 lux of light intensity.

21. The fixture shall be abrasion-resistant, dust and vapor tight. There shall be a switch at
the operator control station to control the light.

22. The cabinet shall have a design allowing proper quantity and distribution of make-up air
entering the cabinet for effective removal of dust from the cabinet.

23. There shall be air silencers with proper size, location, and quantity to provide removal
of nuisance dust. This shall allow the cabinet door(s) to be opened immediately after
completion of a process cycle.

24. The inlet air silencers shall be constructed of steel and shall be lined with sound
absorptive materials to attenuate the noise generated by the machine process.

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25. There shall be manual blow-off nozzles placed in the machine to assist in part cleaning.
A lever operated hand valve and a self-coiling air hose shall be provided at each blow-off
nozzle location.

26. There shall be reclaim ductwork with a media return pipe on the cabinet. This shall
allow a single, continuous airflow through the entire reclaim system.

27. There shall be a ground rod, used by the operator to dissipate static charges, which
may build up on a part or a portion of the machine during the blasting process.

28. The rod shall be constructed of aluminum grounded to the cabinet structure and shall
have an electrically isolated, phenolic handle to be held by the operator.

29. There shall be a step providing an operator access to the personnel door and the
interior of the cabinet.

30. A cable shall be strung in a visible/accessible area and shall be connected to an

emergency stop switch for operator safety. When pulled or when broken, this cable shall
disable the equipment and put it into “E-stop” condition. In this condition, manual resetting
shall be required at the switch unit.

31. The cable product shall be assembled to operate through the wall of a blast cabinet,
keeping the switch contactor away from the abrasive environment inside.

32. There shall be a corner pulley allowing the single cable and switch to provide an
Emergency Stop accession on two walls of the cabinet.

4. Part Manipulation Module

The machine shall have a Part Manipulation Module containing the units below to
rotate the parts to be processed.

1. There shall be spindle table drive system capable of indexing and continuous rotation.

2. The system shall contain a precision right angle gearbox and brushless servomotor
mounted inside of a welded steel box where they are protected from the harsh blasting
environment.

3. There shall be a spindle box guided inside the cabinet on precision aligned hardened
ways.

4. The front travel position shall extend the table centerline beyond the cabinet door
opening to allow clear hoist access for handling heavy parts.

5. The table system shall be controlled completely by the CNC to make it accurate and
repeatable.

6. If the shaft rotation stops during the blast cycle, machine processing shall immediately
stop and a fault message shall occur.

7. The table system shall have the minimum specifications below.

-Rotational speed range: min. 0.3 rpm and max. 30 rpm

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 -Rotational accuracy (± degrees): max. 0.1
-Rotational Repeatability (± degrees): max. 0.2
-Range of travel: min. 750 mm
-Capacity: min. 225 kg
8. The spindle tabletop shall be a min. 650 mm diameter disk, which will be used in
conjunction with the spindle drive product to support and rotate the work-piece. The steel
table shall be hardened to 58-63 Rockwell C hardness scale to withstand the harsh blasting
environment.

9. The tabletop shall contain bung and pin holes to locate accurately a part on the
tabletop. Slots shall be provided to secure a part onto the tabletop.

10. There shall be a shaft spinner specifically designed to support and rotate shafts max.
125 mm diameter and max. 2000 mm long.

11. A variable speed motor shall drive the right side rollers. The left side rollers shall be
idlers, which can be removed from the cabinet when circular parts are being peened on the
table. The idlers shall have adequate adjustment to process a variety of shaft diameters and
lengths.

12. The floor of cabinet extension, which houses the drive rollers shall steeply, sloped to
direct the spent media back into the reclaim system.

13. An adjustable depth stop shall be provided on each side to position the shaft in the
proper location for peening.

14. The shaft spinner shall have the specifications below.

-Speed range: min. 4 rpm and max. 40 rpm

-Speed regulation (± percent): max. 3
-Capacity: min. 225 kg
-Drive system: variable speed
5. Material Handling Module

The machine shall have a Material Handling Module containing the unit below for
loading and unloading heavy parts.

1. A hoist shall be mounted on the side of the cabinet to assist in loading and unloading
heavy parts.

2. There shall be a double pivoting boom allowing the hoist arm to reach a variety of
positions inside of the cabinet, and providing a working range outside the cabinet.

3. The hoist shall allow the operator to place the parts directly onto the center of the
spindle, and long shafts onto the horizontal rollers.

4. The hoist shall include an electric powered lift with min. 225 kg lifting capacity.

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5. Speed controls shall be provided and a bar handle shall allow the operator to
accurately position the part.

6. Gun Manipulation Module

The machine shall have a Gun Manipulation Module containing the units below to
process the parts.

1. Robot; There shall be robot designed for the harsh environments of blasting and
peening processes.

2. Motors, bearings, gearboxes, and position sensing components shall be placed outside
the work envelope to eliminate the contamination problems that damaging robot mechanisms.

3. The system shall be constructed on a solid steel framework.

4. Linear axes shall utilize stiff cam follower type slide and precision ball screws for high
speed and accuracy.

5. All axes shall use high torque brushless servomotors with low maintenance.

6. The system shall have a sealing mechanism for the dirt and noise in the process
cabinet, and keep contaminants out of the robot mechanism.

7. The robot shall have the specifications below.

Stroke lengths;

-Horizontal, X-axis: min. 1200 mm

-Vertical, Z-axis: min. 1200 mm
-Wrist, A-axis: min. 190º
-Wrist, B-axis: 360º
Positioning speed; min. 200 mm/sec for all linear axes and min. 1000 degrees/minute
for all rotary axes.

Positioning accuracy (Bi-directional; max. ± 0.50 mm for all linear axes and ± 1.0º for all
rotary axes.

8. The robot shall be equipped with a Z-axis safety catch.

9. Rotary Lance Drive; There shall be one rotary lance drive providing continuous rotation
of a lance while the lance projects into a hole or slot requiring the peening process. The unit
shall eliminate the possibility of hot spots by rotating continuously. A sensor on the output
shaft shall verify Lance rotation.

10. All components exposed to the media flow shall be constructed of hardened or wear
resistant materials for long life. There shall be a replaceable rotating seal, which is self-
compensating so that it continues to seal properly even as it wears.

11. The lance connection shall be collet or any other style providing lance changeovers
and accurate lance positioning.

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12. There shall be a pinned connection to mount the rotary lance drive to the robot arm.

13. The blast hose shall be attached via a coupling, and the control cables shall be
attached with sealed connectors to the machine control system.

14. The rotary lance drive shall have the minimum following specifications;

-It shall rotate standard lance sizes from 2.5 mm to 15.5 mm outside diameter.

-It shall have adjustable rotary lance speed from 15 to 150 rpm.

-The speed shall be displayed on the machine controller.

15. Pressure Blast Lance and Collet Holder: There shall be pressure blast lances in
different sizes/lengths that can be attached to the rotary lance drive and allow blasting in tight
applications such as slots and holes.

16. To resist abrasion and prolong service life, the lance shall be constructed from
tungsten carbide. At the end of the lance, there shall be a carbide tip deflecting the media
outward to provide blasting on surfaces parallel to the lance centerline.

17. There shall be rotary lance collets securing the pressure blast lances into the rotary
lance drive.

18. Gun Holder and Blast; The gun holder shall mount to the robot miter box. It shall be
designed to switch from mounting a single blast gun to mounting a rotary lance drive.

19. Hose Support; A hose support shall be provided to keep the blast hoses from
interfering with the blast process. This hose support shall consist of an elastic cord mounted at
the robot. The elastic cord shall not be based on typical spring-tensioned reels.

20. The machine shall have a Gun Blow-off mechanism utilizing the blast nozzle to clean
off the part and cabinet area and to prevent media escape. For blow-off cleaning, during
programmed operation, the media shall be turned off, the air shall be turned on, and the gun
manipulator shall be activated.

21. The gun manipulator shall move the nozzle completely around the part, approaching it
from a variety of angles to blow off media.

7. Reclaim Module

The machine shall have a Reclaim Module containing the units below to convey the
media from the machine hoppers back to the media delivery system (Blast Module) as well as
the units required to properly route and classify the media.

1. There shall be an automatic media adder to maintain a stable volume of media within
the Blast System. The system shall have two (2) boxes with a capacity of at least 28 liters of
storage capacity for each media type.

2. There shall be a dust collector, which pulls air through the reclaim system serving two
functions: It shall convey the spent media back to the blast system, and it shall draw
contaminated air out of the cabinet and the contaminated air shall be filtered and returned to
the plant atmosphere.

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3. The dust collector shall use cartridge filters and each cartridge filter shall have the
required surface and filter the air with min. 99% rate for particles with min. 0.5 micron.

4. The high efficiency air filters shall be mounted to make them easily changeable. There
shall be a differential pressure gauge monitoring the pressure drop across the cartridges and
indicating when they need to be replaced.

5. The dust, collected on the filters, shall be removed by a timed air purge, which is sent
as a pulse of air back through the filters. The dust shall be collected in a hoper located below
the filter canisters. The hopper walls shall be steeply sloped to insure that media falls freely
into a trash receptacle. A dust house barrel shall be provided for dust collection and disposal.

6. A sound attenuator shall be mounted on the air exhaust to reduce noise levels below
85 Db.

7. Trash shall be collected in a trash barrel with min.15 liters capacity.

8. A steel dust collector ductwork shall transport the dusty air from the cyclone to the dust
collector. The ductwork shall be designed to minimize pressure drops in the duct, and insure
that no dust accumulation occurs in the ductwork.

9. There shall be a cyclone unit perform separation of the media from the reclaim dusty
air and media stream. Separated good media shall be sent to, out of the cyclone, to the
blasting system. The air and small particulate shall flow out of the cyclone to the dust collector.
The cyclone shall be lined with urethane for abrasion resistance and wear.

10. There shall be a reclaim ductwork, which carries spent media from the hoppers in the
blast cabinet to the cyclone. The ductwork shall be assembled with straight sections and
elbows to reduce maintenance cost.

11. There shall be a mechanical screening system for spent media retrieved via the reclaim
system. The unit shall work by the use of two screens; one larger than the media being used,
and one smaller.

12. The system shall divert properly sized media to the blasting system, and rejected
material to a trash barrel. The system shall include a self-cleaning kit, which reduces plugging
of screens by media and trash.

13. The system shall have screens sized for proper classification of the blasting media.
The system shall have signs mounted on the system to designate the screen size on each
deck and to designate what size media is used.

14. The system shall collect trash in a standard min. 200 liters steel barrel. The barrel shall
have wheeled dolly allowing the barrel to be easily moved.

15. There shall be manual blow-off nozzles placed in strategic locations around the
machine to assist in part cleaning. A level operated hand valve and a self-coiling air hose shall
be provided at each location.

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8. Blast Module

The machine shall have a Blast Module containing the units below to deliver properly
the blast media to the part.

1. The system shall have mini-pot pressure system; one for glass and one for steel
media. The system shall have two (2) complete pressure vessels. One shall be located directly
below the other.

2. All the valves shall be mounted on the outside, eliminating the need to access the
inside of the pressure pots.

3. In locations where media meets the valves, posi-flate butterfly valves shall be used to
transfer media from one vessel to the next.

4. All of the valves shall operate pneumatically.

5. The system shall permit continuous blasting.

6. The system shall indicate proximity probe signals when the media level is low.

7. The system shall have cone shaped pots allowing media change over from one media
type to another.

8. The machine shall include a pressure control system consisting of a manual pressure
regulator and a remote controlled pressure regulator, which is fed with manual regular
pressure set point.

9. There shall be a gauge located on each regulator.

10. There shall be a pressure blast hose made of a composite construction. The inside
tube shall be abrasion resistant blended rubber. Around this inner tube shall be braided
synthetic reinforcement layer, which provides tensile and bursting strength. The outside of the
blast hose shall be covered with a thick rubber cover, which resists flex cracking, abrasion and
aging.

11. The hose shall stand a maximum operating pressure of 150 PSI. The hose shall have
coupling adapter on the supply end for attachment/detachment and NPS female fitting on the
opposite for attachment to a blast nozzle.

12. A pressure switch, which is adjustable over a range of 12 to 150 psig, shall be provided
to monitor the air supply to the machine. It shall signal the operator and stop the machine
cycle if the air pressure drops below the pre-set limit.

13. There shall be a pressure blast nozzle to accelerate the air and media prior to striking
the part. The nozzle shall be made of tungsten carbide for high wear against direct abrasion of
media in the air stream.

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9. Control Assembly Module

The machine shall have a Control Assembly Module containing the units below to
control the machine.

1. The machine shall have a control panel which is NEMA12/IP65 rated against oil and
dirt and built to conform to the applicable National Electrical Code (NEC) or International
Electro technical Commission (IEC) standards.

2. Wire/terminals shall be labelled for easy identification and all doors shall be interlocked.

3. There shall be an air conditioner to keep the control enclosure at constant temperature.

4. There shall be receptacles to power test equipment or light duty tools.

5. There shall be a CNC Controller unit with the specifications below

Hardware:
-32-bit processor computer with Ethernet communication
-Electronic self-diagnostic system
-Color LCD display with sealed keyboard
-Minimum 5-axis control capability
-320 m of motion storage memory
-Fiber Optic Serial Servo Bus connection to servo drives
Software:
-Touch screen “Soft key” function key operator menu system
-Operator help and warning messages
-Edit programs while executing
-Time and Part counter display
-Motion Programming:

-Conform to RS-274 format for compatibility with existing programs

-“Para macro” programming capability

-Graphic motion program verification
-Ladder editor and monitor for CNC ladder logic

10. Process Control Software

1. The machine shall include process controller software with context sensitive help and
Graphical User Interface (GUI) based controls.

2. The software shall provide trend graphs and data logger tools for process engineering
to perform design of experiments. Configurable data loggers shall record specified variables
every second the machine is in-cycle.

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3. The software shall monitor the key process parameters and other machine functions.

4. The software shall run on a MS Windows compatible PC for the operator interface and
the data recording system.

5. The PC shall constantly communicate with the machine control to provide data for the
process control software. The process control software shall communicate with a variety of
different machine control systems.

6. The process control software shall include interfaces below with motion control
systems.

-Utilities for uploading and downloading part programs to CNC/Robot controller.

-A part program editor, which enables the user to insert functions and commands (i.e.
constant surface speed over various geometry, table speed or position, gun or rotary lance
on/off, etc.).
-Generation of complete motion programs by answering user specified dialog boxes
7. The process control software shall include operator interfaces below.

-Cycle monitor and recipe information

-Help messages
-Alarm messages with diagnostics
-Trend graphs
-Part and optional function selection
-Data collection and process recording system
-Customizable reporting
8. The software shall display process set points and process actuals in an easy-to-read
format a Cycle Monitor screen.

9. The software shall allow the process recipes to be easily written or modified. If the
operator enters a parameter not consistent with the process or not within the range of a
particular variable, a message indicating the valid range shall be displayed.

10. The software shall allow the required process parameters to be changed during the
cycle. The process parameter set points, alarm limits, shutdown limits, or recipe numbers
specified by the CNC/Robot Controller shall be passed to the process control software for
immediate implementation. Air pressure, media flow rate (ferrous and non-ferrous), robot
speed, rotary table rpm, rotary lance rpm parameters shall be closed loop controlled.

11. Each parameter shall be protected by a multi-level security system. The process
administrator shall have the option of allowing machine operators to modify some or none of
the process parameters with in the recipe.

12. Recipe selection and storing shall be protected by a security system that safeguards
the recipe from accidental or unauthorized deletions or selections.

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13. The software shall provide a help message for any parameters shown on the display
screens when requested by the operator or process engineer. The help messages shall
provide relevant information on the limits and operation of a parameter. Help information about
alarms shall be specific for the displayed alarm.

14. Each parameter shall have two sets of programmable high and low limits. If a warning
or shutdown alarm occurs, the software shall display a message describing the condition and
the time of occurrence. In addition, a diagnostic message shall be provided to assist in
correction of the problem. The machine and system alarm conditions, such as equipment
malfunctions, shall also be supported by alarm and diagnostic messages.

15. The software shall provide trend graphs to display graphically user-selected
parameters during the cycle.

16. The software shall have a view allowing the operator to locate and select which part to
process.

17. The software shall display a sortable list of all entered parts based on a query made by
the operator.

18. Along with each part recorded in the software shall be a part picture, entered by the
User, and a robot motion program. The picture for the highlighted part shall be shown. When
the part is selected by the operator, the associated part program shall be automatically sent to
the robot controller and made active. The documentation, such as gun selection, setup
description, fixture requirements, and user specific data shall also be shown or entered on the
part identification screen.

19. Each part shall have up to 16 operator selectable motion control or process functions
defined. The software shall allow the operator to toggle each function on or off to apply the
process to only to certain portions of the part to be processed. This data then shall be passed
to the Robot controller, which will only perform selected functions. Once the required data is
entered on this screen, the software shall allow the operator to start the cycle by a software
push button.

20. The software shall record critical process parameters to document the quality and the
repeatability of the process. The software shall collect the specified data every second and
store it in an MS Access compatible database. The reporting shall be done through an
integrated database reporting utility. Reports shall include;

-Process Summary Reports – Provide summary of all key parameters (i.e. set point,
minimum, maximum and average values)
-Alarm logs which shows alarms and shutdowns generated over a given time period
-Recipe prints-outs
-Part Log reports which show all parts processed for a given time period.
-Strip chart records, which show second-by-second data.
21. The software shall generate reports, which summarize data from multiple parts. The
data shall be reported by date, part number, serial number and shot size or any other user

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specified data. The software shall export the reports in a wide variety of formats, such as
Excel, Word, RTF, Text, Dbase, etc. Reports shall include graphs, plots and sub-reports.

22. The software shall have a maintenance module for customer tracking of preventive
maintenance scheduling. The module shall display run time, cycles, or days for all customer-
specified equipment. The module shall have the capabilities below;

-Scheduler: It shall tracks the elapsed operating hours, cycles, or days on up to 100
items. This shall allow maintenance to be recorded for each unique item based on its usage
rather than on an hour basis for the complete machine. Each item shall be assigned an
elapsed time/cycle for maintenance due alarm to alert the operator.

-Historian: At each time maintenance is performed, the maintenance module shall

record the time & date information, as well as the name & ID number of the person doing the
work.

-Advisor: Each maintenance item shall have help available at the push of a software
button. Procedures and checklists shall be displayed to help get the work done. The software
shall also allow this information to be printed.

11. Shoot Peening Programs

1. The Contractor shall provide CNC shot-peening programs on-site at the installation
location for the below listed aircraft parts. The Customer shall provide the related parts (Part
holding Fixtures, Almen Test Fixture, which may be scrap parts with Almen blocks mounted to
surfaces and Scrap Part) for each of the part program development.

-P/N: 2032M91G02, F110-GE-100C/129D compressor rotor stages 1,2 spool dovetail

slots shot-peening,
-P/N: 1499M31P07, F110-GE-129D fan rotor stage-1 disk dovetail slots shot peening,
-P/N: 1499M82P05, F110-GE-129D fan rotor stage-2 disk dovetail slots shot peening,
-P/N: 1359M71P03, F110-GE-100C fan rotor stage-1 disk dovetail slots shot peening,
-P/N: 1993M92P01, F110-GE-100C fan rotor stage-2 disk dovetail slots shot peening,
-P/N: 1559M93P04, F110-GE-100C/129D fan rotor stage-3 disk dovetail slots shot
peening.
-P/N: 2032M93P01, F110-GE-100C/129D compressor rotor stage 3 disk shot peening
12. Process Control Software Display Unit

1. The machine shall have a keyboard and display unit housed in an enclosure mounted
on a suspension arm. The suspension arm shall allow the display unit to be easily moved into
a convenient position for use and then moved out of the way when not needed. The
suspension arm’s movable joints shall be heavy-duty bearings in all movable joints to provide
smooth operation and durability to withstand the stresses of repeated use.

2. The enclosure and the suspension arm components shall be rated NEMA12/IP55 to
provide protection against oil and dirt. The display and keyboard unit shall be equipped with an
industrially hardened keyboard.

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13. Remote Diagnostic Software

The machine shall have the required software/hardware for the machine remote control,
diagnostic, software updates, on-line assistance via internet or telephone line.

14. Printer

The machine shall have a PC compatible color printer to printout the data/information provided
by the software and CNC computer.

15. Process Control Software Computer

As part of the machine control system, a computer with minimum 15” color monitor and UPS
shall be provided.

16. Units

The Contractor shall provide following units (serials 1 to 3 below) with the system:

1. Closed-Loop Air Pressure Control Unit: There shall be air pressure controller with the
following specifications;

-Pressure control range: minimum 10 to maximum 100 psi

-Pressure shall be maintained at the regulator within max. ±3.0 psi range of the
adjusted pressure value
-There shall be adjustable deviation alarms monitor for systems problems.
2. Media Flow Controller Unit:

2.1 There shall be a media flow controller to allow adjustments in media flow rate and to
eliminate different size orifice plates and the downtime required to switch them.

2.2 The Controller shall include an internal flow monitor to measure the media amount
flowing to the blast nozzle and to display that quantity on a digital read-out. The Controller
shall allow the operator to calibrate media flow rate for correct and consistent results.

2.3 The Controller shall have a closed loop control mechanism by a control valve, which
continually monitor and adjust media flow rate to match the set point.

2.4 The Controller shall generate an operator fault message and stop the process if the
media flow exceeds the High/Low limit values that can be pre-set.

2.5 The Controller shall have + 5% flow rate accuracy.

3. Receiver Blast Nozzle and Non-Rotating Blast Lance:

3.1 There shall be one pressure blast nozzle designed to be a receiver for extension
lances. This nozzle shall allow different size lances to be inserted into the end of the nozzle
and secured. Alignment grooves on the end of the lance shall allow for orienting the lance exit
with respect to the nozzle holder.

3.2 When the lances are removed, the extension nozzle shall function as a standard
nozzle.

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3.3 The nozzle shall be constructed from hardened tool steel to provide long life in the
harsh blasting environment.

3.4 The pressure blast lance shall accelerate the air and media prior to striking the part. It
shall be made of hardened tool steel with a carbide insert and shall be designed to slip into a
nozzle receiver mounted to the robot.

3.5 Locating grooves on the end of the lance shall provide alignment for different directions
of the blast stream. A setscrew in the blast nozzle shall secure the lance in the set position.

17. Certifications/Standards

The machine shall be compliant with SAE AMS-2432 Aerospace Material

Specifications, GE P11-TF8 Specifications and Pratt & Whitney PWA36930 computerized
peening specifications.

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