Machine tools : specification, purchase, and installation / Russell Gamblin.

Includes index.

1. Budget phase -- Attend one of the many quality international trade shows -- Develop a return on investment projection -- Prepare a payback projection for the project -- Develop a breakeven cost for the machine tool -- Develop the first specification of the machine tool -- Develop a list of technical differences between the proposed machine tool and the older machines in your factory -- Develop a list of suppliers -- Rate machine tool suppliers, their equipment, and their capabilities -- Visit machine tool manufacturers -- Gather "Ballpark" quotes from each machine tool manufacturer -- Develop an overall budget cost for the machine tool -- Develop a budget for the machine tool foundation -- Develop an electrical cost of the machine tool -- Develop a facility modification budget for the machine tool -- Develop a removal and demolition cost for the old machine tool and its foundation -- Develop a tooling cost for the new machine tool -- Final budget costs -- Create the overall project schedule -- Capital appropriation and level of authority -- Summary -- 2. Procurement -- Prespecification meeting -- Machine tool project specification document -- Selection of the project leader for the entire project except the foundation -- Machine tool supplier visits and quotes -- Machine tool supplier references -- The final approved machine tool specification -- Checklist for the project leader/manager during the procurement phase -- Operator training -- Maintenance and facilities training -- Application and programming training -- Schedule for the machine tool build -- Terms and conditions -- Liquidated damages due to late delivery -- Consequential damages -- Ordering the machine tool -- Visit the supplier's factory during the build process of your machine tool -- Acceptance of the machine tool at the supplier's facility -- Summary -- 3. Layout phase -- Layout during the procurement phase -- Maximize floor space -- General notes for layout of a horizontal boring machine -- Maximum weight of the largest piece of the machine tool -- Soil boring specification -- Minimum requirements for the machine tool location -- Develop the overall schedule of the foundation installation -- Planning the removal of the existing equipment -- Planning the demolition of the old foundation and/or floor slabs around the old machine tool -- Planning the removal of the old utilities (water, power, air, etc.) -- Floor plate layout and installation -- Summary -- 4. Foundation phase -- Prefoundation meeting and foundation project leader -- Schedule for the completed foundation -- Tricks of the trade (trench design and saving floor space) -- Bury the conduit and black iron pipe in the new foundation only -- Foundation pit modifications -- Develop a foundation design specification -- At least five review sessions for the foundation design -- Bid foundation design and purchase order for the foundation design -- Installation of the dust walls and limiting access during construction -- Purchase order for the demolition of the old foundation and installation of the new foundation -- Review and sign-off on the rebar drawings for the new foundation -- Prejob safety briefing prior to demolition and the installation of the new foundation -- Concrete cylinder test -- Foundation cure period -- General contractor specification -- Foundation summary -- 5. Installation phase -- Create the machine tool installation specification -- Installation of the machine tool without maintenance and facility support -- Machine tool installation bid—get at least three quotes -- Machine tool installation purchase order -- Purchase of the machine tool lubrication oils and coolant -- Epoxy painting of the nonshrink grout and concrete foundation -- Purchase and installation of the machine tool metal chip bin-- Purchase and installation of the grout cans, grout forms, and grout pour -- Purchase and installation of the safety rails of the machine tool -- Overall installation schedule -- General notes for installation of the machine tool -- Installation of the ladders and stairs to access the foundation pits -- Summary -- 6. Preparation phase -- Preparation phase -- Chip conveyor requirements when the chip conveyor is supplied by the OEM -- Chip conveyor requirements when the chip conveyor is not supplied by the OEM -- Chip deflectors for the chip conveyor and other sections of the machine tool -- Main power source for the machine tool -- Secondary power source for the machine tool -- Compressed air -- Water -- Chilled water -- Coolant/oil skimmers -- Coolant coalescer -- Coolant wall and enclosure -- Touching up the epoxy coating of the foundation -- Lighting in the foundation pits -- Isolation transformer -- DNC software -- Direct numerical control procedure -- PC at the machine tool for network connection -- Main 480-VAC breaker -- Deck plate, checkered plate, and bar grating around the machine tool covering the machine tool foundation pits -- Laser alignment checks -- Final machine tool acceptance -- Machining test -- Develop and test a part program -- Teleservice provided by the machine tool OEM and installed and tested by the machine tool buyer -- Warranty -- Conduit (EMT, IMC, Rigid, and PVC) required for the machine tool -- Power track or Wireway -- Head attachments (head house or no head house) -- Sag compensation -- Temperature compensation -- Checking of the hard and soft overtravel switches of the machine tool -- Basic reference of the machine tool -- Start-up of the machine tool from an off state -- Lock out and tag out procedures and disconnect for the machine tool -- Backup of all the CNC data -- Viewing of and access to the PLC ladder logic -- Summary -- 7. Start-up phase -- Start-up phase -- Machining test and test parts -- Acceptance tests -- Final machining test -- Continuous running test -- Uptime accountability of the machine tool -- Machine tool supplier support during the first year -- One-year meeting after final acceptance—lessons learned -- Documentation of the machine tool -- Summary -- 8. Maintenance phase -- Why perform maintenance? -- Decrease machining downtime by implementing a daily operational and preventive maintenance program -- Increase overall productivity of the machine tool -- Higher accuracy and quality of parts produced by checking your machine tool's alignments and laser calibration at least once per year -- Daily operations checklist -- Monthly maintenance checklist -- Semiannual maintenance checklist -- Annual maintenance checklist -- Standard spare parts list -- Long-term spare parts list -- Summary.

"Invaluable, difficult to find information for the optimum purchase, design, and installation of large-scale, ultra-expensive machine tools, written by an engineer who has been "in the trenches," saving companies millions"-- Provided by publisher.