September 29, 2006

KPM Group, the North American authorized Herkules representatives, are pleased to provide this remanufacture package for your 28” Mesta roll grinder as follows:

Scope of Work

The scope of work to be completed will include the following:

Alternate Grinder

Our company will provide a used 28” Mesta roll grinder of suitable characteristics and condition to be remanufactured.

Mechanical Remanufacture

Following complete disassembly, cleaning, and inspection, the grinder will be remanufactured utilizing, as much as possible, the existing equipment as follows:

Traverse Bed

1.	All critical surfaces on the top and inside face are to be reworked, including the slide ways, way cover ledges, and vertical contact areas between the work bed and traverse bed.

2.	Flat and vee-ways will be remachined to assure flatness and straightness, utilizing electronic and optical measuring and inspection equipment.

3.	The bed ways will be hand scraped and spotted with the carriage to insure as near perfect as possible mating and alignment.

4.	The bed racks will be recut to assure precise tooth form and spacing for consistently smooth motion and exact lateral positioning.

5.	New telescoping steel way covers will be provided and installed.

Carriage

1.	The carriage will be completely refurbished.

2.	All critical surfaces will be remachined including the way surfaces and end faces (for attachment of new way covers).

3.	Based on the amount of wear and machining required, way liners may be installed if required to bring the machine back to proper centerline.

4.	The way surfaces (or new way liner surfaces) will be hand scraped (in conjunction with the traverse bed way scraping) to ensure maximum bearing and proper alignment.

5.	Cross slide ways will be ground and/or hand scraped to assure straightness and proper bearing.

6.	All accuracy tolerances will be held as near perfect as possible; in all cases less than .001".

7.	The transmission will be modified for direct drive and will be fitted with a servomotor.

8.	The infeed mechanism will be fitted with a new precision ball screw, low backlash planetary gearhead reducer and servomotor.

9.	The electronic crowning will be driven by a servomotor.

10.	The wheel spindle assembly will be completely reconditioned, including spindle, bearings, retainers, spacers, oil/water slingers and housing. Spindle rework would include bearing journals, thrust faces, wheel hub taper, wheel hub/pulley threads/nuts and dynamic balancing. Bearing rework would include restoration of babbitt bearing surfaces, hand scraping for maximum bearing with the spindle journals, alignment, and complete adjustment to ensure proper radial and axial clearances.

11.	One (1) existing wheel hub will be reconditioned.

Three-Point Caliper

A new caliper will be designed, including:

1.	Caliper Design Features

a.	Three-point caliper system with two (2)-measuring arms and one (1) centrally located C-probe.

b.	Includes the design, fabrication, and machining of support boom arrangement on machine carriage.

c.	Linear servomotors in lieu of ball screws eliminates backlash and repeatability errors from ball screws and screw drive mechanics. Also permits free movement upon motor overloads (or stalls) without causing damage to caliper mechanics.

d.	Conventional Heidenhain glass scales for arm positioning.

e.	Heidenhain linear measuring probes (with internal glass scales) for fine increment positioning/measurement.

f.	Preloaded linear ball slides for rigidity and smooth arm movements.

g.	Individually guided arms to allow maximum possible inspection diameter range.

h.	Diamond tipped contact points for low wear and less frequent tip change outs.

i.	A calibration ring will be mounted on the tailstock to provide an absolute standard for the automatic calibration sequence. The control gives the operator the choice to accept or override the calibrated value.

j.	Includes all wiring and interface with machine controller.

k.	Also includes our patented side shift feature, which permits inspection of entire roll body length during grinding operations. This side shift allows independent computer controlled movement 6 inches to either side of the grinding wheel centerline.

2.	Caliper Operational Features

a.	In process gauging and correction grinding using both probes on the roll during the grinding process. This real-time feedback allows the control to make grinding corrections while grinding, thus decreasing the grinding time.

b.	Absolute diameter measurement.

c.	Profile measurement with shape error.

d.	Roundness measurement.

e.	Permits on-the-fly bed wear compensation (for machines with worn bed way surfaces).

f.	Roll alignment is accomplished using all three measuring probes. When making a new or checking an existing setup, the operator pendant displays large meter faces showing roll alignment in both horizontal and vertical planes.

Eddy Current Inspection System

1.	Our company will provide and install a new Eddy Chek Eddy Current Inspection Unit, including:

a.	Eddy Current probe and associated wiring

b.	Signal generation

c.	Data processing and display

d.	All required interconnection cables

e.	The eddy current probe will be incorporated into the A-arm of the caliper

2.	Please see the Appendix section of this proposal for additional information about the roll inspection system and its features.

Work Bed

1.	All critical surfaces will be remachined including the way surfaces, headstock mounting surfaces and vertical bed joint surfaces. If required, bed key/key way will be reworked to suit bed elevations.

2.	The work bed will be set-up and leveled, utilizing electronic and optical measuring/inspection equipment, to ensure maximum flatness and straightness.

3.	The bed ways will be hand scraped to remove loose iron and to ensure proper bearing with the neckstands and tailstock mounting surfaces.

4.	New neckstand / tailstock traverse racks will be provided.

Headstock

1.	The headstock will be completely reconditioned.

2.	All shafts will be inspected for straightness and wear, and will be reconditioned or replaced as needed.

3.	All bearings, seals and drive belts will be replaced.

4.	All pulley groove profiles will be remachined.

5.	Adjusting guides and screws will be refurbished for proper operation.

6.	The center will be reground or replaced as required.

7.	Equalizer assembly will be completely reconditioned including equalizer bar, pins, bearing blocks, driving dogs and driving dog bolts / nuts.

8.	The grinder will be provided with one (1) set of drive dogs.

9.	A new nylon cover block will be provided for the center.

Tailstock

1.	The tailstock will be completely reconditioned.

2.	Bottom side way surfaces will be remachined and hand scraped for maximum bearing with work bed way surfaces.

3.	Quill O.D. will be prep ground, chrome plated and finish ground.

4.	Quill adjustment bore will be remachined and/or honed to suit the reworked quill.

5.	All quill adjustment mechanics and traverse adjustment mechanics will be completely reconditioned. All bearings, seals and drive belts will be replaced.

6.	Tailstock center will be reground or replaced as required.

7.	Exact alignment of headstock to tailstock centers will be accomplished in both horizontal and vertical plane to within .001" tolerance.

8.	A new nylon cover block will be provided for the center.

Neck Rests

1.	One (1) set of two existing neck rests will be completely reconditioned.

2.	Bottom side way surfaces will be remachined if necessary, and hand scraped for proper bearing with the work bed way surfaces.

3.	Based on the amount of wear and machining required, liners may be installed if required to restore the neck rests back to proper centerline.

4.	Bearing block adjustment mechanics will be reconditioned or replaced as required.

5.	Neck rests will be equipped with one (1) set of four (4) babbitt bearing blocks per your specifications.

Grinder Lube Systems

1.	The existing wheel spindle and ways lubrication systems will be replaced with completely new systems.

2.	New components would include pumps, motors, filters, valves, flow switches, pressure switches, tubing, hoses and fittings.

3.	Both lubrication systems will be adjusted to ensure proper lubrication to all lube points.

4.	Both flow switches and pressure switches will be directly interfaced to the machine controller to initiate warnings and/or controlled shutdowns to prevent mechanical damage in the event of lube oil flow or pressure loss.

Guards

1.	All belt and wheel guards will be reconditioned or replaced as needed.

2.	Additional guards and enclosures for protection of the newly designed mechanical and electrical apparatus will be provided.

Coolant System

1.	Our company will provide and install the on-board piping for coolant as well as the electrical control of your coolant pump motor.

2.	The pump, motor, filtration, and off-grinder plumbing will be on your account.

Miscellaneous

1.	All ball bearings will be replaced.

2.	All V-belt sheaves will be replaced or regrooved and balanced with new belts installed.

3.	Brackets and mounts will be fabricated and machined as necessary.

Overall Grinder

1.	The grinder will be reassembled in our shop, tested, and checked for proper operation and exact alignment.

2.	The machine vertical and horizontal alignment will be double checked against test arbors.

3.	The machine will be cleaned, masked and painted.

Electrical Upgrade

1.	A new electrical power section will be designed for the operation of all machine functions.

2.	Electrical components will be selected for use based on the application per the industrial standards and codes as outlined in the Appendix Section of this proposal.

3.	The new power section will be assembled, tested and installed.

4.	All on-machine wiring will be done in rigid or liquid tight flexible conduit.

5.	New servomotors will be supplied for the infeed, traverse and crowning axes.

6.	The spindle or headstock motors will be reconditioned and balanced.

7.	All lube and hydraulic system motors will be new.

8.	A pushbutton station and amp meter will be installed at the headstock.

9.	The main enclosure will be air-conditioned.

Electronic Control

1.	An HCC/KPM 10 multiple axis grinder control will be installed and programmed for the operation of all machine functions.

2.	The moveable operator station will be mounted in a location to provide for maximum operator convenience and efficiency.

3.	A joystick will be provided for rapid traverse and infeed positioning.

4.	A handwheel will be provided for fine positioning of the traverse and infeed.

5.	The HCC/KPM 10 will provide the ability to save and recall up to 100 grind setups with multiple phases in each part setup.

6.	On-the-fly override of grinding parameters is standard.

7.	A TFT flat screen monitor will be provided as standard.

8.	The HCC/KPM 10 control will be programmed for three-axis roll grinding operations.

9.	The HCC/KPM 10 will be programmed for electronic crowning and will include our shape development software.

10.	Additional information concerning the control system is provided in the Appendix section of this proposal. Please see the HCC/KPM 10 Control System Product Description to review hardware, block diagrams, operation, and diagnostic features.

Documentation

We will provide the following documentation with the completed machine:

a.	Three (3) sets of drawings covering all mechanical modifications.

b.	Three (3) sets of schematics covering the entire electrical system.

c.	Three (3) copies of the HCC/KPM 10 Operator Manual will be provided.

d.	Three (3) maintenance manuals will be provided.

e.	Drawings will be on our title block. Your title block can also be included.

Testing

1.	Prior to actual test grinding at our shop, we will perform the following equipment checks/tests:

a.	Drive system check with required parameters.

b.	Sequence system check with required parameters.

c.	Leveling of the machine to specific tolerances.

d.	Alignment of guides to specific tolerances.

e.	Parallelism of the tailstock sleeve to specific tolerances.

f.	Alignment of headstock and tailstock axis (Vertical and Horizontal) to specific tolerances.

g.	Radial play of grinding wheel shaft, at rest to specific tolerances.

h.	Alignment of movement of grinding wheel to axis of the roll to specific tolerances.

i.	Height of axis of grinding shaft and headstock to specific tolerances.

j.	All safety devices (mechanical limit switches, electronic limits, emergency stop circuits, etc.) will be thoroughly tested to ensure proper operation.

k.	Lubrication system pressure switches and flow switches will be adjusted and tested to ensure proper settings and operation.

l.	Caliper, axis, and testing equipment calibration and interface.

2.	The subject machine will then undergo a series of functionality tests by conducting actual roll grinds in our shop. These grind tests will be conducted by our company prior to your approval visit and by our company / Wheeling Pitt (during approval visit).

3.	When our company / Wheeling Pitt conduct grind tests during the approval visit, we prefer to utilize your rolls, wheels and machine operator.

4.	Normally, grind tests at our facility would consist of the following, utilizing your roll, your wheel, and your operator:

a.	Grind flat profile on work roll.

b.	Grind various crown profiles on work rolls.

5.	When conducting grind tests, the following guaranteed tolerances will be measured and verified using hand micrometers, electronic saddle micrometers and surface roughness gauges:

a.	Taper tolerance on roll diameter of + .0002".

b.	Shape tolerance on roll diameter of + .0002".

c.	Ovality (roundness) tolerance on roll circumference of + .0002". (Note that this tolerance is dependent on actual ovality or roundness of roll necks - as machined by roll manufacturer.)

d.	Surface finish on ground roll of + 2 RMS between any two points on body of roll for finish above 8 RMS.

e.	Eccentricity and concentricity of + .0002".

6.	Following shipment and reinstallation at your facility, the subject machine will then undergo an additional series of performance tests. We can provide personnel for these performance tests for as long as your company wishes, on a per diem basis.

… end …

PHIPPS COMPANY note: This quote was awarded to KPM in 2006-2007. In 2007 KPM performed the work and re-installed the grinder. There has been very little use since the rebuild.

PO Box 1164 ∙ Roxboro NC 27573 USA ∙ Tel: +1 336 597 2370 ∙ Fax: +1 336 597 8633 ∙ www.phippsMetals.com ∙ sales@phippsMetals.com

Owner

2017-09-12

Ron Phipps