TESTING OF MACHINE TOOLS

After manufacture or repair of any machine tool, a machine tool test (usually called
an acceptance test) should be performed according to the approved general
specification. Such tests are essential because the accuracy and the surface quality
of parts produced depend on the performance of machine tool used. Testing
machine tools has the following general advantages:
1. Determine the precision class and the accuracy capabilities of the machine tool
2. Prepare plans for preventive maintenance
3. Determines the actual condition and hence the expected life of the machine tool
Machine tool tests are classified in to two categories: geometrical alignment tests
and performance tests.
Geometrical tests cover the manufactured accuracy of machine tools. These tests
are carried out to determine the various relationships between the various machine
tool elements when idle and unloaded (static test). They include checking parallelism
the spindle and a lathe bed, squareness of the table movement to the drilling
machine spindle, straightness of guide ways, and so on. The normal procedure for
acceptance tests is made through the following steps:
1. Checking the principal horizontal and vertical planes and axes using a spirit level
2. Checking the guiding and bearing surfaces for parallelism, flatness, and
straightness, using dial gauge, test mandrel, straight edge, and squares
3. Checking the various movements in different directions using dial gauge, test
mandrel, straight edge, and squares
4. Testing the spindle concentricity, axial slip, and accuracy of axis
5. Conducting working tests to check whether the accuracy of machined parts is
within specified limit
6. Preparing acceptance charts for the machine tool that specify the type of test
and the range of allowable limits of deformation, deflection, error in squareness,
flatness, eccentricity, parallelism, and amplitude of vibrations.
Static tests are inadequate to judge the machine tool performance, because they do
not reveal the machine tool rigidity or the accuracy of machining.
In contrast, dynamic tests are used to check the working accuracy of machine tools
through the following steps:
1. Performing the idle run test and operation check mechanisms
2. Checking for geometrical accuracy and surface roughness of the machined parts
3. Performing rigidity and vibration tests

The important geometrical alignment tests carried out on spindle during

the acceptance testing a lathe are trueness running (rotation), axial slip,
and parallelism (or perpendicularity) between the spindle axis and slide ways.

For checking the true running of a spindle, a cylindrical mandrel having a locating
taper shank is inserted in the spindle taper. The spindle is allowed to run for about
half an hour to let the bearing attain its normal running temperature. A dial gauge is
held stationary with its plunger contacting the mandrel near its free end. Readings on
the dial gauge are taken while the mandrel is slowly rotated. The procedure is
repeated with the dial gauge plunger positioned near the spindle nose. Imperfections
in the thrust bearing of the spindle are manifested in the form of axial slip. It is
measured by placing the plunger of the dial gauge against the shoulder face of the
spindle. Readings of the dial gauge are taken while the spindle is slowly rotated.

1|Page
Parallelism between two axes (between the axis of the main spindle and axis of slide
ways of a lathe) is checked by fixing a test mandrel in the spindle taper and a dial
gauge base is fixed on the saddle. The plunger of dial gauge is made to touch the
mandrel and the saddle is slowly moved. Any variation in the readings of the dial
gauge indicates departure from parallelism. Measurements are carried out in two
planes, e.g. when the plunger is vertical and when it is horizontal.

In order to check the perpendicularity of the cross-slide movement to spindle axis, a

straight edge may be fixed to the cross-slide in such a manner that it is exactly
normal to the spindle axis. This can be done by making the dial gauge readings
equal at two diametrically opposite positions while the cross-slide stationed

2|Page
approximately midway on its ways. The cross-slide is then slowly moved while dial
gauge is held in position. Alignment errors if present are detected by variation in dial
gauge readings.

The important geometrical alignment tests carried out on spindle during

the acceptance testing a Drilling machine:
(i) Spindle True running:
The test mandrel is placed in the tapered hole of the spindle end and a dial
indicator is fixed on the table and its feeler made to touch the mandrel at point A.
The spindle is rotated slowly and readings of indicator noted down. In the similar
way the feeler of the dial indicator made to touch the mandrel at point B and
spindle is rotated slowly and readings of the indicator noted down.

(ii) Spindle Square with the table:

This is performed by placing the straight edge in positions AB and CD. A
horizontal rod is fixed to the spindle, with a dial gauge, attached at a radius of
about 250mm and its feeler is made to touch the straight edge first at A and
readings are taken. Then the spindle is rotated by 180 0 so that the feeler touches
at point B and again the reading is taken. The difference of these two readings is
the error in the squareness of the spindle axis with the table. Similar readings are
taken by placing the straight edge in the position CD.

3|Page
(iii) Spindle slides perpendicular to the table:
The dial gauge is held in the spindle with is plunger horizontal and bearing on the
vertical edge of the true square which rests on the table. Any variations of the dial
gauge readings, as the spindle is moved up and down, measure the error. The
test should be performed with the spindle near to the column and also at the end
of the arm.

4|Page