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Lecture 14 - ACCEPTANCE TEST

The document discusses accuracy tests performed on machine tools to determine their geometrical accuracy. It outlines various factors that can cause machining errors and affect accuracy. It also describes typical accuracy tests done on surfaces, positions, motions, and methods used to test straightness, parallelism, and other attributes.

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63 views

Lecture 14 - ACCEPTANCE TEST

The document discusses accuracy tests performed on machine tools to determine their geometrical accuracy. It outlines various factors that can cause machining errors and affect accuracy. It also describes typical accuracy tests done on surfaces, positions, motions, and methods used to test straightness, parallelism, and other attributes.

Uploaded by

Movie 6890
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ACCEPTANCE TESTS OF

MACHINE TOOLS
 The machining accuracy of a machine
tool is characterized by the
magnitude of the deviations in size,
shape and relative positions of the
elements of the surfaces obtained
from the corresponding parameters of
the given geometrical surfaces.
Factors that cause machining
errors
 Various factors that cause machining
errors and affect the machining accuracy
are:
(1) geometrical accuracy of the machine tool-
fixture-cutting tool-workpiece complex, or
system
(2) temperature deformations of the
system;
(3) processing rigidity which characterizes
the deformation of the system under load;
(4) stability of the system in setting up the
work, traversing the units during
machining;
(5) forced vibrations; and
(6) Dimensional wear of the machine tool.

 All of these factors, except the geometrical


accuracy of the machine tool, are variable and,
to some extent, controllable.
 Their influence on the accuracy of the
workpiece can be reduced by changing the
cutting speeds and/or feeds and other
machining conditions.
 Therefore the attainable accuracy will be
determined in general by the geometrical
accuracy of the machine tool.
 The geometrical accuracy characterizes the
quality of manufacture and assembly of the
machine tool, hence it is one of the important
characteristics of machine tool performance.
 In conducting tests and research in the
geometrical accuracy of machine tools, of
prime importance are the conditions under
which the measurements are made.
 The machine tool should be installed and
leveled in the same way as for regular
operation.
 Certain machine tools, mainly small ones
with a very rigid bed, are installed for
testing on three points of support.
 The great majority of machine tools are
installed in the working position and leveled
to spirit levels on a rigid foundation on
more than three supports.
 The foundation bolts are not drawn up
before the tests.
 Using wedges or adjustable shoes, the bed
or base of the machine tool is positioned so
that the deformation of its ways, measured
by the spirit levels, is at a minimum.
 All traveling parts of the machine tool are
put in their middle positions.
 Accuracy tests usually follow the idle-run
and load tests.
 The influence of the temperature on the
results of the measurements is eliminated
to the greatest possible degree.
 The total volume of tests is determined by the
corresponding accuracy standards followed
during the test.
 Some of the tests which are performed for
determining the accuracy of lathe and milling
machines following the ISO standard are listed
in the table shown in Appendix I.
Typical checks usually include:
 Accuracy tests on the geometrical shape of
mounting surfaces (straightness, flatness, out-
ofroundness, taper, etc.);
 Relative position of surfaces (parallelism,
squareness; and alignment);
 The shape of the path of motion of operative
members of the machine;
 co-ordinate positioning motions and
 kinematic chains.
The principal measuring tools used in
geometrical accuracy tests are:
◼ straight edges
◼ squares
◼ gauge blocks
◼ thickness gauges
◼ stub or centre-type test mandrels
◼ dial indicators
◼ various types of levels
◼ optical instruments.
The straightness of machine tool
components may be determined :
 By optical sighting method (Fig. 284c);
 By measurements along a taut wire (Fig. 284a);
 By measurements made by means of a straight
edge,
 By means of gauge blocks and a thickness gauge; or
 By the hydrostatic method (Fig. 284b).
 By an alignment telescope and collimator (Fig 284
d)
Fig. 284
 By an auto-collimator, combining the light
source and the eye piece in a single
housing (Fig. 284 e).
 The initial straight line, in reference to
which measurements are made by these
methods, is the optical axis of the
alignment telescope, the horizontal
projection of the taut wire, the working
surface of the straight edge or the water
level, respectively.
 Depending upon the adopted method, the
instrument is slid to elementary positions:
0, 1st, 2nd, . . ., and nth.
 At each position, the deviation hlin i of the
elementary plane surface on the way is
recorded in reference to the initial straight
line.
 Due to the misalignment between the
direction of the way being tested and that
of the initial straight line, the deviation hlin n,
measured on the last section, is the
accumulated error.
 By calculating the constant error
bi = (hlin n, i)/n,
where i is the number of the elementary
plane surface,
 the deviation from straightness in the form
is calculated as follows:
hi = hlini - bi.
 A curve is plotted using the calculated
values of hi to obtain a scaled
representation of the actual shape of the
ways.
 An example of such a curve is illustrated in
Fig. 285.
Accuracy Tests Recommended by ISO
 Following Tables (Appendix I) show some of
the accuracy tests required to be performed to
ascertain the geometrical accuracy of a
machine tool.
Appendix I

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