Machine tool measurement

Mohak Patel

1st November, 2011 9003045

Background
The surface of components produced by machining processes is mostly by generation. As a result, the quality of surface produced depends upon the accuracy of the various movements of the machine tool concerned. It therefore becomes important to know the capability of the machine tool by evaluating the accuracy of the various mechanisms that are directly responsible for generating the surface. For this purpose, a large variety of tests have been designed to test quality of slide-ways, accuracy of the spindle and alignment tests. Lathe is one of the most important instruments used in the manufacturing industrial sector. The geometrical test specifications of a lathe are as follow: The accuracy with which the machine has been manufactured. Installation and levelling of the machine. Tests the quality of slide-ways and locating surfaces. Tests the accuracy of the main spindle and of its alignment relative to other important parts of the machine. The accuracy of the workpiece produced on the machine. Power requirements.

The parallelism of spindle with lathe machine beds and the alignment of the spindle in lathe are most important requirements.

Equipment used in testing: Dial-gauge: A dial test indicator consists of a gauge; on the gauge is a pin level mounted on a spring. When the pin contacts a surface, pressure forces the pin lever up, causing the dial gauge to move. Numbers marked on the perimeter of the dial test indicator display the amount of pressure applied to the pin lever. Comparing multiple points will show variances in a material.

Test Mandrels: Test mandrels of large variety are used in machine tool for various purposes. As a result the quality of test mandrel is important. In case of large length mandrels, careful consideration will have to be given to the deflection of mandrel due to its own weight.

Aim
To find the accuracy of the lathe machine by measuring the run out and the axial slip of the spindle.

Procedure
Using the dial gauge: 1. Measure the parallelism between the mandrel and the carriage longitudinal movement in horizontal and vertical direction. 2. Measure the run-out of the mandrel at 5 different points. 3. Measure the axial slip of the spindle.

Observation
We start from the farthest end of the mandrel, we call it position 1 and start moving towards the spindle, with the point closed to the spindle called position 5. Without tail stock:

Position

Distance from position 1 (cm) 0 5 10 15 20 25 30

Axial Slip (m) 0 27 58 79 103 124 144

Maximum Height (m) 733 668 610 540 476 412 343

Minimum Height (m) -150 -164 -144 -120 -110 -97 -88

Run Out (m) 883 832 754 660 586 509 431

1 2 3 4 5 6 7

With tail stock:

Position

Distance from position 1 (cm) 0 5 10 15 20 25 30

Axial Slip (m) 0 -19 -27 -60 -81 -100 -115

Maximum Height (m) 40 55 88 133 142 177 177

Minimum Height (m) -6 -10 -22 -24 -37 -39 -45

Run Out (m) 46 65 110 157 179 216 222

1 2 3 4 5 6 7

For Spindle: Maximum Height (m) Minimum Height (m) Run out +45 -46 91

Conclusion
Without using tailstock the axial slip was found to increase with distance from the mandrel end and the run out was found to be decreasing as we move closer towards the spindle. While using with tailstock the axial slip was found increase with distance from the mandrel end but the magnitude was smaller this time. But run out was found to be increasing as we move towards the spindle. The use of tail stock decreases the wobble and axial slip. The spindle also had some run out which caused the spindle and the mandrel to wobble.

Sources of error
The dial gauge was very sensitive. While noting the reading, the pointer of the dial gauge was found to suddenly jump to other readings. The surface wasnt smooth; this might bring in some error.