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When problems with machining accuracy occurs, it is necessary to investigate the cause. Often excessive backlash or axis noise develops due to various factors. This Does Not mean that the ball screw is at fault. Lost motion or noise can be from many sources, and must be properly diagnosed to avoid unnecessary expense and down-time.
Systematic Inspection
1. Clean the working area inside the machine before removing covers. 2. Remove call covers, etc., to gain access to the ball screw in question. However, keep the machine operable in order to conduct test. 3. First of all, is the ball screw and slideways getting proper lubrication? If lubrication is not present then investigate why. 4. Visually inspect the ball screw ball grove for signs of oxidation or pitting. If corrosion, pitting, or crash damage is seen the ball screw will have to be replaced. 5. Visually inspect the ball screw thrust bearing bracket, (housing) for signs of a crash. Look for loose TAC housing mounting bolts. remove and inspect the bracket taper alignment pins. If these are bent or sheered, then a crash has occurred. 6. In case of Z-Axis inspect the thrust bearing bracket for cracks around its mounting bolt holes. If cracks are present then a new bracket will have to be fitted. 7. Remove TAC bearing bracket End Cap and check thrust bearing lock nut. A. Were the mountings bolts loose??
12.
If noise is also present, and it varies it pitch thru full travel of the axis, then the ball screw may be misaligned due to a collision. Check Horizontal and Vertical alignment of the ball screw to the axis way. Parallelism should be within .015 mm (.0006) for Z-axis and .010 mm ( .0004) for X-Axis. Poor ball screw alignment can also be determined by watching the AXIS LOAD display. Load will vary significantly thru full stroke of the axis.
13.
In case of poor machining accuracy in X-Axis, The ball screw may have lost pretension. Pre-tensioning, (stretch), of X-Axis ball screw, is found on certain models. i.e. LU-15, LB Mark II Series, The Grown Lathe, The Captain, All Okuma Grinders and Machining Centers. Almost all NEW models have pre-tensioned ball screws on one or more axis. This is done to increase machining accuracy and compensated for thermal growth and ball screw deformation. There are no easy checks to evaluate ball screw stretch without disassembly . Eliminate all other possible causes first! Pre-tensioning of the ball screw on the upper turret requires removal of the axis servo motor. Also, the ball nut will have to be separated from the cross-slide so turret weight will not influence the stretch adjustment.
CAUTION!
Support the turret and cross-slide with blocks or clamps to prevent it from falling!!!!!
These systematic inspection checks are for reference. Detailed procedures for conducting some of the checks required are covered later in this manual.
Fig. 3-1
X - AXIS
Micron Indicator
PROCEDURE
1. Set up an indicator and base as ridge as possible in an appropriate position to check the axis in question. Keep the mag base stems as short as possible. 2. In manual mode, position the axis on the indicator and calculate X and Z axis zero using an unused tool offset. See the illustration on page 1. 3. Enter the test program into the control. Refer to figures 1 and 2 on page 4 for example programs. 4. Start the program in single block to prove out each move before allowing the cycle to run full automatic. At this time the indicator can be set to zero. 5. The program is allowed to run seven to ten times while noting repeatability and lost motion. Do not run the program too many times or excessive heat will be generated within the ball screw and thrust bearings causing abnormal thermal drift. Run program in rapid and feed modes. Final backlash setting is the average of both feed and rapid modes. Caution Do not very the feedrate override when recording data, test results will vary. otherwise
CALCULATING DATA
1. The first move to the target position is taken as repeatability and recorded as " A ". The reversal move to the target position is recorded as "B" and is used in calculating total lost motion. 2. Lost Motion is calculated by taking the difference between "A" and "B".
Note
Pay close attention to the signs when recording the indicator readings, ( + / - ). Lost Motion = Gained Motion = " B " more positive than " A " . " B " less positive than " A " .
3. When the data indicates lost motion, the current backlash compensation data is insufficient. Compensation data must be increased. 4. When the data indicates gained motion, the current backlash compensation data is excessive. Compensation data must be reduced.
Note
TYPICAL BACKLASH COMPENSATION VALUES. X-Axis : Z-Axis : .010 mm ~ .040 mm .000 mm ~ .020 mm
TYPICAL THERMAL DRIFT X-Axis : Z-Axis : .003 mm ~ .005 mm / 10 times .005 mm ~ .010 mm / 10 times
X-
Caution
AXIS PROGRAM
If you are not experienced in operating the machine in automatic mode, have someone assist who is familiar with running the machine. Failure to do so may result in personnel injury or machine damage.
G13 or G14 G90 G94 N10 G0 X100.0 Z100.0 T?? /G01 F2000 X0.0 Z0.0 F2000 G4 F5 Z100.0 X-100.0 X0.0 Z0.0 F2000 G4 F5 Z100.0 X100.0 GOTO N10 M2
( Four axis machines only) ( Absolute Positioning ) ( Set feed per minute mode) ( Rapid mode with block delete ON ) ( Feed mode with block delete OFF ) ( Move to target point A ) ( Move to indicator) ( Dwell for 5 seconds) ( Move off indicator) ( Move to second reference point) ( Move to target point B) ( Move to indicator) ( Dwell for 5 seconds) ( Move off indicator) ( Move to Start Point ) ( Repeat cycle) ( End of Program )
Note:
Example: T32 = Tool Offset #32. No actual tool station is called. No turret indexing should occur.
X-Target Pos.
A
(A-B)
For X-Axis
Backlash = (Average @ Rapid + Average @ Feed ) In diameter
B
Rapid
Z-AXIS PROGRAM
G13 or G14 G90 G94 N10 G0 X100.0 Z100.0 T?? /G01 F2000 Z0.0 X0.0 F2000 G4 F5 X100.0 Z-100.0 Z0.0 X0.0 F2000 G4 F5 X100.0 Z100.0 GOTO N10 M2 ( Four axis machines only) ( Absolute Positioning ) ( Set feed per minute mode) ( Rapid mode with block delete ON ) ( Feed mode with block delete OFF ) ( Move to target point A ) ( Move to indicator) ( Dwell for 5 seconds) ( Move off indicator) ( Move to second reference point) ( Move to target point B) ( Move to indicator) ( Dwell for 5 seconds) ( Move off indicator) ( Move to start position ) ( Repeat cycle) ( End of Program)
Rapid
Rapid
Fig. 3-5
Backlash
Fig. 3-6
Fig. 3-7
Check Bolts
Check Bolts
0 + 50 50
Elongation
Checking Method
Bow
Fig. 3-7
1. Place a ball bearing in the center hole at the driven end of the ball screw using grease. 2. Set up an indicator as shown in Fig. 3-8 to observe the amount of end-play or deflection in the screw while jogging the axis back and forth near the headstock side.
Pulley .010 mm ( .0004 ) Maximum
Free End
Fig. 3-8
Rear Bracket
0 + 50
Steel Ball
3. If deviation is as shown in Fig. 3-9, there is possible end-play in the TAC bearings. 4. If deviation is as shown in Fig. 3-10, check axis lubrication and axis gibs. 5. Heavy binding can be also determined by observing the axis load display. 3- 10 Machine Tool Systems, Inc.
0 + 50
50
50
Procedure
1. In order to check alignment you must have a fixture block which locates on the DATUM way as shown in Fig. 3-12. This block is precision ground and hand scraped to have a good bearing. 2. First, position the saddle at its mid-travel. 3. Clean the axis way of all chips, build up, and excess way lube oil. Especially where the ball screw enters each bearing housing. Alignment is checked at each end of the ball screw in both the horizontal and vertical planes. The ball screw must be parallel to the axis way within .010 mm ~ .015 mm ( .0004 ~ .0006 ) full length. Fig. 3-11
Fig. 3-12
4. Before alignment check can continue, you must find and mark the mid-point of total run-out in the ball screw near the thrust bearing end. as shown if Fig. 3-13. This is done to compensate for run-out of the screw shaft over its length.
Run-out Mid-Point
A
0 + 50 50
+
Fixture Block Low
High
Fig. 3-13
Continued >>
Ball Screw Maintenance.pub
B
0
Datum Way
Fig. 3-14
Run-out Mid-Point
Low
Fig. 3-16
Saddle
0 + 50 50
Correcting Misalignment
Correcting misalignment is done in reverse. That is to say, the indicator is set up and zeroed at the driven (free) end first. Then, the TAC bearing position is checked and adjusted in the horizontal plane until alignment is within spec.
Why in reverse?
in most cases the bearing housing at the driven end does not move during a crash. Therefore, its position is usually ok, and can be used as a zero reference. Float Alignment
A B
Taper Pins
Mounting Bolts
Bolts
Taper Pin
Fig. 3-18
B
0
Zero Reference
Datum Way
Fig. 3-14
Adjustment
13. If alignment is not within allowable range, then adjust the position of the TAC bearing housing as necessary. If readings are ok, skip to step 15. 14. Repeat steps 11 thru 13 until alignment is correct. 15. When alignment is correct, torque each bolt on the TAC and ball nut brackets to 70% of their rated torque. 16. Remove taper pins from TAC and ball nut brackets, and lightly re-ream each hole. 17. Install new pins. They should be taped down tight. However, ensure that they do not cause the TAC or ball nut brackets to move during installation. 18. Re-check alignment. 19. Check axis motion for noise, excessive load, etc. 20. Check overall repeatability and adjust backlash compensation as necessary. 3- 15 Machine Tool Systems, Inc. DONE
Ball Screw Maintenance.pub