Acceptance Tests on Machine Tools

What is Acceptance Testing ?

Acceptance Testing of a Machine Tool can be
defined as checking alignment of a component
relative to the other component.
It includes:
1.Geometrical tests or alignment tests,
2.Performance tests or practical tests.
 Equipment for Geometrical Tests
1. Dial Gauges
2. Test Mandrels
3. Straight edges and Squares
4. Spirit Levels
5. Autocollimator
6. Optical Alignment telescope
7. Waviness-Meter
 Dial gauges
Applications

 To check for Run-Out

 Consistency and accuracy in the
Manufacturing process
 Test Mandrel
 Before applying any directional measurements, the working
spindles should be tested for out of true running by means of
an inserted test mandrel
 There are preferably two types of test mandrels:
 Hardened mandrel with a ground cylindrical measuring surface
and taper shank to be inserted into the working spindle
 Cylindrical hardened and ground mandrels held between
centers
 The diameter of the mandrel should be so chosen that the sag
caused by its deadweight is negligible and to reduce the sag
the mandrels may be made hollow
 Straight edges and squares
 A square should have as wide a
bearing surface as possible

 The standard square should have a

tolerance of + 0.01 mm and the
precision square + 0.005 mm

 Where a dial gauge is to be traversed

up and down a square, the block or
cylindrical square is easier to use and
more reliable
 Spirit levels
 Spirit levels are in the shape of a vial mounted in a cast iron base
 The two main kinds are the horizontal and the frame spirit level
 Spirit levels used for high grade precision measurements having
tolerances 0.02 mm to 0.04 mm per metre
 The sensitivity of a spirit level will be defined by

𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑖𝑛 𝑚𝑚
s=
𝑡𝑖𝑙𝑡 𝑜𝑓 1 𝑚𝑚 𝑝𝑒𝑟 𝑚𝑒𝑡𝑟𝑒
 Autocollimator
 An Autocollimator is an optical
instrument for non-contact
measurement of angles

 They are typically used to align

components and measure deflections in
optical or mechanical systems

 Autocollimator with block deflector

and optical square is a very sensitive
instrument for checking deviations of
long beds in horizontal, vertical or
inclined planes
 Waviness meter
It is an instrument to examine and record
surface waviness
Leveling: Spirit levels are used almost exclusively
in the ordinary workshop to check surfaces with
reference to the horizontal plane longitudinally
as well as axially
 True Running of Locating Cylinder of Main
Spindle.
 Locating cylinder is provided to
locate the chuck or face plate.

 can’t be threaded

 The dial indicator is fixed to the

carriage and the feeler of the indicator
touches the locating surface.

 The surface is then rotated on its axis

and indicator should not show any
movement of needle.
 Axial slip of main spindle and true running of
shoulder face of spindle nose.

Axial play means the indispensable

freedom of spindle movement in axial
direction to prevent it from
seizing by heating
Axial slip is defined as the axial
spindle movement which follows the
same pattern and is due to the
manufacturing error.
 To test this the feeler of the dial gauge rests on
the face of the locating spindle shoulder and the
dial gauge holder is clamped to the bed.
 The locating cylinder is then rotated and the
change in reading noted down.
 The readings are taken at two diametrically
opposite points. The total error indicated by the
movement of the pointer includes three main
sources of errors.
1. Axial slip due to error in bearings supporting the
locating shoulder
2. Face of the locating shoulder not in a plane
perpendicular to axis of rotation.
3. Irregularities of front face.
 True running of headstock centre
 If it is not true with the axis of
movement of the spindle, eccentricity
will be caused while turning a work, as
the job axis would not coincide with
the axis of rotation of main spindle
 For testing this error, the feeler of the
dial indicator is pressed perpendicular
to the taper surface of the centre and
the spindle is rotated.
 The deviation indicated by the dial
gauge gives the trueness of the centre.
 Parallelism of the Main Spindle to Saddle
Movement
 If axis of the spindle is not parallel
to bed in horizontal direction, a
tapered surface is produced.
 Any deviation from parallelism of
spindle axis from bed in vertical
axis will produce a hyperboloid
surface.
 For this test, a mandrel is fitted in
the taper socket of the spindle.
 Mandrel has a concentric taper
shank which is close fit to the
spindle nose taper.
 The feeler of the dial indicator is
pressed on the mandrel and the
carriage is moved.
True running of taper socket in main spindle.

 If the axis of tapered hole of the socket is not concentric with

the main spindle axis, eccentric and tapered jobs will be
produced

 To test it, a mandrel is fitted into the tapered hole and readings
at two extremes of the mandrel are taken by means of a dial
indicator as shown in Fig.
 Parallelism of tailstock guide ways with the
movement of carriage.
 Sometimes the job is held
between head-stock and tail stock
centre for turning.

 In that case the job axis must

coincide with the tailstock centre.

 If the tailstock guide ways are not

parallel with the carriage
movement there will be some
offset of the tailstock centre and
this results in taper turning.
 Testing the quality of guiding and bearing
surfaces
 The useful method of checking scraped or ground long surfaces is to
pass the feeler of 0.00025 mm dial gauge over them

 No points on the surface should be more than 0.025 mm to 0.05 mm

below the real bearing spots

 The feeler of the dial gauge should be moved in several parallel

lines along the surface to be tested

 Waves on the surface of slide ways can be checked with the help of
waviness meter
 Sequence of acceptance tests
 Accuracy of the machine tool itself
 Levelling
 Erecting and setting up
 Testing guidance and movement
 Testing the axes and surfaces in relation to other important
units and components

 Accuracy of finished workpieces

 Test for power consumption
 Testing the axes, surfaces and their relations to
the other axes or surfaces
i) True Running and Checking Runout :-
 Out of roundness is the error relative to circular form of a
component in a plane perpendicular to the axis at a given
point of the component

 For a shaft, the out of round is given by the difference

between the diameter of the circumscribed circle and the
smallest measurable diameter of the shaft

 Out-of-round is the measure of true running

ii) Axial slip:-

It is the axial spindle movements which may

repeat possibly with each revolution as a
consequence of manufacturing error
Alignment or Coincidence:-

 The two lines or two axes are said to be coincident or in

alignment when at several points at some distances apart on
the given length, the deviation does not exceed a given value

 The permissible deviation of the axis is stated in the alignment

test
 Camming:-

 It is a defect of a plane surface which when rotated around an

axis does not remain in a plane perpendicular to this axis

 Camming is due to
 surface not flat

 surface and axis of rotation out of square

 periodical axial slip of axis