TESTING MACHINE TOOLS By DR. GEORG SCHLESINGER Seventh Edition (Second Impression) Revised by F, KOENIGSBERGER D.Sc., Dipl.-Ing. M.I.Mech.E. For the use of Machine Tool Makers, Users, Inspectors and Plant EngineersPLANT ENGINEERING DEPARTMENT TESTING MACHINE TOOLS For the use of Machine Tool Makers, Users, Inspectors and Plant Engineers + WHEELS INDIA LTD, n aRN em By. PADI, MADRAB-600080, DR. GEORG SCHLESINGER WHRELS INDIA LIMITED Plaut ag Dept Dae 191-77 Seventh Edition (Second Printing) Revised by F. KOENIGSBERGER D.Sc., Dipli-ing., Ml.Mech.€, With 44 Inspection Charts i@ THE MACHINERY PUBLISHING CO., LTD. Heod Office: NEW ENGLAND HOUSE, NEW ENGLAND STREET, BRIGHTON, | Registered Offce; CLIFTON HOUSE, 83-117, EUSTON ROAD, LONDON, NW. “THE INOUSTAIAL PRESS, 93, WORTH STREET. NEW YORK, 10012, NX.First Published ("Inspection ‘Tests on Machine Tools") 1932 Second Edition ("Testing Machine Tools”) 1938 hitd Edition 0 1940 Fourth Edition : 1948 Fifth Edition 19 Fifth Edition (Second Printing) —« 1951 Filth Eeition (Thied Printing) ws Sixth Edition. noe 1961 Seventh Edition. ++ 1966 Seventh Baition (Second Printing) 1910 © THE MACHINERY PUBLISHING CO., LTD. All rights of, reproduction revereed by the Publishers by Ghriue of the Universal Copyright and Interationol Copyright Uru and. Berne) Conventions and throughout the World Printed in Great Britain by ‘The Whitettars Press Ltd ‘London and TonbridgeJd bs @ Jd CII ISIS SAAS IA ES EF EIS td dS FES SIE Preface to the Seventh Edition 'HE original German Edition of the “Prafbuch fir Werkzeugmaschinen” as well as its translations in many languages have been intimately connected with the personality of the author. In 1901 Schlesinger started the work of establishing acceptance standards for machine tools, and in 1927 he published for the first time a comprehensive series of acceptance test specifications for machine tools. ‘Today this work has been carried on both in the national and international field, and after several countries have developed national standards it would appear that agreement on an international basis will be reached in the not too distant future. Schlesinger himself was a great believer in the importance of international standardisa- tion, and before the Second World War he was an active member of the 1.8.4. Committee 39 (now Committee 1.8.0./TC39, Machine Tools), It is to be hoped that this work will soon lead to the publication of 1.8.0. standards. Nevertheless, the continuing demand for Schlesinger's book would appear to indicate the need for a further edition. This, however, is not intended to compete in any way with the I.S.O. or any other standards but should serve as a complementary publication in which Schlesinger’s ideas of specifying and executing acceptance tests are shown in their logical development. For this reason the work of revising the Fifth Edition was concentrated on the introductory text, pages 1-44, and especially on those points which appeared to have given rise to doubts or misunderstanding, rather than on modification of the actual Test Charts. Changes in the latter were introduced only if either errors or difficulties in the application of existing specifications had been reported to the undersigned. No attempt has been made to adapt the form or contents of the Test Charts in any ay to existing national or international standards. Such an adaptation would be of little if any value; if acceptance tests in accordance with definite standards are specified by a supplier or a customer, only the latest issue of the appropriate standard specification must be employed for carrying out the tests. As, however, most existing standard specifications appear to be based on ideas laid down in the original Schlesinger Test Charts, the discussion of the basic principles and the explanation of testing procedures retain their general value. ‘The new edition is intended to continue the tradition of previous editions to the effect that it should not only assist in teaching the beginner but also advise the more experienced test engineer when he encounters problems outside his field of experience. Mention may be made of a discrepancy between the English and German versions of| est Chart 13, Figs. 8a, 80 and 11a. If these are compared and reference is also made to previous editions, the following will be found: LL. Edition Fig. 84 85 Fig. 1a First (1932). ++ 010001 per 0100-01 per 0 to 001 per 300 mm, 300 mm, 300 mm. Second (1938) and following 0 to 0-01 per 0 to 0-005 per 0 to 0-01 per 300 mm, 300 mm, 300 mm, In the German version, these tolerances were as follows: LLLLLLL LiL Edition Fig. 83 Fig. 88 Fig. La First (1927). s+ Oto 0-01 per 010001 per 0 to 0-01 per 300 mm. 300 mm. 300 mm, Second (1931). s+ Oto 001 per 0100-01 per 0 to 0-01 per 300 mm. 300 mm, 300 mm, ‘Third (1939) ++ 000-02 per 0100-01 per 0 to 0-02 per . 300 mm. 300 mm, 300 mm, my Fourth (1949). s+ 010002 per 0 t00-01 per 0100-02 per Sy 300 mm, 300 mm, 300 mm, ~t Fifth (1951). ++ 00002 per 0100-01 per 0 to 0-02 per —t 300 mm, 300 mm. 300 mm, i L From the above it would appear that Schlesinger left the tolerances for Figs. 8a and 11a in the English version and halved the tolerances for Fig. 88, probably at the request of British manufacturers. On the other hand, in 1939, i.e. one year later, the tolerances for Figs. 84 and 11a in the German version were increased, probably at the request of the German industry. It would seem, therefore, that Schlesinger had a definite reason for increasing the tolerances in the German version. However, the undersigned has advised the publishers of the German version to bring the tolerances in the German version in line with the English version if this appears desirable. ‘The undersigned is grateful to the many firms who assisted him by critical comments on previous editions. ‘They appear to indicate that even today, over 30 years after the publication of the First Edition, the Schlesinger standards are still widely and satisfactorily used. Finally, the undersigned would like to express his thanks to his friend and colleague, Dr. J. H. Lamble, for reading through the script. F. KOENIGSBERGER. LLYLLLLLELLELL yehIndex to Contents eww ee Yee vo CVV ISUGTUUEe ee | Introduction wees Principles of Acceptance Tests ewe ‘The Machine Tool under Load. _ Execution of Acceptafce Tests Measuring Equipment and Method Dial Gauges ‘Test Mandrele Straight-edges and Squares. Spirit Levels Level Measurement by Water Level Alignment by Wire and Measuring Microscope ligament by Telescope and Target Magnitude and Direction of Tolerances Straightness of Slideways and Flatness of ‘Tables ‘Alignment and ‘True Running of Shafts. Lead or Pitch Error of Lead-serews igh Errors of Gears and Dividing Errors of Dividing Heads Desails for Testing Various Machine Too!s Surface Quality : Power Requirements, Speeds and Feeds Minti Macianes (1-4) aso Guan Currinc: Macuises (6-7) 1. Knee-type Hovizoneal Milling Machines Universal Milling Machines 1a, Dividing Heads and 2. Surface Milling Machines 3. Vertical Milling Machines 4. Thread Milling Machines 6. Spur, Worm and Helical Gear-hobbing Machines 2. Gear Shapers Crema Lani, Tuaner Lavis, Mucri-srixptt ‘Avrouamies, Vextieat Howne Mitts (11-20) 1A, inih, Taming Lashes op to 400mm. (bout T5$ in) Height of Centeca 12, Finigh Tuming Lathes with from 400 to 800 mm. (about 15 in. to 32in) Height of Centres ‘Tool-room Lathes (highest degree of accuracy) up e200 mn. (about bin) Heh of Centres, 14, Backing-off or Relieving Lathes 15. Facing Lathes 16. Turret Lathes arranged for Cylindrical Tool Shanks inthe Turrer Fleads, and Single-spindie Automatic ‘Rarer Lathes up to. 300mm. (about Helght of Centres 5 ‘Turret Lathe with Hollow Turret Heads provided ‘with Censrng Recestes for Tool Holders up to 4300'mm. (abour 12 in) Height of Centres 17, Turret Lathes arranged of Cylindrical Toot Shanks “the Turret Heads and Single-spindle Automate $Puree Lathes with more than 300 rm. (1210) Helgi of Centres 17a, Turret Lathes with Hollow Turret Heads provided Wwith Gentsing Recetses.” Height f Centres more Than 500 mime (2nd = 1. Tin) 9 “ 4 “6 ” “ o so s st ss 56 37 58 Co 6 a 6 184, Muli-apindle Automatics (Rotary Work and Stationary Tools) 3 18b. Multi-spindle Automatics (Stationary Work and Rotary Tools) 6s 19, Vertical Boring Mills (Vertical Lathes) 66 20. Double-standard Vertical Boring Mills .- Cy Gronpine Macuiss (21-26) 24, Cylindrical Grinding Machines 7” 22, Planer-type Surface Grinders n 23, Vertical Surface Grinders n 24, Surface Grinders with Horizontal Wheel Axis B 25. Surface Grinders with Vertically Adjustable Horizontal Wheel Spindle ” 26. Universal Tool and Cutter Grinders 7s Drittixe AND Honizontat Bonne Macnses (21-38) 31, Upright Drilling Machines 32, Pillar Type Drilling Machines « 33, Mult-spindle Drilling Machines 34, Ragial Drilling Machines 35. Hoxizontal Boring Machines with Spindles up to ‘BOmm. (about Sin.) diameter 36, Horizontal Boring Machines with Spindles more than 80 mm. (bout 3% in) diameter 37, Horizontal Boring Machines with Adjustable ‘Colurnns : é 38, Horizontal Uoring Machines with Fixed Headstocks Puwsinc, SiaPiNG, AND SLorTiNG Macuines (41-44) 41, Planing Machines (Double Standrd) 42, Openside Planing Machines 43, Shaping Machines 44, Slotting Machines. Shame, PUNCHING, StaxriNc ‘Maciunts Nb Presses (51-83) Si, Open-fronted Power Presses and Punching Machines 32, Double Standacd Power Presses and Punching ‘Machines 53. Shearing Machines and Guilloines Woonwonkinte Macianss (61-70) 61, Cvgular, Sums, aging Saws, Crowe Custing end “renching Ntashines 62, Band Saws 63. Fret Saws 64. Frame Saws, Multiblade 65, Surface Planing Machines 66, Thicknessing Machines f 67, 4-Cuuter Planing and Moulding Machines 68. Vertiea! Spindle Moulders 68. Chain Morsing Machines 70, Wood Turning Lathes 6 n a n st 8 82 3 oy 85 37 88 fo 90 oo 2 7 3 oe oo 9s 9s % 96‘machine tools specified in this book are intended to serve ab a basis for acceptance tests of high-quality machine tools, The experience of machine-tool manu: facturers and users has been used in their compilation. Although the instructions were originally intended only for application to new machines, they have also been successfully used for the testing of reconditioned machine tools and for general maintenance work, TT instructions for the inspection and testing, of Closer Tolerances than those Specified Machine tools which satisfy the accuracies specified in this book will produce components which will mneet the requirements of modern production in accordance with standard limits and fits. If, however, closer tolerances sre needed, these can only be obtained by expensive additional ‘operations and tedious selective assembly. ‘This may be the case, for example, if special lead-screws PLANT Fi: WHEELS INDIA LIMITED INTRODUCTION Pn Plant Snginwring Dept for lathes or dividing heads for milling and grinding machines are to be produced. Such requirements, which are_-necessary only in exceptional cases, will result in additional cost. ider Tolerances than those Specified For the manufacture of components to medium or coarse tolerances, the use of the high-precision machine tools covered by this book may not be nesessary. In such cases wider tolerances, which may exceed the limits specified in this book by 50'or even 150 per cent in accordance with the machining accuracy required, may be permissible. “This widening of tolerances will, however, not apply to all values specified in the text charts, It’ would then be necessary, therefore, for manufacturers and purchasers to come to a detailed agreement on the tolerance values prior to a purchasing contract being signed, 28 the price of the machine will, of course, depend on the arrangements made. PRINCIPLES OF ACCEPTANCE TESTS Where and How the Tests are to be carried out In general, the tests should be carried out at the manu- facturer's works. It is hardly possible for the machine-tool manufacturer to assume the responsibility for the consequences of treatment to which machine tools are subjected whilst being transported from the works to theie destination. Machine tools are very sensitive to impact or shock; even heavy castings are not always solid and rigid enough to withstand stresses caused by a fall during ‘eansportaton, which may ent in, deformations and posubly cracls thereby rendering the entice michine Moreover, the machine is always carefully adjusted and aligned during assembly or on the test stand at the manufacturer's works, whereas experience has shown that rection in the workshop of the user is not always carried fout with” sufficient’ are, Sometimes, for reasons of economy. pariculary in the case of heavy machines, foundatidns are made too light and are not extended to a sufiient depth.” Faulty erection may cause working inaccuracies which may then wrongly Be blamed on the machine. Also, at the manufacturer's plant, skilled men are avallable together with the necessary testing equipment, ‘which is only obtainable with diffculty outside the esting department Obviously, the purchaser of a machine is fully entitled to fepeat the tests in his own works, but if iis fis intention todo so he shuld hye at ho disposal al the necoary festing equipment and an experienced inspection staf ‘The manufacturer's txt char, copy of which fe eupplid to the buyer, should serve as & guarantee thatthe machine has been tested in the manufacrurer’s works under precisely the conditions (on a concrete foundation or east-iron base plats) under which it wil Iter have to work. As a rule castiron base plates are unsuitable for heavy machines because they eatnot be provided with access openings wich may often be equired. "On the other hand, ivis undesirable to install expensive permanent foundations which may have to be removed ata Inter date In the event of any complaint, the manufacturer can refer to his own test records, and insist that in the user's plant the same conditions are established as those under which the machine was originally tested. ‘Tests carried out by the user are to be regarded merely as a confirmation of the results supplied by the manufacturer. “Tu Paseision Tests Coven vie Grave oF AccuRACY oF ‘ont Macutve Toot TF, 480, WESHVER FRASIBLE, ALSO tts Worsixe Accunacy..” Primarily, the degree of the Imanufacturig accuracy of the machine took tel isto be tested, re. the accuracy with which the machine has Deen assembled, This is messured while the machine is idle fd fee of any loa. In the majority of eases, working limits to be attained with sheesh opto re specie tthe end othe test charts. "These apply to inishing operations only. A finishing eut on's lathe, for example, hus been defined a tne producing a chip af about 0110 02 milimetre (0008 10-0408 inch} depth and G05 10 O' millimetre (0.002 to (004 inch) feed, taken with the highest speed which is permissible for the material ofthe werkpioce and the too he resulting machined surface must be smooth and wiht cater marks whith would ide nadie Dring such cutting texts the vatious sucaces of the smachine eannot be kep free fom colant, sat and chips, nd these tests should be caried out before the final painting operations, In cass where, in view of high cows, becuse ofthe lack of the necessary foundation for heavy machines or for ther resons, i sot patible 0 cary out futing operations, the degree of working acouracy may be “gesured of “promised * ol ‘The manufacturing accuricy of the machine and the accuracy of the finhed workpiece are interconnected ‘When a machine tol is assembled from components which have been machined to gauges, the unavoldable machining rors have to be adjusted during assembly in auch @ Tanner thatthe Bnished machine tol all produce work Pisces within the’ required “limits, ‘Phe accuracy Performance of the machine is spciied atthe end ofeach CN ERRTYG TAPARTchart. Recommended procedures for testing the working accuracy of lathes, milling, grinding and drilling machines are given on page 42 e119 ‘The author considers it wrong to draw a dividing tine between practical and. geometrical tests. ‘The so-ealled practieal eats check the atcuracy of the finished component, Whilst the geometrical test. cover the manufacturing curacy af the machine. oth inessurements are practical dndsh orm part of oe inde whl Neth: the lier nor the manufacturer can. dipense with elther of These ‘tet. The reason for giving. prominence, to. tie ‘manufacturing accuracy” of the tathine in. the. (et recreate fat shat 1 covers he whole machine nd can be caried out unambiguously and. without Slifiuly. ‘The eating text can only be carried out for random sizes and. conditions, for. Otherwise the. time necesary for thet exceution and their costs would be prohibitve. ‘The degree of working accuracy of the machine, besides depending onthe machine itself aso influenced by such other factors 28: 1. The type of cutting tool and its condition (rake angles, hardnes, eccentricity in the case of milling cutters, ete.); . The tool holder (e.g. milling arbors); }- The cutting speed, feed and chip section: |. The material to be machined; ‘The shape, size and rigidity of the workpiece; 5. ‘The chucking or clamping equipment; The skill of the operator. is, therefore, not always practicable to guarantee the obtainable degree of working accuraey. Limited or ‘conditional “assurances” or “promises, not binding in law, frequently can only be given to the effect that the machine, when properly erected and applied in conformity with ite design and when proper tools are used, will meet the specified degrees of working accuracies. In anc of the ath te cating et ene ny he turning bf eylindrieal parts ang the cutting of sew threads ove No. the headstock. “This procedure adopted Cohether short of very long machines ae being tested. As the later may have to be used over ther full Tength, even 2 numberof fandom cting tests would ot give suliient guarantee for their accuracy 3t any part of the bed. Tes Ei'more diffele to. check the serew-cutting. accuracy ver the full length of the machine, io order to make eran that accurate serew threads can be cut in spite of posible errors in the spindle, the Teed drive, the lead Eofewe, the sideways, ete. “The text of the accuracy with Which he machine has becn manufactured covers, however, every point ofthe machine over i full length In the case of milling machines, the factors previously stated have a8 much influence as the quality of the machine itself, and promises concerning the degree of working accuracy can only be made with certain reservations. Nevertheless, reputable milling-machine manufacturers ‘eat their machines very thoroughly, using a large variety ‘of tools and different workpiece materials before starting a full programme of production. Planing machines are often used for the machining of caning which may note fee of internal ree and ‘which are lable to possible deformation caused by excessive clamping forces. In order to achieve the working accuracies obtainable on the machines, special precautions have to be taken.” ‘The method by which internal sresues of castings aye relieved and the way in which a cast workpiece te clamped tothe machine ble may greatly affect the accuracy of the. planing operation. In erder to eliminate. such Sources of error which may have a greater influence than the manufacturing inaccuracy of the machine ftsel, the workpices is eplaced by a stright-edge, ‘This represents, 2 sures-free workpiece’ A pression dial gauge camped tothe tol is guided over i top edge thus replacing the planing tol (eee Fig. 2, page 13) ‘The Machine Tool Under Load Deformations and vibrations are crested in the frames and other parts of the machine tool during machining operations. "In spite of considerable research work done in this field, tests which cover the vibration behaviour of any machine tool are dificult for the following reasons: 1, The deformations of beds and other main members of the machine tool are not easy to calculate because the sections are usually complicated and the textbook conditions for beam calculations rarely apply. Only actual measure- ments of deformations caused under various loading ‘conditions can make up for the lack of accurate calculations, and results of such measurements are stil scarce. 2, The stresses and deformations which ste due to finithing cats taken on small and medium-size machine sols every small and therefore iat fo mea Specially in an ordinary machine shop where changes of Tempero, sources of vibration and the lack of sable Shilo testing staff ray fet the accuracy of the results. Stresses and tstortions greater than those specied forthe precision tes woud, of couse our dung roughing Ets, and machine tools are employed for roughing 2s vel S$ for finishing operations However, the permissible Stresses eaused by Toughing cuts ae limited only by the Consideration that permanent deformation must aot be caused even afer several years of continual use. Moreovet ithe final crue of the finishing operation which determines the accuracy petformance af machine, and nly finishing tests are therefore essntal, the result ofthe roughing operation being of Hile importance as regards seeuracy att surface fnah: With regard to vibrations, vari investigations concerning the causes and elimination of ehater on diferent frachine tools have been curled out Some of them Steve for determining the conditions under which a machine tool can be used without the danger of cater, others serve fr the toting and improyng of newly dened ad rototype machines. "Av far as acceptance tests for dart achines rahe than prototype af concerned Ss suggested that, forthe time being, Heishing cuts be sil taken for determining the performance of the machine, ‘This method reveals ot only the geometrical accuracy of the shape produced, but also the quality of surface fateh, the tees being at once simple and severe. It must be remembered that sometimes the high cost of testing. a fraching must be borne by the user, and it would appear thatfor an ordinary good quality machine tol itis sutctent to carry out 2 folshing teat on a workpiece specified by the aset and accepted by the supplier ofthe machine. In the case of machines intended for roughing operations * See the publications by S. A. Tobias in Great Britain, and by J Tasty fo Ceechosiovatie: LLLL L LLLLLLDLLLLLLLLLLLL LL eine) a ve> 7 wv nly, the specfed rate of metal emoval obtainable without Aindve notte, deformation and vibration should be tested. ‘The performance, as far as power requicements, load transmision,etes ate concerned, depends manly on the design, and desige faults cannot to corrected. by the tert workmanship: during manufacture. Any company manufacturing machines, no matter how’ accurately produced, which do not provide the requied performance, Mil soon be eliminated from the market. ‘Phe standard Sf accuracy depends on the quality of the manufacturer's trorishop. on the equipment sed, tod on the eaten on the job. This has to be tested on each machine as Purchased, and ets found can be earrected. when Decesary, : Layout of Test Charts A sor test in the cars dsr ach tet, the cha boeing arranged ia such a manner that at fist the manu facturing scturacy of the machine i tested, and then the accuracy ofits performance." Each tests further explained iy a sketch in which the method of meaturement is also indiated. Inthe third column of the charts the values of the permissible errs ae pected. Execution of Acceptance Tests 1. Levelling the Machine before Starting the Test Before any tests are started, the machines must_be carefully levelled by means of a precision spirit level. ‘The ‘correct installation of a machine is the basis for any test. No design can be such as to prevent deformations beyond permissible tolerances if an upright, a bed or a frame is put down wrongly on its foundation. Spirit levels must be placed on fined (raped, ground er fish-planed) surfaces only. 2 Zero Lines Zero lines are only to be used for general setting purposes. High precision setting and aligning measurements should bbe ‘catried out solely by means of a dial gauge or an equivalent instrument. 3. Auxiliary Equipment Any auliary.tetng equipment required which may have osu patcular Machines, has fo be provided a the ‘manufacturer's works. ® 4 Substation of Testing Procedure by an Equivalent ‘Method a ” * If the instruments shown in the test chart are not available, they. may be substiited by others as long as these are equivalent. It may be necessary to calibrate such alternative instruments forthe occasion, 5. Testing of Specil-purpse Machines Specil-purpose machines which differ from standard machines ti, hereto, ot ovr by hes chart must be tesed by 2 reasonable application of the principle father than the Leer ofthe test specications. 4 Conversion of Tolerances om One Reference Length to Another 2 Ee ve : Tn the ease of very sll machines, itis often imposible practicable ofete errs tose basi lenis sated ih the test char, Le 1000 milimetrs (approximately 7 40 inches); 300 millimetres (approximately 12 inches) or 100 millimetres (approximately 4 inches). For example fon an automatic lathe which has a working length of 65 millimetres. (2 inches), the permissible error must not be reduced exactly pro rata in relation to the reference Tength, because this would result in a permissible tolerance for directional measurement below 0:01 millimetces (0-000$ inch), and such is never required except for precision tool-room lathes and grinding machines where tolerances of half this value, ie. 0-005 millimetres (0-002 inches) are specified. 7. Testing of the Assembled Machine “Te machine ito be tested in is fully assembled sate, and should, therefore, not be dismantled during the tests. No machine is improved by being taken to pieces. Many machine parts are assembled by force or driving fits, and considerable force would have to be applied for separating such parts. This dismantling could damage a machine which otherwise would have worked satisfactorily for many years, In addition, dismantling and re-assembling ‘Operations are time-consuming and expensive. ‘The aveeptance tests are not intended for inspecting the machine components separately. These have to be within the manufacturing tolerances which are essential in quality production. ‘The final accuracy of the assembled machin fs, however, the result of the most suitable combination of the tolerances permitted in the manufacture of the individual components, this being effected in such a manner that errors do not become cumulative in any sub-assembly or in the final assembly. ‘The acceptance tests check only the final result of the whole assembly and not the ‘manufacturing accuracy of each single component. 8. Avoiding Time-wasting Measurements Every endeavour has been made to avoid as far as possible measurements which would take excessive time. When these appear essential, the manufacturer's guarantee may bbe accepted to the effect that such measurements, for instance, the pitch accuracy of lead-screws or the dividing accuracy of master wheels for gear-cutting machines, are within the required limits, As the manufacturer has to carry out the appropriate tests before assembling the ‘machine, the customer should accept a record of these tests. After all, the manufacturer eannot be expected to carry out such expensive tests more than once. 9. Testing Main Spindles after the Trial Run Precision tests of the main spindles should be carried out only on the conclusion of the trial run of the machine, ‘Thespindles are then running at their working temperatures, and have taken up their normal position in the bearings This condition is usually reached when the machine has, bbeen running for about 30 to 60 minutes. 10. Influence of Clearances in Bearings and Slideways In the case of high-speed machines, e.g. machines using tungsten carbide or diamond tools, or ‘machines for the ‘machining of light alloys, or in the case of machines with wide speed ranges, the clearances in bearings and slideways, have often to be’ relatively large and, consequently, can ‘cause difficulties during high-precision alignment mexsure- ments. Such measurements should then be carried out at the normal running temperature of the machines, ‘ig. after the machine has been running for about one hour. Tf necessary, adjustments of bearings or slideways may becarried out during the test. This difficulty need not be considered if spindles run in pre-loaded ball and roller bearings. 11, Axial (or End) Play and Axial Slip of a Spindle End pla is caused by the natural and indispensable freedom of movement of spinile in an axial direction. This is necessary to prevent seizing when the spindle i arming "up. Such rd play must not be oo smal, specially inthe ease of high-speed machines, eg. grinders and machines for ight alloys. and it must be wae aver the fll eieumference of the bearing. Axial slip, on the ‘other hand isan undeseable axial movement which occurs Periodically with each revolution. and. is. caused. by Manufactuting errors, for instance, by lack of parallelisa of thrust-ring faces, regularities in ball aces‘or similar auses.LUib only thin aul lip caused by manufacturing errors which as to be teste, and which hae to be kept Within the speciedsolerances, 12, Working Instructions Apart from the specified tolerances, certain common sense rules must be maintained and observed during the acceptance tests. Bearings must be adjusted so that their temperatures do not exceed the required limits. Gears ‘must be axially in line and run noteelessly, pulleys. and, belts must satisfy the requirements of smooth driving conditions at the correct speeds, etc. No separate specifications have been laid down for these conditions as they have to be observed on every high-quality machine. 13. Test Run Each machine is normally subjected to a test run before despatch. The user may be invited to witness this. It however, unreasonable of the purchaser to request a test un after the machine has already been prepared for despatch, ie. when a test run is a practical impossibility. 14. Errors and Other Causes of Differences of Opinion If these oceur, the measuring instruments are first checked and, if necessary, the tests repeated with other insteuments, or, better stl, by means of another testing method. If different methods give the same answer, the results ‘are confirmed, whilst different results indicate _- faults in the method of the instruments employed. MEASURING EQUIPMENT AND METHODS Any type of equipment may be used ss long as the specified measurement can be catried out with the required degree of accuracy. ‘The accuracy obtainable with 2 particular type of ‘equipment employed must always be compared with the required accuracy of measurement. In addition, the influence of the human element, i, the personal error of each inspector, has to be allowed for. ‘The accuracy in reading the micrometer depends on the personal touch of the inspector, but on the other hand, the interpretation of a spirit-level measurement should be independent of such influence. Dial Gauges "The graduation must be clear and normally need not be finer than 0-01 millimetce (0-0004 inch). Finer graduations which are required in special cases should only be used if the measuring accuracy of the instrument justifies it. In such cases graduations down to lp (0-00004 inch) may be used, Fig 14 Fig. 14. Exumple of Swing-over Measurement Fig. 19 and te, drsncurrieaa spss aloe a6 20 grams (07 Sune) gh fog ee ule gh sg sie at Dep rhe mening etd eld teter gai ana ol cee eal ac Although the maker of dial gauge cer always oa “spindle”, she sem Splongee" wl be ued thoughout ti tone forthe take Fels ahd tt avoldane of cotesion withthe ma spindle of sraching toa PHU] Le Fig. te Fig te Postion of the ‘Two Axes is meatured in Relatdon to Commen Datum Planes LLLLLLLE LLLLLLLLLLLLLLLL L Seep ease.to common datum planes (provided by the bed slideways), the table movement being used for moving the dial gauge along the datum planes (see page 32). “The dial gauge must be fixed to robust and stif bases and bare in order (0 avoid displacements due to shock or Sibration. In order to enaure stability, the base should Lives lage locating surface. The verdcal column should be a round steel bar or. steal tube. of about 16_to 25 llimesses (f t0 1 loch) diameter; the supporting tember should be'a see bar 10°10 16 millimetes (Fo Finch) diameter. Clamping nuts ete, should be designed in such a manner that 2 positite hand grip is possible for tight clamping. Kourled nuts are not usually sufficient. For trammel readings, the bar supporting the dial gauge must be rigid, 2 tapered rectangular bar or a steel tube being suitable. Test Mandrels “The most widely used inspection tool during manufacture and acceptanes touts of new machine tole, and the repair fold en, the fst mandrel the aly of whieh especially is fr at atsighinews and’ roundness are Gkitmned) nf paramount ueportancs fr accurate resus, Honea fro, hh mow ot be oyna he ‘ipatual ag" Ze the defection caused by the weight o the mandig Sig" ocoure when the. mandi "ofed between centres, and mare marked when its supported at one end only by the taper shank, with the outer end freely overhanging ‘This sag is frequently not taken into consideration and may cause trouble and discussions which can be avoided when the characteristics of solid and hollow mandrels are known and considered in the interpretation of alignment tests, of which "axis to axis” (see Fig. 14) and “axis to plane’ (eee Fig. 19, ic) are the most frequent examples. ‘Two types of test mandrel are used: 2 1. Mandrels with a cylindrical measuring surface and ‘taper shank which can be inserted into the taper bore of the main spindle; 2. Cylindrical mandsels which can be held between ‘centres. All mandrels must be hardened, stress-relieved and ground. ‘The measuring length of the cylindrical part of mandrels depends on their purpose. In the case of mandrels with taper shank it varies between 100 and 500 millimetres (# 10 weight of che mandrel, the author used hollow mandcels Er long’ ago as 1902. Their dimensions and: measured defections under their own weight are shown in Figs. 2 and. Deflections caused by the sprog pressure of the lal gauge plunger are negligible if this premure i less than 3} ounees " ‘The centres should be counter-bored so that they are not easily damaged and can be used when the mandrels have to be tested for true running, “The taper bore ofthe spindle of an ordinary lathe must run truer ‘The mazimum permissible eceentric error is 003 millimetre measured at's distance of 300 millimetces (O-001 inch at 2 distance of 12 inches) (see Chart 11 ‘Test 7, page 54) Avail greater accuracy, 002 millimetre na dole of 300 lligetes (DODDS ich a distance af 12 inches) is requted for the parallelism between the Spindle as and the bed, both nthe vertical and horizontal Plate (eee Chart Il, ‘Feat 8). Por te toaloom lathe, the erable error is only 001 milimete per 300 milimetres [00008 inch per foo) Using a solid steel mandrel of 25 milimetsce (1 inch) diameter and 300 ‘millimetces (Fa “nches) Tong the natural sag 2.00096 ‘mllimetre (C-o00%8 inch). This {too uth, whereas the hollow tnandrel of the same outlde diameter has a sag of only 00305 ‘rilimetre (O-000{2 inch), which is withia permissible limits. Before the alignment of a spindle axis is measured, the spindle must be tested for true running by means of the test mandrel inserted in the spindle taper bore, The spindle must then be turned into a position of mean eccentricity error, and if the alignment measurement is, ‘carried out in this mean position the influence of eccentric running is eliminated. Example: Lathe spindle parallel with bed in the vertical plane (spindle rising towards the free end of mandrel only). ‘The tolerance is 0 to 0-02 millimetre (0 to 040008 inch) measured over a length of 300 millimetres (12 inches). The spindle with a test mandrel inserted in its taper bore shows that during one revolution the mandrel axis varies thche) ‘The deter must be such thatthe Se Kept otha permiadble limit Em order 10 reluce He Fig. 2u._‘Holow Tet Mandel dh Taper Shank etal Cpr (nim) ore he “Toa a Tonite Da | Bap Dyan ore | Ch Tepe fey lef. pete ft pet e lala ‘ a fice] = -|-/-]-] 4 BUR ea | eye | byt esate} elo] ay} y 4 Ered ela Ala leslmls | Slald ja fa fel 2] a | ta fab foe ah [te foot | ab | [ah ath © The big diameter of the Morse Taper must be at least as big asthe diameter [-I] of the ‘only in emergency. Fig measuring eylinder. imensions of Hollow Mandsel,its position from I to Il as shown in Fig, 4. Before taking the alignment measurement, te spindle is, therefore, rotated into position 0, ie. the mean position between T and If, ang now the measurement of the parallelism betiween spindle axis and bed can he carried out, Straight-edges and Squares Suraight-edges of cast iron or steel should be heavy, wellibbed and fre of internal streses, Their beating surfaces shouldbe as wide a pestle,” The eo atthe of a standard square should be less than 0°01 mill- toeare (20-0004 inch), ofa precision ‘square les than “0-005 millimetre 440-0002" inch). A master square Which would serve for checking squares in normal use is best made as a hardened steel cylinder, ground all over With the faces accurately square to the cylindrical surface, ‘As such a master square is usvally ground on a precision grinding machine an accuracy ‘of 0-002 millimetre 20-0008 inch) is obtainable,” Master squares made of ox sections are also useful. ‘They are generally made of stress-free cast iro with all faces. mutually square oF parallel. If, for the purpose of some measurement, 3 Inside Diameter Outside Diameter ‘ot Bore Defietion mm. | inches | mm. | inches |» | inch | 3 said | — | 132 | o000s19 ao | 3. = | 116. | o-c00%s6 s | 3%) % 2 | ‘83s | Oooo a | 3: 6 24 | 745 | o-o0293 wo | 4" | soa | = | 74° | oooc21 wo | 4 0 a | 55 | ooootis too | 3 50 Ya | £35 | oopot7 1 | $ | soe, — | 453 | ovoniar 1 | 3 3} 3a | 34 | 000133 ms | § 100 ¥* | 35 | oooorts Fig. 34 Sag or Deflection of Cylindrical Mandres, 1,000 unm, Fig. 4. | Mandrel running out of Truth must be set 0 Mean Position before ‘Testing for Parallelism with the Bed dial gauge has to be traversed slong the faces of a square, the use of a master cylinder or a box-sectioned square is easier and more reliable. Spirit Levels Spirit levels are used in the shape of a bubble tube which is mounted on a cast-iron base. ‘The two main types are the horizontal (ee Fig. 12, page 14), and the frame spirit level (sce Fig. 15, page 15). Spirit levels used for high- precision measurements (tolerances 0-02 to (0+ millimetre per 1,000 millimetres, i.e. 0-00025 to 0-0005 inch per foot) should have a sensitivity of about 0-08 to 0-05 millimetre per 1,000 millimetces (0-0004 to 0+0006 inch per foot) for each division. "A movement of the bubble by one division corresponds then to a change in slope of 6 to 12 seconds. Ifa level of 0-0¢ millimetce per 1,000 millimetres (0-0005 inch per foot) is chosen, then 1 division=0-08 mm,/1,000 mm. (0-0008 in.ff.); 2 division=0-03 mi. 1,000 mm. (0-00035 inf. 4 division=0-02 mm./1,000 mm. (00025 in./ft.): 4 division=0-01 mm /1,000 mm, (0.00015 inf is quite easy to estimate to within a quarter division, and agreement between two testing authorities (the manufacturer and user) is easier to reach than with estimates of } or } division. Spirit levels which ate too sensitive are difficult to bring to. rest ina workshop in which machines are running, while too low a sensitivity (GB inches) in Length, Held between Centres results in insufficient reading accuracy, 38 very small Ouuside ‘rout | Measuring | Detection | Biggest diameter ameter length Tenggh S| ae messuring of aper o position | Morse No. Taper a Appr. ‘Appr ‘Appr. Ne 1] 4 | 1 | Sold [Sonal sz | 148 | si | 100 | 0000s | o0ias |-1anaa| 63) < m1 | 2 | Sema 9j | 230 [9 | 230 | -oooi7 sana] ty} | as | 3} | 330 | 94 | 230 | ‘coor e] i | 3 | sola vf | 31s [atk | 39s | “ooo3e uly | © | Sone Tay | a7 [1p | 350 | oon Sand 6 B] ab | fo | St tab | 398 [138 | 380 | “00023 ae[ ay |e |” soia [sonal arn | $55 | 201 | s2s | coos | ove | 6 ] 2h | 62 | stepped |Sotid| 218 | $55 | 20f | 525 | -ooods | o1s6 bore ies?) © Avoid tapers 1 and 3 here, if possibl because the largest diameter of taper is smaller than the outside diameter of she colts pt Fig. 30, Sag of Solid and Hollow Test Mandrels with ‘Teper Shank and Cylindrical Bore (Constant Inside Diameter). 10 20 >? vive wrm 9 LebLL ve le LDL "19 eee ee PAVTALLLILI LLL 4 we lJibs sractons ofa division have o be eatinated. ‘The wolerance porrally encountered ins goed spirit level may be 10 half a division; but, f posible, a tolerance of only a hares ofa dvsion should be ained a." For meautag Uerances ranging from 01 t0 0-2 allimete por 1 tallimetes (D002 to 00025 inch per fot), spirit levels aving 2 sensitivity of 01 to 03 ‘millimetre per 1,000 rllinetres (000125 to 0087S inch per fot) per division are suluble, ‘The bearing surfaces of spirit levels and Vee-blocks, as well as those of precision frame spirit levels, should be as, Tong a8 possible.” For testing medium-size machines they should be not less than 200 millimetres (about 8 inches) Tong. ‘The supporting face is best interrupted in the middle. Te is often advisable to use a bridge piece (see Fig. 60, page 12) the feet of which are about 300 millimetres (12 inches) apart. ‘The spirit level can then be placed on the scraped surface of the bridge. This method avoids terrors which could be caused by irregular scraping of the ‘surface to be measured. ‘The sensitivity E of the spirit level is the movement of the bubble in millimetres of inches which corresponds to a change in slope of 1 millimetre per 1,000 millimetres (0.0125 inch per foo), Oo Fig. Sa. Sezstivity of Spirt Level Fig. 5s. Spirit Level and ‘Checking Cylinders 4 Movement of bubble in millimetres (inches) = [millimetre per metre (0-0125 inch per foot) ‘The seale value S indicates the change in slope (millimetre per metre or inch per foot) necessary for producing 2 bubble movement of one division. I the distance between two divisions is called ¢ then S=o/E. If, for instance, the distance between two divisions is 5 millimetres (01 inch), and 2 bubble movement of fone division corresponds to a change of slope of (0-04 millimetce pee 1,000 millimetres (0-0008 inch per foot), then the sensitivity is equal to 25 millimetre Linch etre per metre ~ 0-005 inch per foot E 625 millimetre 200 inches inch per foot ‘millimetre per metre and the scale value is = 0604 millimetre per 1,000 mm; or S = FE = 0.0005 inch per foot. 200 If for the same change of slope (0-04 millimetre per 1,000 mm., or 0-0005 inch per foot), the space between divisions was 5 instead of 2°5 millimetres, the sensitivity 125 maillimetres would be increased to — and the scale etre per metre value would be 0:02 millimecce pet 1,000 mm, ‘The inside of the glass tube ofa spirit level has a shape of a ciccular are of radius R which moves during a change fof slope around the centre Af ofits curvature (Fig. Sa). If the slope is measured as a ratio of h/L, and the movement of the bubble is 4, then R—NL and R=af(H]L). As {WG/L) is equal to B it follows that R=E: : the sensitivity of the spirit level is equal to the radius of curvature of the barrel-shaped bubble tube. ‘The Sensitivity ofthe level depends, therefore, only on the radius fof curvature of the bubble tube, and not on the length ofits bearing surface. A short accurate level may be more sensitive than a long coarse one (For instance, @ mason’s level). It is, however, advisable not 10 use spirit levels are so short that small deviations are obtained rather than mean values. Ifthe divisions of a spirit evel are spaced 2-5 millimetres (0-1 inch) apart, and if each division represents a change in Shope of 004 millet per 1,000 milimetes (O0005 inch et foo) then the radius of the iner surface ofthe bubble 25 Rm Fay = O25 metres, on Foaeg — 200 feet. If double this sensitivity is required then the radius must bbe increased to 125 metres (400 fect). Spirit levels with radii greater than about 70 metres (220 feet) are difficult to use in the average workshop, 2s they will not come 10 rest when machines are running in their neighbourhood. Errors of spirit levels are caused by:— (2) Wrong position of the bubble tube in its housings (©) Faulty graduation.‘Scatter of readings depends on:— (0) The quality and length of the bearing surface, This should not be shorter than 200 millimetres (8 inches), and if ‘possible 230 mullimetres (10 inches) to 300 ilimetres (12 inches). (d) Dimensional stability of the cast-iron housing: (0) Accuracy of the isi of the bubble tube which must Errors and scatter can be ignored in practice if they are Jess than a quarter of a division; but they sometimes reach half a division in the case of workshop levels (see above). In addition, errors may arise through'— (A) Tae condition ofthe piece to be tested: (2) The influence of temperature; (i) Personal errors ofthe inspector. (@) The bubble indicates the slope of the spirit-level base in its longitudinal direction. If the surface to be tested is geometrically inaccurate, the base of the level ray not le parallel toi “The position of the level base thus not accurately determined and the indication of the bubble may be misleading as it refers only to a straight line in the measured direction. If planes are to be checked, therefore, the level must be set down in_a number of different directions. An accurate picture of the character of a surface can only be obtained by using additional equipment such as straight-edges, surface plates, auto- collimators, slip-gauges, wires, etc. (0) Calibration tests should be carried out at a temperature of 20°C. (68°F). Indication errors are caused by the level being exposed to the sun or to draughts, by being breathed upon, or by being touched with warm hands. “The inspector should, therefore, carefully avoid breathing on the bubble tube or touching it. A transparent protecting cover for the bubble tube is often advisable, (0) ein beat to take readings with both eyes open, and looking in a direction perpencicuar to the bubble tube. Ifthe inspeeor i, however, used to closing one eye, this permissible as long as he’ does not vary bis method. of Sbservation. The fevel must not be used on its edge, but should always be properly pressed to the surfuce under Ingpection. “Correct measurements re made casier by the use ofa cross or circular level, especialy when inlined surfaces have to be adjusted. If such an addtional level Senor avaliable the correct direction of measurement ‘unt be found by tial and error, the correct direction being that which gives maximum movernent ofthe bubble. It is recommended that spirit levels be tested once a month, and, if necessary, adjusted. As the bearing surfaces are’ often not treated with the necessary care, check tests include those for the following item 1. Flaten of the bearing surface; 2 Relative positon between bubble tube and bearing ‘arte! 3. Seale value 1, Flatness of the bearing surface is tested and corrected with the aid of a surface plate. 2. The test for relative position between bubble tube and beating surface is carried out in a temperature-controlled room at 20°C. (68°F), and, if possible, after the level hhas been left in the test room for about eight hours (eg. overnight). ‘The correct testing method is influenced by the shape of the bearing surface. A level with a plane surface can be tested by turning the level through 180° If the surface is horizontal then the bubble must give the same reading in two positions within not more than 40-25 of a division, For checking a Vee-shaped base, very accurate hardened steel cylinders of different diameters 2 are required (Fig. 5u). The spirit level is checked and. touched up until the two sides of the Vee are parallel with the bubble tube. Care must be taken that a cross level reads zero during each observation. Square frame spirit levels are basically tested by the same methods; in addition, ccare must be taken to ensure that all bearing surfaces of the level are perpendicular or parallel respectively. ‘This can bbe done by checking them against accurate master squares (see page 10). 3, To check the scale value, the ratio A/L per division hhas to be determined. For this purpose an accurate straight-edge is set up level (checked with a special master spirit level) on equal slip gauges a and 6 (sce Fig. $a), and kknife-edges which are 1,000 millimetres (3 feet) apart. Che spirit level which is to be checked is then put on the straight-edge. ‘The straight-edge is then inclined by an amount of 1,000 mm. and, for this purpose, one of the slip gauges is replaced by another one, the difference being equal to the amount A, If this inclination corresponds to the seale value, the bubble must have moved by one division. This’ procedure can be continued from one division to the next until the full graduation is checked. Level Measurement by Means of Water Level Surface and Micrometer ‘This method (see Test Charts 41 and 42, Figs. 2 and 3), serves for measuring misalignments or inclinations of long. beds and work tables. The micrometer holder is placed at various positions on the bed or table, and the micrometer, spindle is screwed down until its tip just touches the surface of the water. To secure uniform measurements, the measuring tip of the micrometer must be very accurately ground, tinned or, preferably, nickel- or chromium-plated. In order to obtain a truly level water surface, any throttling effects must be avoided; if tubes are used they rust be of large diameter. When a planing-machine bed is tested during erection of the machine, or in any case, when the table is removed, Fig. 64. Using Ves of Bed as Water Channels when. ecting Planing Machin 60. Testing Inclination of Bed with Parallels, ‘Straightedge and Spiriclevel LLL ‘L LLLLLALLLLLLLLLLLLLLLLLILL aL fm (|fig. 7. Alternative Méwoa of ‘Testing ‘Staigheness the Vee alidewaye of the bed fan be used as water channels Fig. 61). For this purpose they Sciet) acted Uherende means of lay or cement and Connected by tubes, The micrometer spindle is then held in an adaptor a, the bearing surfaces of which should bbe exactly perpendicular to each other, and inclined at 45° to the axis of the micrometer screw. ‘A method which can be con- sidered equivalent to the above employs a long. straight-edge placed on parallels, the level of which is checked’ by a spirit level (Fig. 68). However, long beds or tables cannot be tested in this manner without repeated- ly displacing the straight-edge longitudinally. ‘Testing by Means of Wire and Measuring Microscope ‘The wire method, Fig. 8, serves for measuring the straight. ress of movements of tables and carriages over greater lengths (Gee, for instance, Chart No. 11, Fig. 2). The two ends of the wire are lined-up by means of the cross-wires (Fig. 9) of the measuring microscope. Obser: vations are taken in the vertical plane as the table is \ waversed. By means of a special system of prisms, however, the wire can be observed both vertically and M4 horizontally. Each vertical and lateral deviation may be measured by the displacement of the microscope tube. ‘The amount of sag of the wire can be accurately calculated and the measurements corrected accordingly. In the case of a lathe or grinding machine, the wire should be arranged to be exactly co-axial with the centres, Fig. 8. Method of Testing. be means of a°Taut Wire and Meas- unin Mere Fig. 9. Diagearn show- ‘ng how. the "Misr scope Cross-wire centred ‘onthe ‘Taut Wire Care must be taken, however, that the wire is free from kinks. ‘The wire diameter should be as small as possible, in any case not more than 0-1 millimetre (0-004 inch), Long beds up to 20 metres (65 feet) and more can be tested without the need for special precautions. For ‘greater lengths it may be necessary to damp the vibrations af the wire by suitable means, for example, by attachiog small paper tags which are suspended in cil. An equivalent method of checking a movement for straightness employs a long horizontally-located.straight- ‘edge which is aligned in such a manner that the dial gauge shows the same reading at both ends of the edge (Fig. 7) (Gee Chart 15, Fig. 5). While the table is traversed, the Seviation of its movement from a straight line can then be read directly from the indication of the dial yauge. Alignment Test by Telescope and Target ‘The weaknesses of methods which employ the taut wi ae avoided ifthe optical aia ofa telescope is used a8 the teclineal reference, a sultable target which slides on carriage on the bed being observed through the eye-piece af the telescope, When the telescope and eolliauor are ‘sed (Fig. 10), the sight mark ofthe telescope is observed simultaneously with the image of the target formed by the ellimator (apparently at infinity). In this manner vatitions in the angle between the axte of the collimator and the tleseope are determined, “The method i silat to that using a opirt level With the telescope-and-target_method, however, the vertical or tateral deviations are "measured. direetiy in mlimettes (or inches) asthe target is moved between its extreme positions E and F (Fig. 11). ‘The telescope forms a teal image by convergent rays. IU is necesary, therefore, to focus it always very accurately according tothe distance ofthe target. This is done with the ad of a movable lens within the telescope which is actuated by the knob ‘K. Tmorder to void errors, the lens must be dsplaced exactly 4 = = Fl. 10. Diagram illustrating the Principle of Testing % bby means of Target and ‘FelseopeFig, 11 along a straight line parallel to the optical axis. The results of the test indicate, at the same time, errors of alignment in both the vertical and horizontal planes of the optical axis, ‘The plane-parallel plate C serves for adjusting the optical axis of the telescope relative to the target during the test. ‘The accuracy of the readings depends on the magnifications MAGNITUDE AND DIRECTION In the test charts, the tolerances are given in three different ways, viz.: 1. As plus or minus tolerances (example: £003 millimetre ‘pet 1,000 mlimetees= +F0-001 inch per 3 feet); 2. As tolerances without signs (example: 0-03 millimetres per 1,000 milimetres); 3. As unilateral tolerances (example: 0 to 0403 mlimete pet 1,000 millimetres). 1. With plus or minus tolerances, the permissible error is allowed-to occur in either direction within the specified reference length. The otal range of error is therefore double the specified tolerance (see Fig. 12). Example: A tolerance of 40:02 millimetre per 1,000 millimetres means that, on a reference length of 1,000 mi metres, 2 deviation of 0-02 millimetre will be permissible in both directions. ‘The total range of error is double the amount of deviation, ie. 0-04 millimetre per 1,000 milli- ‘metres (00014 inch per 3 feet). 2, Tolerances without signs include the total range of error measured on the reference length, no matter in which direction the error appears (see Fig. 16u), 3. With unilateral tolerances, the specified limits cover the total range of error across the total reference length, of error being of great importance and slways heen 2 CEERSSED ete, raed Mina Toeann General Arrangement of Optical Alignment ‘Testing "Telescope of the telescope, the graduation and the distance between the telescope’ and the target.” ‘The measuring, accuracy also depends on the precision of the movement of the focusing lens and of the plane-parallel plate. ‘The mini- soum distance between the target and the telescope is about TA metres (42 inches) OF TOLERANCES stated in the text of the respective test chart (see Fig, 17). In detail, the tolerances are specified in the test charts, and cover the following: 1, Straightness of Slideways and Flainess of Tables ‘These are tested by means of the spirit level. ‘The tolerances are specified either: 1. As plus or mifus tolerances, oF 2, As unilateral tolerances, Ezample 1: Planer bed straight or level longitudinally ‘The specified tolerance is :£0-02 millimetre per 1,000 rillimetzes (0-00072 inch per 3 feet). ‘The spirit level is permitted to deflect from its zero position by 0-02 millimetre per 1,000 millimetres either towards the right or to the left side (Fig. 12). “The measurement may be started at any point ofthe bed, the sprit level being moved slong in deBoite step of, sy, S00 limetees (about 12 inches. ” ‘The maximum plus and the maximum minus deviation are added together and divided by 2. ‘The resulting error should be within the specified tolerance; in the above Greatest Ielinaion, he = 008mmPIV I ILIFII IPE LEPEELL SEIS E EPI Lisa Fig. 14. Tolerances ip Measuring the Difference of Height or Sag of3 Planer Hed example within 0-02 millimetre per 1,000 millimetres. Example 2: Lathe bed straight or flat in the longitudinal direction (convex only). ‘The specified tolerance is 0 to 0-02 millimetre per 1,000 millimetres (0-00072 inch per 3 feet). ‘The spirit level i allowed to deflect in one direetion only, ice, rising towards the centre (Fig. 13) and within the limits, fof 0 and O02 as measured on a teference length of 1,000 millimetres, with the result that the bed will be only ‘The measurement is started at the centre of the bed irate pak op bump, where the pi oe eel read ero as accurately a8 posible, rom this point the spit igre ig moved to the tight and tthe lf, towards ea fend, ‘The level should be used on a bridge (sce Fig. 60) the fet of whiedare spaced about 12 inches apart. ‘The slope has its largest permissible value if the spirit level indicates the maximum reading 0-02 per 1,000 millimetres (convex) along the left, and the opposite reading, slong the ight half ofthe bed in this cate the bed ways ‘would rise in a straight line from the left and right ends towards the centre with an incline of 0-02 millimetre per 1,000 millimetres. ‘The largest permissible rise of a bed having a length of 1S metres (5 feet), would be 175 x 0:02=0-015 millimetre (about 00006 inch). Fiatness oF TABLES AND Beps or Lonc PLANING ‘MacuNes ‘The fatness is measured separately in the case of long planing machines only. * “The specified tolerance represents diretly the permisible difference in height between the highest aad lowes point ofthe bed or table being tested. Example: Bed of a long planing machine straight in the longitudinal direction; largest’ difference in height, 008 milimenre (0002). ° geen Sy s\t 0 gar ay OD a Fig. 15a. Tolerances in Fig, 150. Use of an Inter ‘Ping ¥ sures for Ft medite Piece for‘lolined 1s In Fig. 14 the deviation of a planer bed, from its theoretical straightness is shown. “The measured amount ¢ ‘must be within the tolerance of 005 millimetre (0-002 inch). 2. Flatness of Slideways (Twist of Cross Rails and ‘Arms) ‘These are tested by means of the spirit level. The tolerances are specified without signs. Example: Front slideway of the planer sail flat within (0603 millimetre per 1,000 millimetres. ‘The spirit level is moved along the surface to be tested. ‘The range of the largest readings taken in both directions indicates the error which must be within the specified tolerance of 0-03 millimetse per 1,000 millimetres (Fig. 15). Tt is not necessary for the measured surface to be vertical ‘oF horizontal, -e fr the spirit level to be inits zero position. "The surface being tested may lie at any angle, and a wedge- shaped piece K (Fig. 150) may be interposed so that the air bubble lies near zero. 3. Alignment of Slideways and Axes, or Centre Lines Parallel or Perpendicular to each other ‘These are tested by means of the dial gauge or the spirit level ‘The tolerances are specified in the form of cither: (1) tolerances. without signs, or (2) unilateral tolerances. In each case the specified tolerance represents the total range within which the dial pointer is allowed to deflect. Example 1: Milling spindle parallel with bed. The specified tolerance is 0-02 millimetre per 300 millimetres (0-0008 inch per foot) (Fig. 168). ‘The dial gauge is applied at the initial point of the measuring distance of 300 millimetres (12 inches) and traversed along the latter. During this traverse the total movement of the pointer must not exceed 0-02 millimeire (0-0008 inch) no matter in which direction the movement takes place (i Fig, 16a Greatest Deviation Upwards somt—— a Grlatest Devistion Downwards Ye tia reese elim. ihe Me Fig. 164, 168 and 160. Double-sided Tolerances for Directional MeasurementsIv by no means correct wo set the dil gauge to zero at any point in the centre ofthe measuring distance, xo that i Shox deviation of 62 mieten one dretion hen moved the left and of 0-02 millimetre in the opposite diresion, shen moved to the right; such a. procedure would be wrong becsuse the total ercor would be doubled x02 00H neve 0 018 Teh, Fe, 16, dowed When a spitit level is used for this test, the total movement of the air bubble must not exceed a value corresponding to a change of inclination of 0-02 millimetce per 300 millimetres: Example 2: Lathe spindle parallel with bed in the vertical plane (spindle rising towards the free end of test mandrel only) Fig. 174 Gregtst Deviation Uonards Tolerate Ares Fig. 170 Unilateral Tolerances for Directional ‘Measurements Fig. 17a and 17s, “The specified tolerance is 0 to 0-02 millimetre per 300 rillimettes (Fig. 174) When the dial gauge is being moved along the test mandrel, the.pointer is alloxced to deviate in the stated direction only (Fig. 17), “The same applies to the testing for perpendicularity of surfaces relative to axes and vice versa ‘The perpendicularity of an axis relative to a slideway is usually measured by means of the turn round (trammel) method, ‘The dial gauge is set to zero when it touches the surface to be tested at the left side; it is then turned round and the deviatinn of the pointer should not exceed the perspitted tolerance when the dial gauge touches the surface to be tested at the right side, “The direction of deviation is of no importance. Example: ‘Vee-slots in the table of a surface milling machine square with cutter spindle. ‘The tolerance specified is 002 millimetse per 300 millimetres (Fig. 184). ‘The dial gauge touching the centre T-slot in the left- hand position is set to zero. In turning it round—the total distance between the two measuring positions is 300 millimetres (12 inches), ie. the length of the lever arm 150 millimetres (6 inches)—the deviation of the dial pointer must not exceed 0-02 millimetre (0-0008 inch) towards the left or right (Fig. 188). With lever arms of different lengths the accordingly. tolerances must be converted Iris not petmisible forthe dial pointer to deviate b 102 milmetee in one direeon when touching the let side, and by the sane amount inthe opposite direction when touching the right side of the T-lat (Fig. 18), because these deviations would correspond. to an inadmissible Sauareness error amounting to U4 millimetre per 300 ilimetres (P0016 inch pet oo) 4. Alignment and True Running of Shafts The tolerances for the true running of a shaft have to be taken as the admissible total deviation (range of deviation) of the dial-gauge pointer. reitest Deviation, rant j he creates Devation, Rear Fig. 180 Fig. 186 Figs. 18s, 180 and 18. Tolerances in Measuring by the Turn-round Method Example: Testing lathe spindle for true running. ‘The specified tolerance is 0-01 millimetre (0-0004 inch). "During ‘one revolution of the spindle, the dial pointer is allowedl to deviate over a range of 0-01 millimetce Similarly, the tolerances specified for the axial sliding movement (slip) of spindle indicate the total permissible deviation of the dial-gauge pointer. “‘Vhe tolerance specified for the alignment of wo shafts indicates the permissible deviation of their axes from the theoretical centre line (the amount of off-centre). If this is measured by means of a dial gauge, using the swing-over ‘method, the deviation of the dial-gauge pointer would be twice the amount of off-centre, as shown in Fig. 19. ‘The dial gauge pointer is thus allowed to deviate by twice the petmissible error in this ease. Example: ‘Testing the alignment between the bore of the outer arbor support and the cutcer spindle of a surface milling machine, ‘The tolerance specified is 0-02 milli- ‘metre (0-0008 inch). When the swing-over method is used, the dial gauge pointer may deviate by 0-04 millimetre (0-0016 inch). 6 LLL bbb bedded dnbb bbb bbb, ‘L |step A, which is rigidly clamped to the lathe bed. The position of the face plate is determined by the adjustable ting R, which is held firmly against 2 stop block b* by a TT IITIT ITT t Fig. 19, (See piye 31 and Fig. 6c). ‘Tolerances in Testing the dlignment of Two Ases by the Sweing-over Method 5. Lead or Pitch Error of Lead-screws ‘The lead or pitch ero i generally based on a reference length of 300 millmenes (12 inchs) Dogioning om any given inital postion, the test nat is shoved ver a nimber of threads corresponding to an accurate travel of 500 milimetres for mete or 12 inches for Whitworth read sores, The actual travel ofthe nut may be either larger or smaller than 30) milimetses and 12 inches sepenvly, by not more han the specie permis Example: ‘The accuracy of the lead-serew of a lathe is usually assured by the manufacturer. ‘The tolerance specification is 0-03 millimetre per 300. millimetres (00012 inch per foot). Let the lead-screw have a pitch of E inch, ‘The nut is moved by exactly 48 threads Corresponding to a basic length of travel of 12 inches. ‘The actual length of travel is allowed to vary by not more than 0:0012 inch from the nominal length of 12 inches. ‘The problem of accurate screw-cutting on 2 lathe cannot be solved merely by using an accurate lead-screw which meets the tegt specifications. It is necessary for the lathe itself to be of rigid design’ and for the lead-screw to be carefully mounted, otherwise an accurate lead-screw may give inaccurate results. Moreover, the accuracy of the driving gear, the rake angles of the tool, the smoothness of its cutting edges, the coolant supply, etc, have considerable influence on the accuracy of the thread to he cut. ‘Tesrinc Merions Fig. 20 shows a very simple method fur testing a lead- serew oxer a measuring length of 30U millimetres (12 inches). ‘This his been employed in practice for more than $0 years, and can be carried out with equipment usually available in the machine shop. ‘The method involves taking two ‘measurements over a given distance (say 300 millimettes oF 12 inches) the earrage being traversed along the bed by ‘means of the lead-serew. 1. ‘The first measurement is taken with a dial gauge A touching a precision length gauge a. 2. For the second measurement, the position of the carriage is determined by means of the dial gauge M after the length gauge a has been removed. ‘The distanc to be measured is referred to the adjustable ” Constant weight ona lever. In testing the finished lathe, the accuracy of all the co-operating transmitting members is tested by comparing two measurements as follows: In the starting position shown at the top (Fig. 20a) the ring R firmly touches the block 6. ‘The slide carrying the dial gauge M is so adjusted that the length gauge a just touches the stop at its left and the plunger of the di gauge at its right end. A pressure of about 50 grammes fon the dial gauge plunger is sufficient to ensure the necessary contact. After the reading of the dial pointer has been taken in this position, the length gauge a and the block 6 are removed. ‘The lathe spindle with the face plate is then turned until-the calculated distance through Which the slide has been traversed by the lead-screw corresponds to the length of the precision length gauge @ (G00 millimetces or 12 inches). If the ring Ris again brought into contact with the stop block 8, the dial-gauge plunger should just touch the face of the stop A, provided that the lead-serew is free from errors. Any deviation of the dial pointer indicates the magnitude ff the error. In other words, it corresponds to the plus or minus variation between the movement of the carriage and the length of the gauge a. In this way, cither cumulative pitch errors of the lead-screw over its full Tength or individual errors of each thread can be determined. Fig. 22 shows a test chart of a lead-screw of 6 millimetres (Pinch) pitch and 3,360 millimetres (11 feet) length. Cutting tests can be carried out by cutting a right and 2 left hand thread on a cylindrical test piece having a length ‘of at least 10 times the piteh, the pitch errors being decermined by a suitable indicator. “The maximum permissible ertor is -£0-003 millimeter (000012 inch) for tach pitch, and the cumulative error should not exceed that Of the lead-serew. For a medium quality serew, 002 ‘pee 50 millimetres (0-0008 inch per 2 inches) is, * Dock & could be replaced by 2 dial gauge. Fig. 20 (op): Fig. 201, (atom "(iti suien kino by Compusaon with te Bad Coe Method of Measuringallowed. "Fig. 22 shows the test chart of a good tead-acrew. Fig. 23 a test chart of a corresponding right-and left hand Sfewed tat piece, 6 millmeties pitch 6138 thant nt with the lead-screw. a Principle of the “Cazeneuve” Test Another simple and practical method of Droposed by Cuzeneuve (France), As in the former test, the accuracy of the lead-screw is checked by determining the movement of the saddle Produced by the rotation of the lead-screw. “The distance travelled by the saddle is measured by moana of scope and a yraduated scale, the dividing ervore of which are known, testing has been Description ofthe Measuring Device (Hig, 21) [The geaduated scale a is positioned in the centre wf the lathe bed where it is located and held by means of the clamps 8 which are similar to those used for clamping the tallstock. “Ihe saddle earies a microscope c, the eye-picce of which is fitted with a micrometer cross: hait The Meth of Measuring 1 only those traversing ercors sehich result fom the lead sero ate io be dette from the taistock end, If the the errors ofthe wa of years wr screw, the lead-serew is dtven fo the usual yea drive, he lead-serew is driven surements must include audition to those of the ym the headstock endl via In the first instance, « lever is mounted serew at the tailstock end, long to reduce errors in the: on the lead ‘This lever must he suliciently angular readings to 4 minimis Jn practice, a lever of 500 millimetses (about 20 inches) sadius is used, giving a toxal eizcumnferential stovement o 2x 500% w, ie. approximately 3,010) millimetres for ove fall revohition, “This corresponds then toa suite 22 (Left). “Vea Chart for un Avourate Lead:-serew displacement equivalent to one piel of the hend-terew iu 22 10), “Tess Gare foe wn Aesrte Le Uf the pice is assumed to be 12 millimetres (approximately determined by reference to a precision block gauge the whl Rights and Leftchanded ‘Threads errors are reduced in the ratio of 12': 3,000 Sind the effect is thus negligible. If che drive fs taken from the main spindle, & face-plate of the largest Permisible diameter is mounted. 09 the spindle and. its votaion checked nsuatey by mean of Hop,» Sal gun amall and of the order 1? 200 or 1: 300. Irrespective of which of the two auernative methods is employed, testing can be cared out piteh’ by pie and i perry, ven by frastons of a pich, By’ comparing the results obtained wth the. two tere methods of moving he saddle (cher by the lead-serew alone or from {Gotan inl) severe das tthe tesin of gears can be determined. plese] fee ems eer) em) ey) se) me) LL 4 ‘LL ic ir errors produced on all kinds of threads, Re Bi View ging he Magenngy op See wed inthe care ese imevorth and eltPISEIIFEFFEF EE EEEEE SEE EF EEL IIS IIIS module pitches, whether these errors are due to the lead- screw itéelf or to other causes, such as for instance, the Norton-type gear box. ‘The accuracy of the testing device depends only on the quality of the steel or glass scale, the terrors of which are known from a calibration curve. British makers of repute distinguish between ‘Standard Guarantee” and “Special Accuracy”. An example is shown in the following specification ‘Standard Guarantee with any lath +0:002 inch (440-05 millimetre)’| in any 6 foot (1,800 ~0.003 inch (~0-075 millimetre) J" millimetres) length. =EDGDL inc (£0425 mime) any for (0 2. Special Accuracy, which can be provided at increased cost: 64 inch (165 millimenres) centre lathe on 6 foot (1,800 millimetres) length of bed 8} inch (215 millimetres) centre lathe on 8 foot (2,400 millimetees) length of bed “£00006 ineh (+0015 ss} #001 CHO a25 mince) in he length eapaciy of “0-002 (~0-050 millimetre), the lathe, 6} inch (165 millimetres) centre lathe on 8 foot (2,400 millimetre) length of bed. 84 inch (215 millimettes) centre lathe on 10 foot (3,000 ‘millimetres) length of bed. * Dean, Smith & Grace Limited (Keighley), 1943 10} inch (275 millimetres) eentee lathe on 10 foot (3,000 millimetres) length of bed, -+0-0006 inch (40-015 millimetre) , Brorortoexceed{ +P inch( 0.8 miners any foot (300 milimetes), oF +0-001 inch (+0025 millimetre) Yin length capacity 0.0025 inch (0-064 millimetre) fof the lathe. Length of bed more than above: Error not to exceed— +0-0006 inch Y +0001 inch Yin any 6fe. ~o-001" inch fi9 ay foot: To.onas inch flengtt at any part of screw. 6 Plich Errors of Gears and Dividing Errors of Dividing Heads ‘The term “permissible single error” indicates the talerance by which the actual pitch i allowed to be larger tor emaller than its prescribed basi siz. ‘se ‘The cumulative pitch error is the amplitude of the tooth. error curve plotted against the number of teeth (see Fig. 25). It is taken from the record produced by the gear-testing device or computed from measured single errors as follows: Example: ‘To determine the total pitch error of the dividing wheel for a gear-cutting machine {rom its single- pitch errors. 600 rnillimetres (about 24 module, 10 millimetres (D.P.=2'54). In the Table (Fig. 24) the measured single-pitch errors ‘number of teeth, 60! } ‘Tooth Single Error ‘Total Error ‘Tooth Single Error ‘Total Error we | mm | tne | mm | tren xo fmm | th fmm | tach 1 | 409% wo, | 49 x ese or | Hom | | # i | tbs 3b, | 88m | | es “Sm | SS | | 5 | a8als soon | x38 || 3 | tees Heshs | teem |] ie 5 | Fest | ees | tee | | # o | ees. sor | tend | | & 5 | ais soe | Hee | | 8 8] 3 yee | este | | 8 | Bons sees | Hees | | a | 38h soa | tose | | 8 B | a whos | theo | | 8 1 | bone woes | Hee | | H B | sees #885 | Het | |S ve | 8008 “a0 | aan6] |e | $83 soot | tess | | & a |B soe | tees | | o B | $005 180i | tebe |) B ie | feet toe | 88s |) fe B | sS8is | tee | ieee] | 8 B | 333! Hee. | toRe | |e B | 23a Soe | Ease |] 8 E | x | teeed | $e] |B] Tha # | $0. 48H | eshte | | S| Haat | & | ial. 480s | EGR | | de | Ehebs B | 23h | Hag | Giese | | 8 | 308 “eels & | 38s 48s | Hest | | oe | teal “B65 B | at oust | taste | | 8 | Saat 388 3B | Sons | 33a | SRR | | oo | 28h. 1m Fig 24. Sg ad Tol Fich Eros fa nding Wie ore yg ea 9Se: pot Fig. 25. Diagram of Pitch ems Errors of a Dividing Gear (millimetres and inches) are contained in the second and third columns. ‘The fourth and fifth columns contain the ‘cumulative errors, i. the algebraic surn of the single errors. In the graph of cumulative errors (Fig. 25) the sum of the single errors is plotted progressively over the numbers of teeth. From the selected example it will be seen that the largest positive deviation occurs near tooth No. 26 with an amount of +0-09 millimetre (0-0036 inch) and the largest negative deviation near tooth No. 50 with an amount of 008 millimetre (0-0032 inch). The total error (amplitude of the curve in Fig. 25) is, therefore, 0-17 milli- metre (0-068 inch). DETAILS FOR TESTING VARIOUS MACHINE TOOLS Milling and Gear Cutting Machines, Tables 1-7 In establishing the permissible errors of horizontal milling machines, consideration was given to the fact that, in the direction parallel to the eutier spindle, the work table must not droop, but is permitted to rise only towards the front face of the ce. While working, the table tends to droop under the influences of the weight of the work- piece and of the cutting force, while the cutter arbor tends fo. be deflected upwards. “As in other cases, great sportance had to be attached therefore to the necessity of the folerance being in the opposite direction othe expedted deformations under loads tolerances and. deformations should never be cumulative. In universal milling machines the offset of the swivel axis and the centre Tslot with respect to the cutter spindle must also be tested. Both alignments must be in order to obtain undistorted profiles milled. In the case of thread-milling machines, a special testis carried out in order to ensure that the cutter axis is at the same height as the work spindle. Unless this requirement is met, true thread profiles cannot be produced. ‘The permissible errors of gear-cutting machines are very small, because modern requirements for quick and ‘quiet running conditions and, therefore, accurately-cut gears must be met. It has not been considered possible, however, to specify tolérances below 0:02 millimetre (0-0008 inch), hecause the drive mechanisms of gear-cutting machines ate relatively complicated and the gear trains are rather long. | These facts make it difficult to maintain very high degrees of accuracy in the normal manufacturing process. ‘The most important component of a satisfactory gear- cutting machine is the dividing wheel which primarily ‘controls the accuracy of the gears eut on the machine. Close tolerances have been specified for single-pitch and ‘cumulative error. It is necessary to limit the cumulative pitch error in order to prevent a large number of successive Eingle errors occurring in the same direction (plus or minus). Gears produced with such errors result in non-uniform velocity transmission, and cause noisy running conditions, periodic shocks or impacts, and perhaps vibration. In printing and similar machines gear-driven rolls have to act lupon parts of low strength. Even small cumulative errors of the gears driving the rolis will cause irregularities in the drive and thus damage the parts transported by the rolls. Lathes, Capstan and Turret Lathes, Automatic Lathes and Vertical Boring Machines, Tables 11-20 Lathes ae grouped in accordance with their uses, their sises and the degree of accuracy cequited. fom them. Experience shows that lathe bede wear mote rapidly fa the centre than at the ends. Moreover, the overhanging Sright of the cariage and the custingtesistance force the Front shears (apron side) down and lft the rear shears Hence, the tolerance must be directed in opposition to this Geformation. The fron shear of a new lathe are therefore Dermited to be arched or humped upwards ony, while the Fe hens may be less convex er even sigh conve ‘To avoid she ‘undesirable combination of 3 maximum convex tolerance for the front sheate and 4. maximum Concave tolerance forthe rear shears = spirit evel text for fwist inthe transverse direction i alo caied out 2» ‘The headstock should be so aligned that an arbor inserted in the spindle nose rises or inclines upwards only at its free end with respect to the bed ways, whilst inclining in the horizontal plane tovvards the tool post only. This will counteract the deformations resulting from the weight of the workpiece and the cutting force. Similarly, the tailatock spindle when fully advanced is only permitted to deflect in the corresponding directi ‘The slideway surfaces of the lathe bed ate not only datum faces for levelling the machine but also. working Strfaces for guiding the cariage and the tilstock. The Gualty of these sliding surfaces, of whatever design is of ‘Tal Smportance forthe accuracy of workpicces produced fn the lathe. These slidewaye vary in length rom 12 Ics to 6 fect and ore Whine the lope eles, of planing, grinding or milling machines cover large portion Ef the idlewayy the short ‘carriage of the lathe eaves the tlideways wide open. Special eare haa therefore to be taken in their manufacture. For this reason the testo on LLLLLLZ aa LLL: LLLL. LL. TTP ELLE ¢ ‘aca * VLE= > “> _ > _ > ~ > ~~ ~ > ~ > — > = » "> ~ ~> ~ > “~ ) ~ S S S S > > > “= ~ > > = X S ousanage Fig. 26. Checking the Pallets of Guideways Charts 11, 12, 13, Fig. 3 were specified. These serve for making certain that the locating elements of the three main parts (headstock, tilstock and stay) are accurately aligned both vertically and horizontally with the carriage Slideways over their full length. Moreover, the tailstock guides must be carefully scraped of ground. ‘The tests Of the slideways are carred out by putting the plunger of the dial gauge ditecty on their scraped or ground surfaces. If the surfaces are tested in this manner along three lines (see Chart 11, Fig. 3), this can be done in a few minutes and the alignment and the quality ofthese important sliding surfaces can be judged, There is no objection in principle to inserting a block (Fig. 26) between the slideway and the dial-gauge. plunger, but by doing so the surface quality cannot be determined. Instead of the intermediate block (Fig. 26) the tailsock itself is sometimes used, In this case, however, slight’ movement between the tailstock proper and its base due to tightening oF loosening of the lamping serews may eause errors which can be avoided if 2 simple measuring block or bridge is used. Its, perhaps, lunnecessary 10 point out that inthe ease of long and large size lathes the use of the talstock for such measurements 13 completely out of the question. All tistock-quill measurements must be taken with the guill inthe clamped position. Although the test Chart 11 Fig. 9 sth only check onthe paalelism between the tool test slide and the spindle in the ver plan, thi {important because in this ery complex assembly the guides for three teclineat movements and one rotating movement are superimposed. In the eae of «high-quality machine ite therefore, necessary co ensure that afin test of the cumulative crror caused by this super-postion be caried outs If the toobrest aide is ted for automate feed movements (for instance for the wning of sphere) ie ‘movement has to Leas accurately tested as that ofall the other moving pari. In this cate, it would even ‘be feceaaay to test the vertical aigament of the swiveling Skis which can be checked bya turn-round. method, Firma of repute cary out this test for all ther machines. 1k thould ‘be ‘mentioned however that the specication Chart 11, Fig. 9 has been slightly relaxed because of the felaively lesser influence of any error in height upon the Cplindrieal or tapered shape of the workpiece. "As the raighiness of the tol-est movement i important in the case of sutomatic feed drives, atest in tie respect has been Sided. ‘The lead-serew is one of the most important parts of the lathe. Te is of the same importance as the main spindle Various erross may affect the accuracy of the serew thread, produced on a machine; viz: 1. The pitch error of the lead-screw. 2. ‘The axial slip of the lead-screw due to faulty thrust bearings. en PLANT NGI no + opener 3. The alignment of the lead-screw axis in relation to the carriage slideways. 4. The axial slip of the main spindle. 5, Errors in the transmission of the feed drive from the main spindle to the lead-screw through » Norton gear box for other means. ‘The lead-screw is subjected to quite unusual loads. ‘The end bearings locate it axially and radially. The nut, in the apron which transmits the drive fram the lead-serew to the carriage is usually split and has to be opened and closed repeatedly. It also supports the lead-screw at any point throughout its full length. The position of the split hut is determined by the slideways of the bed. It is there: fore essential to test the alignment of the lead-screw relative to the bed slideways. ‘The perinissible errors, (04 (0 02 millimetre or 0-004 to 0-008 inch—according to the size of the lathe) has been determined in relation to the influence which the misalignment of the lead-serew exerts upon the pitch accuracy of the thread produced {tis not permissible to reduce the permissible pitch errors specified for a measuring distance of 300 millimetres (12 inches) prorata of other measuring lengths, If necessary, the following values may be used for the case of specified tolerance of 003 per 300 millimetzes (0-0012 inch per foot): error measured aver 125 millimetres (5 inches) t0 be 0-02. millimetre (0-0008 inch); cumulative error over 1,000 millimetres to be 0-08 millimetre (0-0032 inch). ‘Turret lathes are grouped according to their size. The basic tet instructions apply to machines sth both hexagon and drum-type turret heads. ‘They do not apply, however, to turret lathes arranged with hollow recessed turret heads, in which centring recesses. locate the cylindrical shanks of drills, counterboring tools, reamers, 12ps, etc., by means of adapter bushings or tool holders." Two, supplementary instruction sheets, No. 16s and i7a are provided for this type of turret lathe. ‘The turret head is also tested for positional rigidity in its bearing and indexing holes. To this end, the inspector tries to turn the turret head about its axis by hand with the aid of a lever having a length of 0 or I metce (1-7 or 3-4 feet). ‘The actual angular displacement is measured bby means of a dial gauge. Grinding Machines, Tables 21-26‘The next measurement concerns the rise and fall of the wheel-head slideway, and therefore of the wheel spindle, while the wheel is fed towards the work table (Chart 21, Fig. 14). The position of the spirit level in the test of Fig. 13 is used as a starting point. After each adjustment of the ‘wheel slide, the precision gauge blocks on the wheel spindle are changed until the indication of the spirit level remains constant. According to Figs. 134 and 14a (Test Chart 21), similar tests are prescribed for a grinding table with a horizontal surface, In these tests itis assumed that the table surface is parallet to that of its swivel-plate. Variations in this connection, which may occur during manufacture are, however, negligibly small when compared with the specified tolerance for the difference in height of the two spindle axes. The movement of the wheel slide must respond with great sensitivity and consistency to the precision depth setting operation. Moreover, it must return to its set osition after the grinding wheel has been withdrawn and fed forward again. When the depth setting for the grinding wheel is tested, other settings of the machine must not be disturbed, In order to test the direction of the in-feed motion of the wheel slide, a fattened test mandrel is mounted between the centres and a square pressed against its flat surfaces the plunger of the dial gauge which is secured to the wheel slide traces the free leg of the square (Chart 21, Fig. 15). ‘A test grinding operation is carried out without the use of steady rests, a8 these should not influence the test results Of the machine itself, A good grinding machine, once set for cylindrical grinding, should grind cylindrically or eather slightly convex, since compensation for concave grinding is. very difficult indeed, whereas a slight convexity may be climinated by corresponding adjustment of the steady rests. Slightly conver grinding may even be desirable ao that the steady rests can be correctly set. Similarly, deviations from the straight line movement of the table are permissible as long as they result in conver, grinding. Drilling and Boring Machines, Tables 31-38 Separate test charts have been compiled for heavy upright, light pillar and radial drilling machines. Toler- ances for light pillar drills are wider than tolerances for the rigid upright machines, because they are of lighter design. drilling machines in which the position of the spindle axis sag fav Tien Piece See eae eae suum eta ang i 2pm See eee aera At the conclusion of the acceptance tests, the deflection under the largest possible axial force acting on the drill spindle must be measured, Theoretically, it would be important to determine the inclination of the spindle, i.e, the angular deviation of the spindle axe from its vertical poston ative tthe base: “However, if thin were 0 be Teasured, eg. by imeans of a spirit level applied to the Sealy loaded spindle, the result would be-unreliable Under practical driling conditions the drill produces a hole in accordance with the spindle position. {F the spindle is Ehilly loaded for test purposes, ts nose will be held in its ginal direction by the loading device, which means that Inclination would be atleast pary prevented. According to the aimoust by which the spindle protrudes from the headstock it ill be rather buekled than inclined, and a teasurement of its ineination by means of a spitt level willbe useless. For this reason the inerease in the distance between spine nose and base pate, under the action ofthe ada fore, fs measured. ‘This measurement should not be carried out during drilling operations. ‘The axial pressure during drill depends upon the rake angles of the drill. the dimensions ofits cross edge, the hardness of the material being drilled, ete., and it may vary by 20 per cent or more. ‘This means. that the magnitude of the axial force exerted during the deflection test would be uncertain, ‘The test is therefore carried out with a stationary drilling spindle. A load cell is placed on the table or the base plate under the spindle nose, and the spindle is then fed down by hand until the gauge incicate the required axa pressure, Any mensuring levee of simple construction can be used for this purpose. It is advicable for the manufacturer to specify the masini premreforwhgh the machine engl Tie also possible for the maximum drill diameter to be specified with which holes can be drilled into solid material Having an ultimate tensile suength of approximately 30 to 40 tons per square inch. Recommended feed valUes are given in Fig. 27. If high-speed steel drills are used these Dismeter of | Proposed Feed ‘Dall Rate inches | mm4eev.| inch/rev. Open Hearth per Stare + Fig 27, Steel (Tensile. Stren Millimetre. Approximately 30 to 40 ‘Tons’ per sa Axial Drill Pressures when Dail “of from $0 x0 60, ? 7 LLLLL LL. PLETE LLLIE LILI LLL 7 TTD Pe « |. 5 ANPIPE FEG FTI FEF EFEFG EEG CEFF FESS SSS STG feed values can be maintained in continuous production. Temay, however, be necessary to reduce these feed rates in practice if the stifiness of the workpiece, the required ‘smoothness and accuracy of the holes 10 be drilled or other factors require it.The specification of the maximum drill diameter does not imply that it would be impossible to drill even larger diameter holes into solid material. In such cases, however, smaller feed rates than those specified would have to be employed in order not to exceed the permissible axial force. Furthermore, it is not advisable fo combine the maximum drilling capacity ‘of a machine with a very high feed rate as specified in Fig. 27. The production engineer will usually refrain from overloading expensive large diameter drill, and if hole of the maximum, possible diameter has to be drilled, the speed of the Speration is of little importance. For the actual test it is best to specify the maximum permissible axial force, as safety devices prevent this being exceeded in practice. bed rather than to the work table. The machines shown, fon Charis 35, 36 and 38 are equipped with tables which are shorter than’ their slideways by an amount equal to the Tength of the cross traverse of the table (Fig. 28). In some designs the length of the table is equal to that of the slide: ‘way, and a longer eross traverse movement is thus possible (Fig. 29). In such cases it will, however, be difhcule 10 maintain the tolerances, specified on Charts 35, 36 and 38, for the permissible inelination of the table during its cross traverse movernent. Ifa machine can achieve the working accuracies specified in the top left hand corner of page 83, it will be able to perform the required work without heavy boring fixtures, guiding bushes, etc, It is wrong to assume that the horizontal boring machine provides only the driving gear for a spindle which is best connected to the tool by Universal joints in order to avoid errors caused by faulty rite 1 pe oe Fig. 28, Table that a Shorter than is Stideway by an “amount equel to the Cross-traverse of the Table ‘The Test Chart for universal-joint multiple drilling machines concerns two main types, i, machines wit Adjustable spiadle head and machines with adjustable work table, The tolerances for the spindles of such machines, cannot be as tight a8 those specified for upright drills, because their spindles are guided in one bearing only, with the inclined thrust of the universal-joint shafts acting at the top of the spindle. If the spindles are guided in fixed ‘earings on an interchangeable cluster plate, rather than in adjustable brackets, the tolerances can be much tighter. [A high degree of accuracy is required for horizontal boring machines, Very close Limits are therefore specified Te'take Chares 35 to 36 to wit the various sizes ofthese machines. If, on smaller machines, che outer stay bearing Ermoved automaealy together with the headstock, the wert sjusument mt be cael texted wih ga 2 the ligament between the say support bearing and the tmsin spindle. During the tex the headstock: andthe Support bearing: must be moved from the low position ‘pltard inet to eliminate bueldas in bevel geare and sew thread. Heavy types of horizontal bering machines ‘rth movable uprighs sve avally equipped with separate Wrork table” For this rato, the aigement of the main Tplnalef tcted in relaon to he movtble upright and the 29, ‘Table with Length equal to that of the Slideway spindle bearings, and to leave the accuracy of the operation to the guiding devices in a boring fixture. Planing, Shaping and Slotting Machines, Tables 41-4 ‘The extremely close tolerances for long planing machines are useless unleas the machines are very carefully erected and installed and subsequently checked and ce-levelled jelly. Planing machines for work of highest “sion should not be grouted on a solid foundation but justable wedges so that they can be re~ levelled every two to four months. ‘The accuracy which is today obtainable with shaping machines is of a very high order, and these machines are often used in preference to milling machines beeause of the simplicity of the tools employed. Power Presses, Punching and Shearing Machines, ‘Tables 31-33 Power presses and punching machines are grouped into one-sided open type and double-sided frame type machines The tolerances of open-sided presses must be s0 chosen thatthe frame is straightened out under the acting force, Due consideration hav also been given tothe various sizes of tush machine.ACCEPTANCE TESTS AND MAINTENANCE OF MACHINE TOOLS The acceptance test of new machine tool in the manufacturers works is carried out by experienced faters tnd inspectors who know every component and who have Co-opersted in the manufacture of components, sub. aseemblies and Sally the complete machine. "These men Know how to use meaturing instruments’ and how (0 assemble the machine in such a manner that the man facturing tolerances of individual components have 4 compensating and not cumulative effect ao far as the accuracy of the whole is concerned. Similarly, the user fends 2 representative who is capable of ‘catrying out Acceptance tests ofa machine, This man siko know when ihe must insist on rigid adherence to the specified limits and when he may allow relaxations in debatable eases a3 long. asthe machine produces ‘workpieces within. the required limits af accurtey. Complaints about awkward inspectors may have occured when the specifications were first introduced but they have soon disappeared. Manu. faeturer and eustomer have learned to ute the specifications both for inspection and test purposes, and. work can proceed smoothly. ‘An additional field of application is the current inspection of machine tools during their use in production, and after ‘maintenance and repair work has been carried out. ‘The machine-tool user expects the machine to produce accurate workpieces not only when is new but throughout its working life. A machine tool must be able to produce workpieces within specified limits without the need for special professional skill on the part of the operator to ‘compensate for faults of the machine. For this reason the ‘wear of the machine must not exceed certain limits, it must be watched, and parts which are faulty, due to wear of ‘other damage, must be replaced or repaired without delay. Repair and maintenance work must be carried out in ‘accordance with preventive planning rather than by default. ‘This is important from the point of view of planned steady production and it eliminates costly delays which would ‘otherwise occur when an important machine tool breaks down. Emergency. repairs are, of course, occasionally tunavoidable but the experience gained should be used to prevent their recurrence. ‘The maintenance of the machine tool includes: — 1. Checking the accuracy ofthe finished workpieces. 2 Preparation of materials and component parts necesary for repair work, including bought-out rts. Any repa work must be easfully planed Eeforehande v 3. Tastructions to machine shop foremen and operators in order to ensure correct ue ofthe machines. 4, Overhaul or rebuilding ofthe machine tool 5. Emergency repairs 6. Estimate of maintenance and repair cost. After 2 certain working life, natural wear ofthe various pars of a machine tol wll ease error in the workpieces rodvced Ht ths nated in ine can bee by making use of adjusting devices or by seraping, fiting, cen, without interfering withthe productivity of machine, "When the machine has been in operation for 9 Pa certain period, or if it has been over-strained, it must be subjected to a thorough overhaul, preferably in accordance with a definite time schedule. Such an overhaul can either be restricted to replacing oF repairing worn or damaged parts, or it ean be used for modernising the machine by “rebuilding” i. In the fatter Case, the machine tool engineer would have to ensure that after rebuilding, the machine will meet up-to-date demands of power, speed and productivity. New bearings, improved tain spines, new gears, better lubrication, et wil help in making « modem machine out of an old onc. It w nega conidr no oly de methods of maintenance tnd reptir but alo the people who carry out the worl involved. The head of the maintenance shop should be responsible othe wocks manager and should be given ful Suthority to carry out the work required for keeping the tnachine tools the factory in good condition. Foremen, fiwers and operators must be earefully selected and trained for the specialised work which they haveto cary out. They need the ability to watch and observe. they mast be reliable fnd able to carry out precision work,” ‘They must have the Skil o dismantle a mechanism and the sound judgment and txpetiencs which will enable thern to decide on action to be taken, The maintenance shop must not be the departinent to which worn-out and scless men sredemoted, ‘The men Jn the maintenance shop must be abie to carry out high Pression work and to detect weaknestes in design and ther Elimination. : “The measuring and testing equipment, used inthe tmaintenance shop is practiealy identical with that used for Aceeptance teste In addition, scrapers surface. plates, Straightedges, cle. mutt be available ae well as special equipment necessary to suit the requirements of particular ‘machines which have to be repaired In small machine shops inspection and repair are usually carried out bythe same men, "In lrger shops, sn nepector wil work side-by sie with the workmen who carry aut the Tepair work, I'l seo be advisable to crete repr gongs afroperstors who are each responsible for osrain types of foups of machine tools,” Each gang will then const of Spelalists withthe Knowledge of weak spots of the machine Under their eate which have to be watched ‘Today there exists an industry which does nothing but rebuild “machine tools. In their workshops not only standard but also special machines are dealt with in large numbers, and the experience gathered produces a staff of expert maintenance men, repair fiters and inspectors, ‘The periodic examination of bearings for gear-cutting ‘machines, of slides for che diamond-dressing devices for grinding machines, the examination and testing of hydraulic drives for grinding, planing and milling machines, are ‘examples of detail maintenance work required for keeping important machine elements in an_ efficient working condition, Such work cin be done during the lunch break ‘or in the evening without interfering with the output of the machine.” A complete overhaul or even rebuilding of a machine tool is advisable after a long period of service. A typical st ok ok ~4 a ~ ot ot os = ol ot of 4 ~ q ai 4 a 4 a x x a a 7J > > ~ 7 ~“ > > ~ > ~ ~ > “s > = ~ = > S > ~> ~ > “s ~ » » ~ > ~ > . . v > . . ~ . ~ v > N v works order for the overhaul of machine tools inthe factory of a British motor manufacturer is shown here: MACHINE NO ees a8 an Jos No. —. ‘Machine Overhaul Sanction Form Description of machine Date purchased a Present book value Present market value Cott of « new up-to-date machine of rame type... A brief statement to denote the relative production value of a new machine of same type Hours in we... Repairs for last two years cost Repairs for current year cost Last overhaul co:t Special reason for overhaul —_. Extent of overhaul proposed... Extimated cost Remarks. Length of time machine can be releated for overhaul obtained from progress department) a. Overhaul sanctioned considerations have been weighed against each other. ‘Apart from the regular general inspection of the machine tools, immediate steps must be taken when faulty work- Pieces are produced by 2 machine, ie, when machined dimensions lie ‘outside the specified limits (emergency repair). In such cases the accuracy and performance of the machine must be tested without delay. Faults can be climinated only ifthe causes of errors are known, In order to earry out such a test the following information must be available: 1, The requied accuracy of alignment, direction of ‘motion and shape of those parts of the machine tool which affect its performance. The, basic principles. for maintenance, repair and ‘rebuilding of the machine tools are identical with those for their manufacture. ‘The Test Charts provide, therefore, the required information. “Their practical value lies in the fact that they not only show the type and location of errors but also indicate the permissible limits within which these have to be kept. Practical tectification is possible only after errors of geometrical shape have been determined. ‘The machining tolerances of the workpieces, which are stated at PLANT ENG the end of a Test Chart, are in accordance with standard systems of limits and fits. 2. The best methods of carrying out the required measurements and of using the necessary equipment. ‘The application of the measuring equipment and the actual execution of the measurements will be discussed in the following chapter. Present-day machine tool manufacturers specialise on a limited number of types of machine tool, and sometimes on, only one type. Some produce only lathes, others specialise on the manufacture of milling machines, grinding machines ‘or radial drilling machines, and each manufacturer is an ‘expert in the production and testing of his ype of machine. He mast, however, use other machine tools in his workshops, perhaps even in greater number than machines of the type he is producing. " He is, cherefore, as much a customer and user of these other machines as any other machine shop, which has no direct connection with the manufacture of machine tools. For this reason the problem of systematic, checking, current maintenance and thorough overhaul of machine tools is of major impartance for all engineering workshops. Manufacturers cannot afford to use only the latest and most up-to-date machines, and have to give serious consideration to the question: when is a machine tool old? ‘The answer has to be considered from both the technical and economic viewpoints. It must be accurately checked by performance figuret and not backed by guesswork based on general experience. ‘The necessary Performance figures are provided by the tests specified in the Test Charts. These’ describe the general layout of the tests and the tolerances for the accuracy of the various parts fof the machine. In this chapter additional information is provided as to how the operator has to apply the measuring ‘equipment, The general procedure is laid down along the following. Tines:— 1. ‘The machine is installed and carefully levelled by the proper use of a spirit level 2, Where necessary the straightness, flatness, parallelism and quality ofthe guiding and bearing surfaces of beds, uprights and base plates are tested. 3. The main spindle, one of the principal elements of the machine, is tested for true running, axial slip, and location and position of its axis relative to other axes, and surfaces. 4. The movements of other main parts of the machine are checked. 5. Working tests are carried out in order to determine whether the machine as a whole produces workpieces within the specified limits of accurary.. eee ee sey ‘This description should assist the foreman and the experienced craftsmen in a repair shop in earrying out the tests in a satisfactory manner. In large organisations a ‘qualified inspector will supervise the correct application of, the test specification, and in other eases the foreman can do this job. If, however, the same person is in charge of the gaecution and inspection of the work especially when delivery schedules and cost requirements ae tight, this may lead to conflicts of conscience. These can best be avoided 2s 4by the inspector being directly responsible to the works management and not to the foreman. ‘The works management should expect first and foremost good quality overhaul, second place being given to the requirements of speed and cost. For this reason frietion amongst personnel in a maintenance shop must be avoided, and this ean best be achieved by simple and unambiguous insteuetions for measurements and tests. If rebuilt ‘machines are to compete with new machines in a workshop, their performances must be of comparable quality. Test Specifications ‘A. The accuracy with which the machine has been manufactured. 1, Installation and levelling of the machine. UL, Testing the quality of slideways and locating surfaces. II], Testing the accuracy of the main spindle and of its alignment relative to other important parts of the machine. B. The accuracy of the workpieces produced on the machine. CC. Power requirements. A. I. InsraLtavion anp LavELLino oF THe Maciine Measurements are carried out with the spirit level the sensitivity of which has to be in accordance with the required accuracy (eee page 10). Tolerances for straighmess and evenness When the straightness of edges or of movements atid the evenness of surfaces are tested, the tolerance indicates the permissible devigtion from a theoretically exact straight line or accurate plane. If the horizontal plane is taken. 35 ddatum, the measurements can be carried out either with a spirit level or by means of a measuring point touching the surface of a liguid. It is also possible wo use a tracer instrument and’ to compare either horizontal or sloping surfaces with accurate planes the shape and position of Which are known. ‘The support of the tracer instrument tan be moved along the datum plane or it can be moved along the surface to be measured, the tracer moving in this ‘ase along the datum plane. For long slideways, the test with wire and mierotcope has proved uscful (eee Fig. 8). ‘The tolerare concerning straightness or evenness indicates the amount by which the reading on the measuring instrument or on the mieroscope i allowed to vary. When the sprit level is used, the deviations have to be determined bby means of calculation or by plotting the results over the full est range. In genera, the deviation from strightness may occu in the specified plane or if no plane is specified, in any plane, When evennes le tested, the deviation may’ occur normal Xo the surface tested, causing ether concavity or convey. If the deviation is permisble in only one-diestion, ths must be dear sted; for instance, tolerance 6013 li metre in 1,000, surface only concave (a) Levelling the Lathe Bed (Test Charts 11-13, Fig. 1) 1. Longitudinally. 2. Transversely. During the test of short machines the carriage must be in the middle of the bed. In the cate of long beds with ‘more than two legs it must be between two legs. Fig. 30, Levelling the Lathe Bed 1. A spt evel (sale value 004/100) is best put frst on the eat slideway (ie the slideway opposite the pecatore side), This sideways usually plane whilst the font slideway inay be intentionally convex. By checking sitions a and B of the rear slideway (Fig 30) and Fepestng the measurement for the from slideway straight te of the beds can be determined. 2, Its advisable to check the levelling in the transverse direction simultaneously with 1. ‘This is done by means ‘of a second spirit level alternatively placed in positions ‘and d, A + twist is not permissible, because the sliding ‘surface of the carriage would not be properly supported by twisted slideways, ‘The above tests make it possible to ensure that the four corners of the bed lie in a horizontal plane, and this plane is the datum for all following measurements. ‘The actual profile of this plane between the four corners is determined ‘when the slideways are tested (see II (a)), and these tests are usually carried out immediately after the four corners have been levelled. (@ Levelling the Table of Horizontal and Vertical Milling ‘Machines (Test Charts 1-3) 1. Longiuinaly 2, Transverse. “The table is Brought int its middle position in order to preven ating inthe sideways 1, "The piri level is placed in the centre and at both ends of tne table (positions &, ¢, Fig 31). "The deviation of the air bubble in a plis or mints direction is recorded. Deviation in both dlrecions fs permisble as the table furfae it nota slideway. 2. This is carried out in a manner similar to 1 (positions ve f, Fig. 31). (0) Levelling the Grinding Machine Bed (Test Chart 21) 1, Longitudinally. 2, ‘Transversely a & c cel d e f + ff + Fig. 31, Levelling the Table of « Milling Machine a , ~ vos o aAIIS IE IIISE LEFT I EL EES EDP ESL SI ATES Fig. 32, Levelling the Bed of « Grinding Machine 1. The spirit level is placed longitudinally at one end of the bed (position a, Fig. 32). The table can then be moved to the other end and the spirit level placed in position & (eee Fig. 30), 2. The spit transversely on the bed in positions c and d (Fig. 32, see also Fig. 30). ‘The table can be moved toits extreme right-hand position for measurements @ and ¢, and to its extreme left-hand position for measurements 6 and d. It is, however, advisable to remove the table and to put the spirit level on the slideways at intervals of about 300 millimetres (12 inches). (@) Levelling the Base and Testing the Position of the Column of a Radial Drilling Machine (Test Chart 34) 1. Levelling the base plate (Fig. 338). The radial scm and driling head ae inthe muddle postions. A staight- tdge about 1,000 millimetes (40 inches) long is placed Siagonally onthe baseplate, anda sprit level in the middle of the straightedge. ‘Conveniy of the base plate is not permisible 2, Testing she column (Fig. 339, 33e) with the radial arm and the driling head inthe tame positon as before. ‘The Galuma must be at right angles fo the bate, ‘The Vee- shaped face of the frame spt level i held firmly against the’ front and Side of the column, Deviation from, the wena! i only permitted towards the base plate. “The devin indie by the api evel us not exe the ermissible value inary portion around the column into Sihich the radial arm maybe turned, especially if the base plate hasan angular or ctuiform shape A. IL, Testinc tHe Quatity oF Locarine Sunraces SLIDEWAYS AND Although definite standards for the surface finish of slideways have not yet been established, measurements Fig. 34. Wovinese Meter (S.A. Tominion, NPL level on a measuring bridge is placed ” Fig. 334 Levelitg the Base a (Checking the Coluran O Fig. 330 and 33¢. concerning fatness, straightness and paralleisin of the principal machine ways have been introduced successfully One method of checking scraped or ground surfaces consists in passing the plunger of the dial gauge over the surface to be tested. The dial-gauge support must have a locating surface of generous dimensions and must be guided along 2 good datum surface or edge (surface plate oF straight-cdge). ‘The radius of the hardened plunger stylus, shouldbe about 15 milimesrs (006 inch,” The plunger of the dial gauge is then moved dizectly over the surface to be tested along a series of parallel lines. ‘The pointer iniestes the peaks and valleys of the surface without being decsived by the mottling of the sliding surfaces. Thie rethod determines the average heights and depths of peaks and valleys. "The valleys of a well-scraped or yround {face should ie not sre chan 0-002 to 0.003 millimetres (0-000 to 00002 incl) below the min bearing aes ‘The waviness meter developed by S. A. Tomlinson (Fig. 34) also measures and records waviness. The tracer 2 is ball, 4 inch diameter, fited to the bottom end of a vertical rod’, which in tuen pastes through a hole in the base plate ¢, "The latter rests on the surface to be tested. The rod 6 is vertically adjusted by means of the screw d tantl the ball a protrudes approximately 0-003 inch b the face of the base plate c. This adjustment is easily carried out with the help of a thin shim of paper. When the base plate ¢ is now pressed against the surface to betested, the rod 8 is moved by an amount equal to the height or depth of the waviness. ‘The axial (vertical) ‘movement of the rod is converted into a rotational move- ment which actyates the recording pointer f.. This carries at its free end a seriber g for scratching a smoked glass plate hh. “The glass plate is automatically moved at right angles to the movement of the scriber by an amount proportional to the distance along which the instrument is moved by hhand over the surface to be tested. ‘The smoked glass plate carrier j, sliding on wxo cylindrical guides, is moved by rotation of the lever A. ‘The lever h is moved by means ‘of a cord J, the other end of which is fastened to'a brass block m. ‘The brass block m is in curn fixed to the tested surface by suction pads, Plasticine or similar means. ‘The ‘cord can be attached to the lever & either at 1, of 7, thus producing a traverse of one or two inches respectively. ‘The instrument is moved by hand over the tested surface, If this movement has to be exactly along a straight line, a straight-edge can be used for guiding purposes. ‘The small record scratched into the smoked glass. plate is magnified by photographic means, the usual magnification being 50:1 (a) Lathe Bed ‘The bed must be straight longitudinally (Test Chart 11, Figs. 1a and 1b). "In the ease of beds up to three metses (10 feet) long, it is sufficient to place a spirit level on the slideways; if necessary an intermediate block, see Fig. 26, a Fig. 35, Level on Bridge or a bridge piece, Fig. 35, can be employed. ‘The base of the spirit level must always be parallel to the direction of the slideways. ‘The straightness of the latter is checked by placing the spirit level at intervals of about 300 millimetces (12 inches) “along the whole length of the bed. ‘The difference between this test and the levelling of the four corners (sce page 26) ies in the fact that for the straightness test the spirit level readings are taken in several positions along the bed. For machines of more than three metrs (0 fect) between centres, other methods are used for testing the steaightness Of the sideways, eg. the taut wire, the telescope, the auto collimator, comparison with a long straightedge, ete (see page 13). ‘The tolerances for the front snd rear sideways Of the lathe differ. ‘The front slideway has to be convex: the displacement of the bubble should always be directed towards the eentre ofthe slideway (i. to the right coming from the headstock end and to the left coming from the tailstock end, see Fig. 13). The rear slideway is usually flat and for this reason is suitable for use as the sta surface for all measurements, The straightnes: surface quality of the tiltock sideways as well as their parallelism (Test Chart 11, Fig. 3) with the slideways for the saddle is best tested with a dial gauge clamped to the saddle (Fig. 37) and measuring both surfaces of the Vee. ‘The full length of the slideways is tested, including the bridge piece which cover the gap, if preent. "The unger of the ¢ indicates any small depression fn the surface whick might be caused, for instance, by mottling. These surfaces are relatively small in relation to the load to which they may be subjected, “They may, Fig. 36. Checking Flatness of Table therefore, be subject to considerable wear, and their quality is of great importance. If intermediate blocks are used when checking the parallelism between saddle and tailstock slideways (sce Fig. 26), the quality of the scraped surface will not be indicated by the dial gauge. (®) Milling Machines ‘The table should be flat in the longitudinal and trans- verse direction (Test Chart 1, Fig. 3). This is tested by means of a spirit level (scale value 0-04/1,000 millimetres ‘or 0-0005 inches/foot) which is placed directly on the table at intervals of 100 millimetres (+ inches). ‘The deviations of the bubble at various points are indications of the table surface quality. It is advisable to record these devi in a sketch, In this case the measurement using the spirit level combines the levelling of the machine with a test of the heats The ings othe abe nai be checked by means ofa straightedge placed on equa slip gauges or parallel blocks which rest on the “table (Fig. 30) Variations in the gap between the steaight-edge and the table are measured with s precision dil gauge, de support Of which rests onthe table whilst ts plunger fs moved slong the bowtom face of straightedge. The straight-edge and the paralel blocks. are moved fiom the original datum poston AL (Fig. 36) to posiuons indicated by the dotted fines (C,D, E, F. Fig. 36) and comparative néasurements are taken.” ‘This method is very accurae. but. slow, requiring great eare and an extremely thorough inepector On the flatness of a millng-machine table depends the gual of the surface milled the machine. The works plese has to be clamped tighly tothe table. If the table Kita Wavy surface and istifer than the workpiece the Inter wil be distorted by the clamping foros. “After the = o> = = Fig. 37, Acceptance Test for Guideways LLLLI. L LLLLLLLLLLLLLLLLL v4 LL y poles |VI SFIS ESI I STE LEP ETE SCEPC EF SUSY EUOUS al ‘milling operation is completed and the clamps are removed, the workpiece will spring back causing the milled sucface to lose its Rates. Its important, therefore, that workpieces aed for teat cls are auficently stil to. veret. auch distortion (eee ‘Text Chars, pages 42 and 49) (©) Grinding Machines 1 stfaightness of grinding machine slideways is tested when the bed is levelled in the manner described on page 26. Long beds have to be supported at intervals of not ‘more than 800 millimetres by means of wedge pieces which, rest on the foundation. Sound foundations are essential for all grinding machines. For long slideway grinding ‘machines, cast-izon base plates grouted on a concrete foundation are often used. The slideways of eylindrical- grinding machines are not 3s unfavourably loaded as those of the lathe. ‘The grinding forces are small and the long grinding table carrying headstock and tailstock, which are Rot heavy, distributes the load. ‘The straightness of the slideways and of the locating faces for headstock and ail- stock has to be catefully checked (Fig. 38). ‘The swivelling table must be in the position for cylindrical grinding. ‘The dial gauge is fixed to the bed with the plunger touching the locating face under test, ‘The table 18 then moved along slideways and readings of the dial gauge are taken (Test Chart 21, Fig. 2). (@) Radial Driling Machines The straightness and flatness of the base plate, the surface of which serves for locating workpieces or drilling jigs, is tested longitudinally and transversely either directly with a long-base spirit level (length of base not less than 250 millimetres, or 10 inches) or with the help of a bridge DBiece as indicated in Fig. 35 (distance between the legs 300 to 500 millimetres; oF 12 t0 20 inches). ‘The radial arm and drilling head are moved into the middle position. ‘The bridge and the spirit level are placed slong three parallel longitudinal lines a, 8 and ¢, Fig. 398 we base plate. On each line, readings are taken every ‘300 to $00 millimetres (12 to 20 inches). In a similar manner, readings are taken along three Fig. 40s, Checking the Centre Fig, 406, | Checking Fig. 38. Grinding Machine Test Fig. 394 and 390, Checking Flatness of Bose parallel transverse lines d, , f; Fig. 390, As the base plate has to be concave in both directions, the deviation of the air bubble changes from plus to minus over the measured length. Long Bridge pieces would hide the shape of the surface, Short bridge pieces are preferable because they avoid this drawback and also eliminate the influence of small irregularities which would affect the measurement if the spirit level were placed directly on the bate plate. AIIL, ‘Testixc THE AccuRACY OF MAIS SPINDLES AND OF wen Auignwent Revative To Oruen Important Paxrs oF THE MACHINE ‘These tests concern:— 1, True running of (a) The centre (Fig. 404}; (6) The internal taper; (© Cylindrical locating spigots, external tapers, ete. (Figs. 408 to 400). 2. Axial slip. 3. Alignment between spindle axis and other axes. 4, Parallelism between spindle axis and slideways, 5, Perpendicularty between spindle axis and slideways. It may be repeated here that, in all tests concerning running conditions and alignment of the main spindle, the ‘machine must be at its working temperature, as other the spindle will not be in its normal position in the bearings 409. Checking rer Fig. 400. Checking « Cylinder ‘Gylindsiea! Spigot »Te ice Gry Section an £2. Tea gresterseay 5 —— Aue of Rtston [gy __ mantoperoty —letfeay’ Sources of Error in Rotating Mandrcle Fig. 41, Le True running ‘Three source of errors have to be covered and are often measured simultaneously (Fig. 41); these are + (2 Inclination of the spindle axis in relation to the axis of rotation (angle a) (ii) Eccentticity of the spindle axis with respect to the ais of rotation (distance ¢). (ii) Lack of roundness of the surface tested as shown, in the enlarged cross-section XX. For all these measurements, a precision dial gauge is used, the calibration of which should be checked every few months by means of slip gauges. ‘The tolerance specified for true running indicates the permissible movement of the dial-gauge pointer during one complete revolution of the machine spindle, In order to evaluate this measurement, the axial distance of the dial- ‘gauge plunger from the spindle nose has to be clearly stated. ‘When test mandrels are used, measurements should always be carried out at tito points, ie. near the spindle nose and at the end of the mandrel. (a) The tests for true running of the centre points are usually required only in the cases of lathes (Test Chart 11, Fig. 4), and grinding machines (Test Chart 21, Fig, 4). (b) Im the cases of machines with a rotating spindle, e.g. lathes, grinding machines, milling machines, drilling ‘machines, etc, a test mandrel, with a locating taper shank and a cylindrical portion, about 300 millimetres (12 inches) long, is used. ‘The method of carrying out these tests is shown in Fig. 42. ‘The taper shank of the teat mandrel is located in the spindle taper. The dial-gauge plunger rests fn the cylindrical surface of the test mandrel and readings ‘of the dial gauge are taken while the spindle is slowly rotated. Readings are taken with the dial-gauge plunger both near the spindle nose (a) and at the end of the test mandrel (). Fig. 42, ‘Test for Hose Running ab c (©) External cylinders or tapere (Fig. 402 t0 400) are used for locating a chuck on a lathe spindle (Test Chart 11 Fig. 5), for locating a cutter head on a milling spindle (Test Chart 1, Fig. 2a), and for locating a grinding wheel fon a grinding’ spindle (Test Chart 21, Fig. 1a). Tests for true running are carried out by resting the dial-gauge plunger at right angles (radially) to the surface to be tested. Readings of the dial gauge are taken while the spindle is slowly rotated, 2. Axial Slip If the plunger of the dial gauge rests against a shoulder face, the total error indicated may be the result of three sources (Fig. 43): (@) Exrors in the thrust bearing. () The face of the locating shoulder is not perpendicular to the axis of rotation. (©) The shoulder face is irregular ‘The total error indicated by the dial gauge is then (a) (re wheen (2) and @) ae usualy erge compared If the shoulder face has been machined with the spindle in its bearings in the headstock, and if the dia-gauge plunger touches the shoulder face atthe eame spot at whieh the tesing tool of the glinding whee! has acted, the dial- ‘gauge indication would not vary at all, For this reason all thoes memurents fx ial ip at beers Out at two diametrically opposite postions (Fig. 4). After the ‘plunger is placed against the shoulder face of the spindle, eadings are taken while the epindle, axially loaded against’ the thrust bearing, is slowly rotated. Measurc- ments are repeated with the dis-gioge, plunger resting gains the shoulder face ata point diametrealy opposite 10 that of the first measurement. ‘The Influence of the errors ofthe shoulder face can also be eliminated by placing the dial-gauge plunger as sccurately 28 posible in ine with {he ais f tation ether against a ace which = perpendici Jar tothe axis of rotation (Fig. 45a) or against a ste ball Fig. 4. Testing the Face of a Shoulder LLL LL LLL LL LLL LI? tr: iFVIISTIT ESI STIS EE FEET ECE TEE UMM Fig 4. Axial Slip of Spindle =} Fig, 46 ———————— Axial Stip 9 Lead-tccew SSS which rests in the centre bore (Fig. 456). ‘The first method (Fig. 45a) is often used when axial slip of the spindle is meauured, the second method (Fig. 455 and Fig. 46) is employed for testing the axial slip of lead-screws, 3. Alignment ‘This concerns errors of alignment between wo axes or faces. I often neceary t describe the plane in which the ligament ior has tobe eure, the menue. ‘ment is carried out by rotating » dial gauge about one axis in such a ianner thatthe phinger point describes a izle Bound the axis of rotation (Big. 47), the permissible deviation of the dia-gauge pointer is twice the error of Sligament and. may, therefore, be wice the permissible tolerance indicated in the Test Chart. An eccentricity (Fig. 4) produces a deviation 27 ofthe dial gouge pointer. When tet mandrels are used (cee page 9) erzors due to the ang of the mandrel and an addtiona! deformation used by the weight ofthe dal gauge the plonger pressure, S'alp bushing, ete, must be avoided. ‘Three methods are used:— (a) The swing-over or turn-round method (Figs. 1a and 47). . (© Phe doulesande method Figs 10, te, $0 and (0) The slip bushing method (Fig. 53) ¥. Turnround Reading Fig “Tubular Holder for Dial Gauge ep Fig. 49. ‘Testing 2 Ture, "Sng a Tube Stand (2) The swing-over or twrn-round method. ‘This has been shown and discussed in Figs. 1a, 19 and 47. The dial gauge must be of the required accuracy and the ‘mandrel of the necessary size and stiffness, Readings are taken at 180* positions in the horizontal and vertical planes, and, as mentioned above, the alignment error is equal 10 half the difference between two diametrically opposite readings. Tn horizontal readings, errors ae lee likely to occur than in vertieal ones athe influence of the dalgauge weight it climinated, Tn the case of vertieal readings is weight increases the pressure when the dil goige is above the mandrel snd decreases it when its below. In the ease of an aecurate dal gauge the result depends, therefore, on the tlfiessof ts support. "The supporting structure for dial fuuges consist usually of joint, ding pate ete, which fre Clamped by means of serewe and nuts. "The diameters Gf the supporting. bare are relatively small and. the defections are inflenced by the varying lengths of these tars Tor this reason, meaauremens from a Bxed datum lane on which the dl gauge support is moved (Fig. le) tre often substituted for tammel fedings with 2 moving dial gouge. If, however, the dialgauge support can be made sufficiently st to keep defection duc tothe Weight ofthe ge and the spring pressure on the plunger within given iis, the ‘tcammelreadiog. method “is useful” and satisfactory. A proper support forthe dial gauge isthe Steel tube (Fig. 48)" ‘Testa with such a tubular support hve shown that the errors encountered with a OUDDI inch dial gauge are. very small, and. within. permissible limits as far ss measurements on capstan lathes, turret Ishes, milling” machines “and grinding machines are Concerned, Calibration measurements taken with 2 dial fauge (weight about B ounces, maxinium plunger pesaute Pouncess total load, 12 ounces), mounted on 2 stecl tube {Ghites exeral diameter 4 nes eral ameter, Tolinches lang snd weighing approsinately § pounds) gave the following results: "520 wd: ua i. Deflection of the free end of the tube without dial gauge 0.000014 inch. fi, Additional deflection (vertical) under weight of dial gauge and plunger spring pressure (12 ounces) 0-0000036 inch. |. Additional defleetion(horizontal) lunder plunger spring pressure (4 ounces) 0-0000024 inch. “Maximum total vertical error (i.-bii.) 0-0000176 inch. ‘These deflections can be neglected. ‘The design of the support is simple, the bore of the tube is large enough to allow even a hollow test mandrel to enter during measure- aeFig. $0. Arrangement of Double Mandre! Test ment. Fig. 49 shows the application of this method for the test of a capstan lathe where it would replace the usual double mandrel test (Fig. 50). Fig. 52 shows the method applied to a test on a milling machine where the alignment between main spindle and arbor support bearing is checked ‘The test mandrel is fixed in the arbor-support bearing and the dial gauge holder fastened to the spindle. ‘The dial- gauge plunger touches the test mandrel, and the main spindle is then rotated slowly. Readings of the dial gauge are taken at four points, in the vertical plane (a, and 2) and in the horizontal plane (6, and 6,). ‘The differences between the wo vertical readings « and a, and between the two horizontal readings b, and by are equal to twice the eccentricities of the mandrel relative to the arbor support bearing in the vertical and horizontal directions respectively. The measurement is carried out in two positions A and B of the arbor support, the first at 1 distance of about 300 millimetres (12 inches), the second ata distance of about 500 millimetres (20 inches) from the spindle nose (8) The double mandrel method (Figs. SO and 51). A special mandrel (M) is used which ean be accurately aligned with the spindle axis by means of a flange and adjusting screws Ay, A, and A, for tension, and By, By and B, for compression. Say is reduced by using a hollow mandrel. ‘A second mandrel 7” of exactly the same diameter (tolerance 4- 0-00002 inch) is clamped into the bore to be tested. ‘This method is used for testing the alignment of the tool holder bores in a turret head with the spindle axis Fig. 51 Double Mandeel Test 2 “Phe adjatment of the mandrel by meant of the six adjusting tjews ib ot eany and ean be cari out ply by"an experienced and coneieniovt inspector. "The tabod hat several disadvanages" the digtnce beoween the spindle nove and turret head io atleast 600 milietres (24 ches) Beene the two mandrels must face each other Jind each his a measuring length of 300 ralipetres (12 inchs). Ione mandrel fepingle) is hollow and the other tne (iret head) ald the} wil ag by diferent amount, ‘Thespindle must be rotated unl the axes of both mandrels tein one plane at ight angle othe diesion of measure ‘Whe twrret head bores are often machined in the lathe itself under its normal working conditions. For this reason the double-mandrel test must also be carried out alter the spindle bearings have reached their working temperature (©) The slip bushing method. ‘he alignment berween main spindle and arbor-support bracket on the overarm of a milling 1 can also be checked in accordance with Fig. 53. ‘The plunger of the dial gauge .M touches the test_mandrel D. ‘The true running of this has been checked beforehand and it has been rotated into its mean position. ‘The bore of the bush B is a sliding fit on the test mandrel whilst the outside diameter of the bush B is a sliding fit in the bore of the arbor-support bracket A. ‘When the bush B is pushed into the bore of the bracket 4, misalignment causes bending of the test mandrel D, the amount being indicated on the dial gauge. If several arbor Fig. 52. Checking Spindle Alignment Fig. 53. Slip-bushing Method LILLLL IZ 1. LLELLELLLLLLLLLLLLLLLLte.- " |ee ee ee eat emerge FETUS SCTE ECC EP ee Fig. 5%. Checking or’ Barlclsm Ay ‘supports are provided, the test has to be repeated with all, of them. ‘The method, although simple, has several disadvantages. ‘The mandrel must be very accurate and must run true ‘The readings are affected by errors in the main spindle bearing in a manner similar to the turn-round method, ‘Therefore, the mean position must first be established. ‘Measuring errors can be caused by i, Inaccuracy of the taper shank. Eccentricity. iii, Out of roundness. iv, Lack of eylindricity Under no circumstances must an ordinary milling arbor be, used as a test mandrel, beeause no milling ator is sufficiently accurate for the purpose. Sag has to be considered and for this reason measurements in the vertical plane are hardly reliable. In the horizontal plane the influence of sag can be considered negligible. ‘The outside diameter and the bore of the bush must be concentric and cylindrical within close limite, and a tight sliding fit must exist between the bore of the bush and the ‘outside diameter of the test mandrel on the one hand, and the outside diameter of the bush and the bore in the support bracket on the other; otherwise the testis of ne value. Cast-iron or bronze bushes are too heavy and increase the sag of the test mandrel beyond permissible limits. Specially prepared light-alloy bushes chould be used. ‘The alignment of the lathe spindle and the external diameter of the tistock sleeve isnot critical as longs the xen ofthe two intemal tapers ace inline ifthe manufacture is" properly controlled, however, the external diameter and ‘the toteral taper aze bound to be. concentric. The same applies to grinding machines, Tr is often easier and more accurate to check the alignment of two sxe by ‘measuring their position relative to a common datum face. (See Figs. 1, 1e and 50) 4 and $. Paralleliom and Perpendicularity Parallelism between two aes, between two surfaces of between an axis dnd a surface is checked by measuring the distances @ and bof two sets of pointe 4, 4, By By (Fig. 54). eis usvally necessary t© determine’ the angul deviation which can also be measured by means of a spirit level or determined by relating the difference To the distance L. Parallelism i usally measured in two plane, Vertical and horizontal, Measurement in only one plane is sufficient when the position in the other plane ts adjust able, (ailtocks, swiveling tables, ste). ‘The tolerance for perpendicularity is specified in the same ‘manner as that fer paral, Ite checked by imeans of a trammel reading or direcly with a reference square. Py Fe 58. Spindle Fy. 56 Taltock 208 Fig. 57. Taitoeh = (A) IN Tue Case oF THE Cexmae Lani, parallelism has to be checked 1. Between the saddle slideway and 0) the titck sideway (ee Fig. 37). between (© So sures (Lane Chal Be. (b) the spindle axis (Fig. 55), ie. between a surface Mra boas (Text Cre, Big (6) the outside diameter of the talstock sleeve (Fig. 56), ie, between a surface and an axis (Test Chart'I1, Fig. 10). (@) the tailstock sleeve taper (Fig. 57), ie. between a surface and an axis (Test Chart 11, Fig. 11). (e) the lead-screw axis (Fig. 58), ie. between a surface and an axis (Test Chart 11, Fig. 14). 2. Between the spindle axis and the tool rest slidewsy (Fig. 59). ‘This requires a test similar to the one shoten for 1 (b); (Test Chart 11, Fig. 9). Test 1 (a) has been discussed before (see Fig. 37). Tests 1 (6) to 1 (@) (Figs. $5 to 58) are identical in le and are carried out in the vertial as well asin the tal plane, Asan example, Test 1 (6)(Test Chart 11, Fig. 8), may be described in detail, The test mandrel is located’ in the spindle taper (Fig. 55), the dial gauge is mounted on the saddle, the plunger touching the test mandrel. “The spindle is rotated into its mean position (see pone 10). The saddle is moved along the mandrel by an amount equal to the reference length and. the indication of the dial gauge noted. Measurements have to be repeated in the vertical plane @ and the horizontal plane 6." ‘The spindle must have been running for aboutFig. 58. ha an hour before the measurement is taken so that the thain bearings at its working temperatore (ae page 7) Tn view athe lading condone soring trong, the (0) tise, and (@ point toward the toot towards it free end. ‘The tailstock sleeve (Figs. 56 and 57), which cannot rotate but can be axially moved, must be clamped during each measurement, asthe effect of clamping may affect its working position. In a similar manner the height aligoment of two axes is tested after each axis has already been checked for its parallelism with a common datum slideway. In the case Of the lathe such tests concern the alignment of spindle axis and talstock sleeve taper (clamped), (Test ‘Chart 11, Fig. 12), and pian lead-screw nut (closed), and lead-screw bearings (Test Chart 11, Fig. 14). ‘ For measuring the height alignment of spindle and he Fig. 39. Upper Slide Fig. 60. Height of Centres oe Lead-serew u tailstock sleeve (Fig. 60), a hollow test mandrel, 300 to 500 millimetres (12 to 20 inches) long, is held between the centzes, the spindle bearing being again at its working temperature. A dial gauge is mounted on the saddle, the plunger touching the top of the mandrel. The saddle is, moved along the bed and the indication of the dial gauge noted, ‘The tailstock centre must be higher than the spindie centre, __ For measuring the alignment ofthe lad-screw (Fig. 58), che saddle is moved (othe middle ofthe bed and the aut closed. ‘The ial gauge is mounted on a bridge piece Svhich is located by the front Vee of the bed and freely Supported by the rear slideway. ‘The dalgauge plunger touches the outside. diameter of the leasctew The bridge piece is moved to the right (Fig. $8, Two TIN) and to the left (Fig. 58, I to II), and the procedure repeated both io the heriaomtal a and the verte! b plane. ‘The Teadvserew is also tested. for true running (tolerance Ot mnillimetre—000$ inc). indicularity between the cross-slide movement and : thecked either by a. surfacing ‘operation (TTest Chart 11, Fig. 15) or by means of a trammel reading. the surfacing test, a workpiece is fixed in the chuck or fastened to the face plate and a fine finishing cut taken starting from the inside diameter. A straight-edge is then placed against two equal block gauges which rest on the Fig. 62. Checking Perpendicularity TUT TTITTILILLI LLL LELLLLEZ Up i? M1707 77> S > vw ws Gd dvs Vv ee UY 6 et el U VU CW TUNIS outside diameter of the turned face, and the distance Detween straight-edge and workpiece measured by means. fof block gauges. ‘The turned surface must be concave (Gig, 61). ‘This test combines an alignment test and a cutting test. Tt would be wrong to check the machined surface by means of a dial gauge fastened to the eross-slide because the dial-gauge plunger would traverse exactly along the path of the tool edge and would indicate a zero reading whatever the inaccuracy of alignment. It is also possible to test the perpendicularity between ceross-slide and spindle axis by means of a straight-edge L (Fig. 62), fixed to the eross-slide, and a dial gauge mounted on the ‘face plate. ‘The straight-edge is set cxactly perpendicular to the axis of rotation of the spindle (dial- gauge reading in wo diametrically opposite Positions a and a). If the cross-slide with the steaight- edge is then moved along the dial gauge, alignment errors, can be determined directly from the dial-gauge reading. (BV bx Tue Case oF THe Hontzowrat MiLuise Macnist parallelism has to be checked 1. Between the surface of the table and the spindle axis, i.e, Between a surface and an axis (Test Chart 1, Fig. 1) ‘The table must be flat and level 2 Between the table surface and the direction of the longitudinal table movement, i.e. between wo surfaces (Test Chart 1, Fig. 4). This is deseribed as, rise and fall of the table during its movement. 3. Between the direction of the eross-traverse movement and the spindle axis, between a surface and an axis, (a) in the vertical plane (Test Chart 1, Fig. 5). G6) in the horizontal plane (Test Chart 1, Fig. 6). 4. Beween the centze T-slot of the table and the direction of the longitudinal table movement, i. between two surfaces (Test Chart 1, Fig. 8). 5. (a) In the vertical plane between the overarm and the surface of the knee (see Test Chart 1, Fig. 123). (8) In the horizontal plane between the overarm and the direction of the transverse table movement (vee Test Chart 1, Fig. 126). ‘The parallelism between overarm and spindle axis has been discussed previously (see Fig. 52). 1. (Big. 63)." With the table in the middle position of is longing! movement 300 millimetres (2 inches) long test mandrel is placed in the spindle taper. A gauge is placed on the table underneath the test mandrel With the dial-gauge plunger touching the mandrel. After the spindle has been rotated into its mean position, Fig. 64. Paralielism between the ‘Table Sytface and the’ Direction of the Longitedins ‘Table Movement measurements in positions A and B are taken without the table being moved. ‘The base of the dial gauge support must, therefore, be of sufficient length (about 8 inches) for the necessary displacement of the dial gauge to be possible. 2. (Test Chart 1, Fig. #. From tests 34 and 3b in ‘Test Chart 1 the Matness ofthe table e Known, It this has been plotted, the errors of parallelism ean be measured direely by moving the table Under the plunger of the il tauge.” If the table Ts not suficeniy Mat for such a tmeasorement, a sitaight-edge has to be placed evel on the table surlace. The length of the straightedge must be approximately equal wo the total longitudinal movement ofthe able Q0 to inches). Testing procedure: A. straight-edge is placed on the longitudinal centre line of the table. A dial gauge is fixed to the spindle. ‘The dial-gauge plunger is placed in contact with the straight-edge and the table is moved longitudinally and the dial gauge readings taken. (Fig. 64). 3, (Test Chart 1, Figs. $ and 6), With the table in the middle position of its longitudinal movement, » 300 rilli- ‘metres (12 inches) long test mandrel is put in the spindle taper. ‘The dial gauge is fixed on the table with the dial-gauge plunger touching the mandrel. After the spindle has been rotated into its mean position, the table is moved transversely and readings taken (2) in the vertical plane (Fig. 65); () in the horizontal plane (Fig. 656). 4. (Fig. 664). The vertical inner walls of the centre tee-slot must be clean and smooth throughout. Direct measurement with a standard plunger of a dial gauge is dificult and it is recommended, therefore, that an angular | Fig. 63. Parallelin beswoen the Surface of the Table ind the Spindle Axi e° SJ Fig. 65 7 “Teanaverte Movement of ble parallel with ‘Spindle Axi 3sattachment (Fig. 660) be used, as this can be easily introduced into the slot. ‘This enables manufacturing blemishes, which are often encountered (burrs, faulty cuts, etc), to be detected. If an angular attachment is not available, it is also possible to place a short reference bracket (about 150 millimetres, 6 inches, long) in the slot and to go along the face of this bracket with the dial-gauge plunger during the movement of the table. However, such a reference bracket covers up lucal blemishes. Testing procedure: (Fig. 67), The reference bracket is placed inthe cente sot of the able. |The dial gage i ced to the spindle taper with the dial-gauge plunger touching the edge of the reference bracket in the horizontal plane. ‘The table is moved longitudinally, and the reference bracket is held in the T-slot by hand and readings are taken 5. (Fig. 68), The overarm is clamped in its fully extended poston, "A dal gauge is placed onthe knee in the two posious (a, 3), the dal-gauge plunger touching the Bottom ofthe overattay readings ate taken Fig. 664, Set-up for Checking T-slots Fig. 660, Dial Gauge with Angle-lever Attachment Fig. 67. Checking Parallelism of TT-slot with the ‘Table}Movernent ahs Fig. 68. Checking the Parallelism of Overarm with ‘Transverse Movement Forth cond ie (Fig, 8, he dl euge Sed to the table, and, with the dial-gauge plunger touching the Side of the overarn, the table i Wavefeed across’ and readings are taken, If the parallelism between overarm and spindle axis in the horizontal and vertical plane is to be checked, the following procedure applies (Fig, 69). A300 millimetres (12 inches} Tong teat mandrel is piace in the spindle taper. ‘The overs fe clamped in te extreme poston and the dial gauge ls fixed to. supporting piece which fits the overarm® slideway (dove-tal or cylinder. With the Galgauge plunger touching uhe test mandrel, the dal suge supporting piece is held by hand sgainet and moved Fig. 69. Parallelinm between Overarm and Spindle Axie LLLLLLLLLLLLLLLLLLLLLLEZ L. 4 jee) aimless *L |BVI FEIT I TELE LEE LEE EI EIEI I IIE TEES Fig, 70. Perpendiulaiy between the Centre T-slot id the Spindle along the overarm slideway and readings are taken. Before the testis taken, the spindle with the test mandrel must be rotated into its mean posi Perpendicularity has to be tested between: 1. The centre T-slot of the table and the milling spindle (Test Chart 1, Fig. 7). 2. The table surface and (a) ‘The columaway for the knee (front measurement, ‘Test Chart 1, Fig. 9) (2) The columnway for the knee (side measurement, ‘Test Chart 1, Fig. 10) Testing procedure: 1. (Fig. 70). With the table in the middle position of its iongitudinal movement, a reference bracket (at least 6 inches long) is placed in the centre ‘Tslot. "The dial gauge is fixed to the spindle with the dial-gauge plunger touching the reference bracket in the horizontal plane. ‘The reference bracket is shifted from gone end of the table othe other and trammel readings are 2. (Figs. 71a and Tl). With the table in the middle position of its longitudinal and cross-traverse movement and the knee clamped in position, a square (vertical leg about 12 inches long) is clamped to the table. A dial gauge is fixed to the spindle with the dial-gauge plunger touching the vertical leg of the square at the top end in the horizontal plane. The ‘knee is then unclamped, raised by 300 millimetces (12 inches) and reclamped, readings being taken in the top and bottom position. ‘Two sets of readings are necessary: (@) to test the perpendicularity between the table / | Fig. 71 Fig, 71a and 7iu, Perpendicularty between Table Surface und Columnvsy for she Knee ” (®) to test the perpendicularity berween the table surface and the side of the columaways (Fig. 710). As far as possible no differences should be found between the readings taken with the knee in its clamped of un- clamped position, It is recommended that at least five readings be taken. Care should also be taken to check the square before this testis eartied out. (C) IN THe Case oF CyLinpRIcaL Grinpine Macitines, patallelism has to be checked between: 1. The table slideways and the slideways or locating faces for headstock and tailstock. (Test Chat 21, Fig. 2) 2. The spindle axis (internal taper) and the direction of the table traverse in (2) the vertical plane (TTest Chart 21, Fig. 62); () the horizontal plane (Test Chart 21, Fig. 6b). 3. The spindle in the swivelling headstock and the dizection of the in-feed movernent of the grinding head in, the vertical plane, measured with the headstock in the 90° position (Test Chart 21, Fig. 7) 4. ‘The tailstock sleeve (internal taper) and the direction of the table movement (@) in the vertical plane (TTest Chart 21, Fig. 9a): @) in the horizontal plane (Test Chart 21, Fig. 9b) 5. The grinding wheel spindle and the direction of the table movement (a) in the vertical plane (TTest Chart 21, Fig. 123); @) in the horizontal plane (‘Test Chart 21, Fig. 12). 6. The internal grinding spindle and the di the table movement (see item 5) (2) in the vertical plane; () in the horizontal plane. |. This has been covered on page 29 and Fig. 38, 2. Fi The table is put in zero position for cylindrical grinding and 2 300 millimetres (12 inches) long test mandrel is fixed in the workpicce-spindle taper. ‘The dial gauge is fixed to the grinding-wheel slide, with the dial-gauge plunger touching the test mandrel (in the case of machines with rotating workpiece-spindle this has vo be rotated into its mean position). ‘The table is traversed longitudinally by an amount equal to the length of the test mandrel and the readings are taken. (@) The free end of the mandrel must rise, (#) The free end of the mandrel must be inclined towards the grinding wheel, 3. (Fig. 73). This applies only to universal grinding machines. ‘The test is similar to test 2 except for the fact, that the dial gauge is clamped to the grinding wheel slideFig. 73, Parallelism berween the Spindle Axws {nd the Direction of the Infeed Movement (Uaiversal Grinding Machines) which is moved by an amount equal to the total in-feed movement. For the 90° setting, itis sufficient to rely on the graduation of the swivelling-head scale, as the measure ment is only taken in the vertical plane and excessive accuracy in the angular position is not essential. The ‘mandrel must rise towards its free end. ‘The inspector also checks whether the spindle is level with the mandrel in the zero and 90° position, 4. (Fig. 74). With the table in the zero position for cylindrical grinding, 2 300 millimetres (12 inches) long test mandrel is located in the taper of the fully withdrawn, and clamped tailstock sleeve. A dial gauge is fixed to the of Fig. 74, Parallelism between Tailtock Sleeve and ‘Direction of Table Traverse srinding-whes! slide, with the dial-gsuge plunger touching fhe wet mandeel ‘Phe cable is traversed longitudinally by fn amount equal to the length of the text mandeel and readings ate ken: (@) the free end of the mandrel must rise, (8) the free end of the mandrel must be inclined towards the grinding wheel. 5. (Fig. 75). A 100 millimetres (+ inches) long test mandrel is fixed to the grinding-whee! spindle (the locating ‘and clamping depends upon the design of the spindle nose), and a dial gauge is fixed to the table with the dial-gauge plunger touching the test mandrel which has been rotated {nto its mean postion. ‘The table is traversed longitudinally bby an amount equal to the length of the test mandrel and es 208 Fig. 75. Paralelism between Grinding-whee! Spindle and Tele Movement 38 (2) the free end of the mandrel must rise, () the free end of the mandrel must be inclined towards the table, 6. (Big. 76). A 100 millimetres (+ inches) long test mandrel is fixed in the internal-grinding spindle support (method of concentric location and fixing depending on the particular design). A dial gauge is fixed to the table with the dial-gauge plunger touching the test mandrel 7 Bo Fig. 76. Pacllelism between the Internal Grinding Spindle and the Table Moversent which has to be rotated into its mean position. The table is traversed longitudinally by an amount equal to the length of the est mandrel and readings are taken. ‘The height alignment of two corresponding axes is tested in a similar manner as described previously for the cease of the lathe (see Fig. 60) and the milling machine (Gee Figs. 1, 52 and 53). In the case of the grinding machine the following height aligaments are checked: 1. Workpiece spindle and tailstock spindle centres (Test Chart 2, Fig 10). 2. Workpiece and externak (Test Chart 21, Fig. 13). 3. Woripince and ineral grinding spinal (oe Rite and fall of grinding wheel spindle during its in-feed movernent (Test Chart 21, Fig. 14). Testing procedure: 1. (Fig. 7). A 300 to 800 milli metres (12 to 32 inches) long hollow test mandrel with accurately centzed faces is held between centres. A dial gauge is fixed to the grinding-wheel slide, with the dia inding wheel spindles Fig. 77 juge plunger touching the test mandrel (for measurement fi tke verteal plane), The table is moved longitudinally and readings are taken, ‘The talstock centre must be Higher than the headstock cent. Measurement in the Rorizontal plane ie ot necesary, as alignment in this plane is adjustable. 2, (Rigs. 78 and 79). Two test mandrels (D, and D,), approximately 100 millimetres (4 inches) long, and of exactly equal diameter are used. Test mandrel D, has @ standard taper shank and is located in the workpiece ‘spindle taper; test mandrel D, is fixed to the grinding- ‘heel epindle, the type of location and fixing depending on the design of the epindle nose, je |e an LL LELLLLLLLLLLLLLLL. * eateo laste enAIITIFEF FF IE LE LTET LLL EILEIL II III IE ENS Fig. 78 Section AB If the grinding-wheel spindle has a cylindrical portion, this may be used instead of test mandrel Dy. In this case the diferenee between the diameter of test mandrel Dy and that of the spindle cylinder must be compensated by block gauges a : ‘The grinding-wheel slide is moved into the middle position of its traverse and the test mandrels D, and D, are rotated into their mean positions. (2) (Fig. 78). A straight-edge is rested on bith test mandrels and 2 spirit level ls placed on the straight edge. Spirit level readings ace taken or eee foal ‘les Fig. 81a Hig hw » (2) (Fig. 79). A dial gauge i fixed tothe machine table with the dialgauge plunger touching the tops of test tmandrels D, and Dy and readings at taken. ‘The table is swivelled in both directions and readings repeated with the table in extreme postion. 3. (Fig. 80) (see also item 2). ‘This uses two test mandrels D, and D, as before, but the test mandrel D, is, fastened in'the internal grinding spindle support. ‘The test mandrols are rotated into theit mean positions. The dial gauge is fixed to the machine table. ‘The dial-gauge plunger touches the tops ofthe free ends ofthe test mandrels, and readings are taken, 4. (Figs. 81a and 810). ‘The grinding-wheel slide is located in the extceme backward position. A100 milli- ‘metres (4 inches) long test mandrel is fixed to the grinding- wheel spindle as before, and rotated into its mean position, (@), ig. 814). Here, a straightedge and spirit level are placed on the awo test mandrels D, and Dy; or (2) (Fig. 819). The dial gauge is fixed to the machine table with the dial-gauge plunger touching the top of the test mandrel and readings are taken, ‘The grinding-wheel slide is fed in into its extreme forward position and readings are taken, “The final test concern the perpenioularty berween the infeed’ movement of the giding-whec! sige and the workpiece axis in the zero postion of the table, when the workpiece aie must be parallel tothe sideways ofthe bea (Test Chart 21, Fig. 15). Teting Procedure: (Pig, 82). The machine table i st inthe tere poston: and the undef aide in he txcine backward poston, ASO mines (20 inch) fang tx andra wich stiatly cnaed aces mounted be pean inoadnyreereer faves 300 tilimetse C2 thei) lon’ foc. dost 20 miles (nc) we, agit whith aque canbe Held The da gauge i fxed‘e he grinding wheel ade, with the dialgetge plunger touching the fe leg of the Sauare The grinddg-vbed de ifmaved ford and readings are ben, It is also possible to fix the dial gauge to the grinding- wheel spindle and take a trammel reading against the free leg of the square. (D) IN THe Case OF RapIAL Deintinc Macuines the following have to be checked: 1, Parallelism between the drilling-head slideways on the radial arm and the base plate (Test Chart 34, Fig. 3). 2. Perpendiculaty between the spindle axis and the baseplate (Test Chart 34, Bg. 6): (2) Longitudinally. (Oj Transversely. ai Section AB= Fig. 84. (Checking the Arm Fig. 83, (Checking for Peralelian 3. Perpendicularity between the feed movement of the spindle and the base plate (Test Chart 34, Figs. 7 and 8). 1, ‘The radial arm must remain parallel to the base plate whatever the position into which it is rotated round the column. A spirit level (scale value 0-04 millimetre/1,000 ietres;, oF 0-0005 inch/foot) is placed at the extreme end of the radial arm (Fig. 83), ‘The drilling head is moved along the radial arm and spirit level readings are taken. As the permissible error is 0-2 millimetre/1,000 millimetres (0-0025 inchjfoot) the maximum permissible ‘movement of the air bubble is five divisions. "Moreover, the radial arm must always be inclined downwards towards its outer end, because the drill thrust will tend to raise it. In most designs the drilling head is guided on an offset vertical surface of the radial arm, ‘The flatness of this surface is checked in a manner similar to that used for testing the horizontal surface of a lathe bed. A frame spirit level is held against this surface at intervals of 200 illimetees (8 inches) (Fig. 84). In the case of radial arms with a central drilling-head support (eymmetrical design), the procedure has to be modified accordingly. In. an alternative method of checking the parallelism between the drilling-head slideways and the base plate, a dial gauge and straightedge are used as shown in Fig, 85, ‘The radial arm’is raised to the middle position of its vertical movement. A 1,000 millimetres (40 inches) long straight-edge is piaced longitudinally on the base plate el” tewl.-c = Fig, 854, Parllellem of Dailing*head Slidewaye ‘tnd Base ‘of Checking Parallelism Fig. 855, Alternative Method Fig. 86. Perpendicularity of Spindle iF Fig. 87 after the latter has been levelled. ‘The dal gauge is fixed to the spindle, the dial. gauge plunger touching the stsigh- tage. The drling head is raversed over the whole length athe eadal arm. "The teading of the dal gauge must not wary by more san 02 milimettei000 millimetres (00025 inchjfoot,(NB-—Ie is not slficient to check Isolated orton ofthe traverse and to calculate the cor prorat) Ins thied method, the dial gauge is fixed to the spindle s= mentioned before. and. readings ate taken in three positions (a,b, «) of the delling ead on the radial arm (Fig. 850). ‘The dial-geuge plunger touches the surace Of the baseplate. ‘Tho radial arm i rotated round the axis ef the column’ and readings ate taken, the maximura ecmisibe error being, 02 millimetre), 000 limetres {00025 inchffoo)."Phis method's particularly sutable Inthe cae of Teshaped or ervelfom plates positioned at approximately 300 millimetres (12 inches) distance from the column Range. A trammel arm at least 250 millimetres (10 inches) long and carrying the dial gauge is fixed to the spindle. The dial-gauge plunger touches the surface of the base plate or the surface of a straight-edge placed on it. The spindle is rotated by 360° and readings are taken. ‘The drilling head is moved outward by an amount equal to two-thirds of the length L of the radial arm and readings ate again taken as above. The radial arm is raised to ewo- thirds of its total vertical movement and readings are again taken in both positions of the drilling head on the radial aria as before. If the dial-gauge plunger is not touching the surface of the base plate but that of a straight-edge (which should be about 1,000 millimetres, 40 inches, long) (Fig. 87) trammel 0 / LLL LL LLLLLI. ! ? the LLLELL ‘L ‘LL: LLL; L 4 L a Ped —ZKar,ISTISEVTI ISIC EEC PESO CU TC PPE SF PCC tC td Ids EQUIVALENT TABLES For Converting Mm. Tolerances into Inch Tolerances Mm. och Mo. och 0005 o-o0012 0.08 oon 0.003 0.0002" 07, 0028, oor -0004 ors 0030 outs 20008 G08 00032 oor 2-008 cio 00080 42s 9.0010 ous 0052 005 6.001, ons 0060 0032 o.00126 20, 0080 0038 Sons 035 0100 oo, 2.0016 03 0120 Oo8s 2.0018 10 0400 098 0.0020, 1 0.0500 0052 o-00205 25 ‘7000 2. Metre Reference Lengths into Inch Reference Lengths Ma. Inches Mm. Inches 20 7 130 é 8 1 300 2 is uv 500, 2 0 2 00 2 3s i 1,000 % 100 4 3. Mewic Tolerances Referred to Various Lengths into Inch "Tolerances Referred to 1 Foot and’) Feet Mm, nek per Foot | Inch per 3 Feet 001 per 11600 mm. ‘o-d0012, ‘obp036 bois 1 o-00018 0.00036 -00024 00072 o-000%6 600108 o-o0048 S048 ‘-00060 00180 ooo2te 3 8 ‘00072 0.00120 00240 00360 001200 BEREEEEE 22 2: fet B:—<— Fig. 8 Fig. 89 readings can only be taken at the 0° and 180° positions (A and B). ‘The 90° and 270° measurements, (C and D) must be taken after the straight-edge has been turned 90°, This method is more cumbersome and waviness of irregularities of the base plate surface are covered up. 3. (Figs, 88, 89). The radial arm is sated to one-half of its vertical’ movement and the opindle axis Toeated at Spproxmatey “300 "malimecs (12 inches) ffm. the column Mange. "The square is placed on the bate plate ssn the longitudinal and then inthe transverse desion. ‘The dial guuge i fixed to the spindle, the dial gauge plunger touching the fre le of the square. Spindle and 4al gauge are moved up and down (hand feed) and readings axe taken. ‘The driling head is moved to two-thieds of the Faia ar length and essence fepeated in both planes B. ‘Testing THE Accuracy oF WoRkPIECES PRopuceD DURING A FINISINNG OPERATION Reference is made to pages 5-7. It is not yet possible to establish rigid specifications for this purpose similar to those for testing the accuracy with which the machine has been manufactured. ‘The working accuracy of each machine is specified at the end of the ‘Test Charts. It will often be left to the manufacturer to choose workpieces and tools for testing, and to ensure that Performance Tests ‘Teat tobe spplied Dimensions of piece Gauge and methods ‘Tolerances 1. Lathe (@) Round suming (chucking) | Diameter=f centre height .. Lengthsrcentre height Made on 2 bands of cylinder, inch distant from each end and T inch wide. "Standard Eilesometers 0-025 mm. 0-01 man. (-0004-inch) Woser inch (2) Paral suming (chucking) - a 003m, pe 30 ma, (0 0012 ra (@) Parl cursing berween | Dizmeter=) lengthy Length | Sandard role 002 mm, (00008 Inch) ay po fom {ro dnnce weenden ios Oe? (a) Facing Concave only) >>| Diameter cones help Beandard vols O02 rane por 300 mm din Length about contre eight ‘meter (008m per fon (Sawing Diameter 25 mam. (inch), | Standard wool O92 mm. (OO008-nch) tral engefthread 0 mm. pitch enor inches) Length thread, 300 mm. (12 = +£0.05 mm, (0002.nch) ‘nthe 2. Milling Machine © {2} Shy mling(nishing cu) | Canton (or mild see block | Take, 2 ft one fishing cut | 0425 mam, per 300 mm. (0008 ‘the top afd bottom faces ofa block vo a uniform thieknens fof at leant 75X75 mmm. aches 3 finches) 2400 rom. inches) long. For longer Pleces 100% 160" mn Ch Fnches x4 inches) x750 min, Go inches) tong (Fig. 904) ef approneetty On| “on por fos) Cake depth verens Sere gma peeie Thecanpiga eGo sul pert tne te tobe gompled In ont feting "the exec of Se ling caer when positon shoal ne be more $ian 803 mm. nc ‘recurso 59 a inches reap 19 mom Gass) mee Cast iron (or mild sea block, TSOmnm.o¢ 130mm. (inches % 6 inches) "shaped for clamping (Fig. 908) a Ghort arbor ia the Spindle, “Traversing Tengieudinaly. Ming all eps te higher lower ones “Take 3 finishing cum $0 mm. | 0015 mm. per 300 mm. (00006- inches) welex0-10 mm. | in. per foot) longliudinally, (0-008 neh) deep. which | and {6005 mm, (O-0002-ine fyerlap by 10 mm. (inch). | axis “overlap variation ‘Verde frowemens of the | fn lock reading lence by hand. Test struight-edge ind clock 2 LLLLLLLEZ ” he LEELLLLLELLLELLLLLLLLI L a “SLPad ddd ddd dye rn ne a a a a a a PEP « PLANT Beri “Teat wo be applied Dimensions of piece Gauge and methods ‘Tolerances 2. Grinding Machine G) Machine grinds round | Diameter 80 min, (34 inches) Piece either berween dead een. | (1) 0003 mn when teas (QD) Becween centres | 8010200mm. GO web inches) | tues oF in chuck.” For long (0000i-ineh | "tian ) checking Toni pieces, 3 bands $0 mm. (| (2) 0008 mam mn | Miehies) wide at both ends (00002-inen) | tong Over 200 mm, (8 inches) | and’ at centre. Grinding ‘shel’ well dreased,maxie ‘asin periaible diameter, Wide, Or Se diameter ot wheel Speed 40000 5,000, Feetper ining Heed 4 width ot wheel Standard tools (1 001 mm, "(00064-neh)— sien over 200 mmm tong (© Machine geinds paralicl | Shals 1000 um. GO inches) | Pies ware round between ‘erween Centres Tong % 80 smin. Q- inehes) | dead centres without diameter Seadies. Standard tools attetee Saiecr (Fine infeed west (Fig. 906) = (2) Quick approach (nfved) - to. the work repeats seeately to grinding positon (Fig. 900) ‘Shafts "S00 me. (20 inches) Tong, 80 ‘mm. (2 inches) ‘Shafts "250 ane. (10 inebes) Tong, 38 mun (1'5 inches) “Test against grinding wheel Bertheny diane of ‘whet spind Be Feading epeaed six times. i eva ily amped (0.015 ean. (00006 inch) (0-008 ram. (0.0003-ineh) (0-005 mm. (0-0002-inch) 0-002 mm, (00001-inch) 0-003 men. (0-00012-ineh) Fig. 90. Performance Tests Various Machining Operations, Recommended Dimensions of Specimene, Gauges and Methods, Permissible Tolerances the machine is free from vibrations and other faults. If itis, of course, possible to agrce beforehand with the customer on type and form of the test piece, An attempt has been made to establish specifications for performance tests of lathes, milling machines and grinding ines (Fig. 90). No such specifications have been atteinpted for the case of drilling machines (Test Charts 31 to 34), presses and shearing machines (Test Charis 51 to 53). ‘When rough holes are drilled it is only imporiant for these w be perpendicular to the base and parallel to each other. In this case, itis sufficient to check the deflection under the — Fig. 904. Peeformance Test on Milling Machine — ‘Slab Milking Fig. 900. Performance Test on Milling Machine— "Bice Milling Fig. 90e. Fine tn-feed Test *J Pressure Gauge Fig. 91, ‘Testing Vericl Thrust on Dailling Machine largest possible axial force acting on the drill spindle (see page 22). ‘The testing procedure is as fullows (Fig. 91): ‘The radial arm is raised co half its vertical movernent and the drilling head placed in its extreme outward position. A dynamometer (oF load cell and pressure gauge) is Positioned under the spindle. A dial gauge is fixed to a column on the base plate, the dial-gauge plunger touching the bottom of the diling head, ‘The spindle is fed forwar (hand feed) until the permissible axial chrust is indicated By the dynamometer, when the reading ofthe dal gauge is In the ease of power preses the accurey ofthe sideways rust be maintained when the machine fe subjected to the ‘maximim permissible force. This is essential in order to prevent the punch being damaged inthe de Surface Quality ‘The author iivestigated the problem of surface Gish during the years 1999 to 1345. His attempt to speily the nirface’ quality which ought 10 be achieved’ with various machining operations is shown in the Table Fig. 92). oP C. Powen Reguinemenrs, SPEEDS AND FeEps ry machine tool must be ao designed that its parts will not ‘be deformed’ beyond permissible limits when Subjected tothe maximum working load. Ifthe supplier ‘wishes to limit the permissible load orif he doesnot trend the machine to be used in a certain specie manner this should be defaitely stated’ either ia writing or in his prospectus. For instance, many lathes are not designed Tor taking the largest posible cuts when the tool acting on th mica diameter. On the othe hand, od ever-increasing. speeds. will be accompanied by’ smaller Cutting frees f the power ofthe machine remain constant. The relation between speed, cutting force and power Fxv 5.000% Fescutting force in pounds, ‘consumption is P= hip. where vecutting speed in feet per minute, ficiency factor. ” If the mean efficiency for the whole machine is assumed Pxv 22,000 ‘The power consumption of a machine can be determined by taking voltmeter and ammeter readings. 10 be »=0-67 then the formula becomes P=. hp. The performance test of a machine tool should also check the speeds and feeds. Most modern machine tools, carry plates which show the numerical values of the various speeds and feeds available, and the actual yalues can be checked against the nominal ones by means of rev.-counters or similar instruments. Standardisation of speeds and feeds based on the internationally accepted system of “preferred numbers” should facilitate the work of designers, ‘manufacturers and users of machine tools, and should form the basis of suitable acceptance tests + G. Schlesinger, "Report on Surface Finish”, The Institution of Production Engineers, 1981; ‘Messung der Oberfichengite™, Springer-Verlag, 1951. ; ave ine Remarks Machining Commercial Fine Supetine a plane wurface by Finsh Finish nish Milling we 16132 Bi t0 16 | Face milling gives ner vurfaces than slab milling Planing - e108 Biwi 1008 | The planer ie » very robuw machine, the tool "s ‘exon i uniform Surface Grind Bole Fos Biw4 |All depends on the machine and. the correct = teleion a he grading whee! ‘Scraping Biwi Fit Bito4 | All depends on the all ofthe operator Fig. 92. ‘Sutlace Gnish teats for Plan Surfaces i eles LLL? aTesting Knee-Type Horizontal and Universal Milling Machines fg. f.10 en nh DT RPP OR AD PP PwTest Chart for ‘eeciype Horizontal Milling Net "Fest Chant for Kneetype Horizontal Mi a ing Machines’ | Char Net Machines and Ualveria Milling Machines’ [Ghent] | Machines and Usivertal il “Tea tobe Applied [ke | eer Testo be Applied Re ——"Lpvalng af work able fa i Work able Marr fore in fongcudinal | 3a | 4008 per | | Centre Tesot parallel with ble move. | 8 econ athe“ peed neem | |? ane ee “Tou tor up 10 00 mm. (28 in) Ditto, in |e 1,000 man. (40 in) above 1000 un 0 in} ‘A, Horizontal milling machine Gutter spindle: Internal taper runs out of eeuth (i Rear the pale nse G2inj | Exeqal oper or overnal Slide Surface runs out of truth Fastening of mandrel corresponds to wandards ‘Gutier spindle for axial slip va machines ‘with frank bearings “up to" 80 mm, Gin) dia Rise and fall of Tongitudinal Over 300mm. addition of 001 per pacalel wit 6 (able sing towards fron side te | Front beaing over $O mun. (2 in.) dia caster spindle | 1 | Too fg ‘Width of Tsou: Brom ve Fm], Over 18 men. (hin) wo | Colum ways fr knce square with work | 9 ‘able, inclination wards front or fear tides “Fened with camped and isoee knee. “Dit, saline fo a ara aban Bas bom eeeTERD | Mgucaed ovceain pare wih cater Ditto in horizontal plane measured near | Tim ote and in 300 mm distance Bore of arm Bracket aligned with cuiter | 12 ‘spindle 1 Pable in top position: (i) ay ay an verical plane (Q) by by in horizontal plane 1, "Table in boxtom postin: gm vere line 3) By is horizontal plane «. tress outer postion)" for i Bracket in muddle position J and It ‘hem and bracket clamped fo aligned with cutie | 13 inde, "wih igh. outer ar Sippor, meewuted inthe top 2nd eho pontine of nee TD. Univers) milling ac re care Ais of wvivelcarnge ote with expect to eater tpindle Centre Tt of wok GOVE Oeaet wih | Sse coettr spindle Dividing head spindle square with ‘a rrfeee [Piping ed ict patito | Diving Feed ape Teel ofr | with Fespeet to cent Magnan pers dividing Or Hor intermediate divisions B Reeihe twat Wor ale with clamping surface (degree Sfindline berween viding head and araliel with centre Testo (lateral off Kee'berween dividing head and tale Bee | > 60m, Noa Chan’) by vermisse Sor |__002 O01 oor” 502 per | 500mm. | 002 per 500 eam O02 £4Ssce. E1 min. 0.02 per $00 men oor per 300 chen tock) EL 9 fs LILI. olf ee el LLAL : DA ; oS : = LALL2 ” "4. fb a a:Testing Surface Milling Machines ‘rbor aligned. with “cutter spindle, | 14 fressuredsat several distances rot | 300mm. |_main bearing For Table of Equicolents in Enlsh Measure see page 51 ” — = = > ~ MU a . 2 | | = | f- P ~ TM Ti E % I ~ . > Fig.1 fig-4 ~ 3 a ; ~ I-- ! > |e H —~ Sher u P > ry |* ma Fig6 Fig.8 a | ~> ! Fig. it Fig. 1 Fig. 13 ~ 7 No. a ti i No) = [__Test Chart for Surface Milling Machines | QS) “Test Chart for Surface Milling Machines | Sia “Test to be Applied Wied eae “Test to be Applied Be] Pease J ‘Levelling of work table’ ae mm. rr 7 Wor he far tn logan! | 28) 288 per | | WERT, ges ms ots =e From 14 to 18 mm. (f to fin.) ~ Bi fransverse: co Over 18 mm. (fin). | tae —-—|—| [Werk able square with vert aaj | \ “SF tnternal taper of caster spindle runs erve: | ta at of heldsteck in plane of ever | FR pede ne ‘pind S| pf) At a distane ean. (12 in, Ditto, in plane perpendicular to that of per “9 | pier ete sit lie Saree | ‘Gatier spine for al tp er WaCHAGY SS ~ witht to 30 mam. @in) dia af front | | Verieal Gjanimen of averse suppor | 10 | 002 per | Dearing at 2 opposite positions oor ‘square with work table in plane of 300mm. | Over 30mm, Btn dio potte—| | ERS TnaEE” Suppor ateaye | Sp [ee and Tall of sable ia ts Tengthwse | Fon wee Egivene yee S00 ms mm jitto, in plane perpendicular to that of | 11 002 per | es esi can eerie od Pier epndle Sonn | i ‘Work table paraliel with cutter spindle ‘Over-arm parallel with movement of | 12a] 002 per | ~ a Owedatein Veen plane Soom _| TEN caver ndis nvntal sane Sarai eatconal Gaon ime | gat pc » rein oulerarn suppor aligid win [1 | 002 | Set annanamed sever dates \ cine s Lore of cater arm suppor or enucr oI > > SS . SN Testing Vertical Milling Machines 3 et > t | | § ot \ - TTT ok Fig.# Fig.5 Fig.6 at Fig.7| . “a ot 4 7a Fig.9 Fig ot ‘Tesi Chart for Vertical Milling Machines | 0-3, 1 i ace ot . i 'ermissible ig. | Permissible | ‘Test to be Applied Re | Pei ‘Teat to be Applied Ne | Peer Ni Teetinestwonmpe | | am i Wektotiog "wt ©T Uwe im fengina | 38 | Dest | 7] Sunes of work table paral wih te| 6 | o88ger | Ditto, in transverse direction ‘3b Sransverss movement al Cease Tot parle wi Ton ‘ Goma Sie movecbar Inga pera cts te: | Gene Tl aguas wih Wanner | : RPS opiate ease oot “AE sottned . BAYER, iin oe ee en Entel per rane oot of uth we | oat From 1wlemn (peri). gtoos| oA cupid fr chip pvaztnes| 2 | |_| Beaganigen chet) seisas| vbw 0mm @ in} dof fot FE | eet ee aes OO | vee fam. (in) di of fon beating oe ~i 27s 50 mm. in) dia of ont bewing |_| 02 _| Column: ‘ Work table: Vertical adjustment of cutter slide square | 9 | 0 to 0-02 per » ine and at fabs lentatoa! | 4 | 992 pe is workable isne hsugh Bog So ma oorement a waaay eed ee ee adie comm movenene oor | | gave | | _aia. et carape OB he wn ase Kacr | |_tomaristherenestgey” TT) n et Sed mm, —___|__|_s00mm_| lige. in-plane gerpendicuar to thar | 10 | O02 per Werk able square wih canes spndieln | 3 |v—002 per] | PMO, plane zependi Some | oN facing (eo rou neta ae Riemer | I Cotaran ways for knee square with work | 11 | 002 per | 7 Bithioe Goes ell mettedt le clunn ways for nee square Wik wo ff ung tous ae fot sd oly) | | SRR ao eoettae ee Sore | Work table square with cutter spindle | 5 | 002 per | ——sises seopectively | __ J) id : ton petted oat tcuek, Seok. || Bin, tater incline | oop see eT oat ees six | For Table of Equivalents in English Meature vee page ¢ Pp ein iTesting Thread Milling Machines a Tye ling Machines SES SE PF SESS III SET EA —"Werking sczaracy of) 1, Horizontal and Universal milling ‘machines, knee-ype— Slabemiling, fishing cn” surface i Facing by cutter head or end mill For each 500 mm. (20 in.) more 2, Surface milling machine and’ plana ‘ype ming tachine— ing) Agcuracy of | Machined yt dno Net ‘Test Chart for Thread Milling Machines | Cyr Fig | Pemniaie Ne.| "Error ‘Test to be Applied Bed Bed straight in longitudinal direction 12 | 0t0 002 per ‘convex oni) 1100 tb | £002 per 11000 en. Bed level in eaneverse direstion No twist permited “Tailtock Vees parallel with movement of sit ang ein ae 002 per cane eee Pr Headeck pen Game | | cents pone tre ing 3. Vertical miig macine— Feces ma ae Centing sieeve forte running re, Be rooming out | [asataipotmon nnd ‘a LE ee paaelsracesof Same al nt a nipid block, deviation from 200 en ‘Taper of work spingle runs true: 01 Re a iie mcs —— aaron oe fos tht al Ser BAT Hace ood tm. Gzind “The wil pis w be eT ‘Work pial par ih bed veel [Be [O.002 per tear lt Sin by Sey te iPtomande he hee oalat | | Soon ForTlnger pes, tin by in by : cla i Ditto, in horizontal plane (front end | 3b | 0 t0 002 per ‘The dinping ofthe block should permit ee hs tent Wo" be’ completed i one inclined towards the direction of 300 Be eee ot he paling cover || “OUST | | Chuck runs out of ih, measursd on {6 | 008 "Tignes i postion thea net be mere hued mandeel, 300 shan (C2) than L J Tength SISASI ETI ISLS Et : For Table of Equivalents in English Measure seepage 51‘Test Chart for Thread Milling Machines | Sic “Test to be Applied j Tailetock: “Tallstock sleeve’ parallel with bed in| Vertical plane (rising towards the Tree: cd) {rome end cation of cut Tig | Permissible “Test wo be Appl Fie | Pens Tea wo be Applied | “hea were and carer deving sae | Dearinys.of lead screw aligned with each atte, oof ean peril ih Bed waye) in vertical plane (mean ments taken in positions TY and ti | Die, in horizonzat plane ‘Wearing of lead screw align ut in vertical plane (meaurements 72 [010.008 per 00 rant 7 [01001 par YOO mnt sof tltock a ame height ae head. | 8 de middie penan or aay Sis (ativock high only |__| along bed, position T being the starting ‘Cutter slide ‘Taper of cuter spindle rine true; maxi- Thum amount by which mandrel 100, measurement) 9} oo Di “Ditto, in horizontal plane | [ead screw for sal aipformachineswith | Tee ‘C005 mmm. (12in) in length rune out at “up to 150 men (6 in) height of centres = a ver 150 mm (6 in) height of centres oo __| Gutter spindle for trae running (lor | 10s ‘Accuracy of pitch of lead serew is assured 3a5 per _—tnachines without internal taper) a ‘wi 300 mn. “Cutter spindle for axa lip Toe [e005 Front and rear bearings of shaft driving | 152 |— O18 ___In-tsn opposite poscons Taser spindle parle wih work spindle in hoglontl plane (at re end of wor Spindle inclined toward cutter spindle) the cutter aligned with each other and |__| ‘with cuter slide bearing (aes of ear per ngs parallel with bed waye) tn vertical plane. (Position 1 i che starting measurement, cutter slide ia middle ‘Cutter spindle level with work spindle | 12 002 sition of halfway along bed) or machines up to 130'mm. (ein) ‘Dito, in horizontal plane =| 188 os Steet gh Same GO). “008 over fSomm (Gin) height ofcencen...| | __ 005 Lenath of 1608 min G8. 008 Bac fear ctersuppor aligned with | TE | O82 Mesuted ira i006 10min is, || E008 attr spindle oti) : Jesting Spur, Worm and Helical Gear Hobbing Machines Testing Spur, Wo id Helical Gear Hobbing Machi 6 Precision spire Lever Ee or Table of Equivalents in Buglich Meare se page $1 so SPELILELIULLLLLLILLLELLIZ 4 NN) A ay a4 4 : > Feat Cine Tor Span Worm aad HSI Ro) [Tet Chaar Spar Warm gad Wa Nat Sesehabbiag Nockines aa] | Goat habbing Machines is > “Teatco be Applied Rie | Pernissibte Tests be Applied Perpine = Be | et = Tor cae 5 =a = Am beahet signed with | B88 ide-ways for cuter side square with | 1 |e BE pee| | Armen shaved ith sp | CSR ci ate cage Sonne ented nea ipsa eel mete one ce eet tide ‘pues eke . towards work arbor only) Cutter slide: v ‘Taper of cutter spindle runs true: 0-02 aspect | Fee || eerie ave tn echienel S| Pie, pap snare EOI oe ae Pes cg ea < Werk ate: © per 3 | Teble ene cut ofeach 3 | sapetn | [ec apnate for acar ain =| om Titre opts posta [Wor abe square with guewofor| te lOwooe| J i ene a oa Sooan cet spinal pari with sare 7 a Se ate nb oe or Cues syne parlel with surtace of 9 | "902 per See Sh a a Sts ; Set toy Ditto, in plane perpendicular to that | 2b| 0-015 per _ ii Baa ie Soo Workarborruns uti gamumameanr | 4 | @or Chast apna pele wih gdewape [| OO per tee deta ae 2) ‘eeeahet sider stattrnta | "| Sapte Ruger Sona Sean poor Work arbor par with & [owoe pe] | ———____|_| Siete Ba at endl Q8022| | Ricatewnaing cer siae oan nay [2 | 005 Ter oP abelne Cnpet aeleined wepee io maleic rte owed ak tne pee as Pesce) Dio im plme gerne wo ta} 5o| OG? per vnwding ange | 1 Pibteagh Frade Soieke, | [Aiseleriveling case sie of B | 8 eat Chaat fog Spar, Worm and ¥ Tae Gearchobbiag Machines \ ‘Test tobe Applied Dividing whee: | Maximum penmisnbie individual pitch Sorel aheding esl meaner Atizmm Gin) per 207 (din ‘Maximum permissible worl pitch eror of Gividing ‘whee! (amplitude in the dine | fram of errors = tigebraic sum of the fuximum + deviston and maximum | | Mdeviaton from the eorect basic | | pitch value) is amured for diameters Lup to 500 min. (20in) From "00 0 1,000 mim. (20 6 40 in} ‘000. 40", 80) 24 ‘ fi 0 "120 7) For gears cut on the machine, the fllow- ing accuracies measured from tooth to ood ate assured, in diameters: Upto 500 mum, Gin) From 800 fo 1,000 min. (20 10 40 in.) "4,000 ear. and over (40 in) { Becentricity steer { { ‘pees [UP £0 300 mm. dia, parallel Over 0 200mm. dia to 500 mm. dia. 500 mm” die os 0.09 19 015 O16, O18 019 |, 025 loo125 vo 0.02) Joo2t vo 0025) ponoos (0-008 v0 0012} for 75 rn, ‘width cota dors per 150 mm, width | 0021 eo 003 [0012 w 002 1 ‘TABLE OF EQUIVALENTS For Converting Mm. Tolerances into Inch Tolerances 4 & 0 300 man. (12 in. dia. | Shape of too ver 300 min. (2 in) dia, CY Sws CTY FG CEP Fuse USVI | ‘O08 0-005 20 0.01 [oMoars By Me Min | sk 33 | ott Sots, of 88948 sae | tls | See bees ee | ee ger | 83s | Botan cu | oF] Sol eet I { 2. Metre Reference Length into Inch Reference Lenght wim | ince [atm | ince is : se ‘3 | Inch per 3 Feet ‘ob0360. 00120, ‘00180 Doorso, bovis 00072, 6.00360 oooTesting Gear Shapers Fig. Figs Precision Spirit Level rye figs igs i Test Chart for Gear Shapers a] Test Char for Gear Shapers ee ‘Test to be Applied Rie | Permissible ‘Test to be Applied NE | “Ener ‘Spirit level (a) on faceplate; along and | 4a a a ae else m * ‘Maximum permissible individual pitch Es oot Av id am. (bin) pitch 001, Face ofthe faceplate fr rue runaing (for |e “+ deviation and maximum = devise Up to 300 mm, (20 in.) 0-08, = ag siete Teasured af two surface lines of man? Woeling acestacy of michine TERT resem) | | eas | | ee oer FEB wna 2a rghate team com | | ome | | RRBERG aeiin 2a peers Sear is Seager aratee | 7 | i | | egg ster cine 0mm. | | B8 Trelination of saddle ta fa wanwverse | Se | 001 per | | From'30to $09 mm, (to 20in) oo1s omsmmiteatice wa | | Sate | [REAR in | | Be 300 min. peo enh oe in Oots TPPITPIITITITIIIILIILELSE laa 7 7 79 PP Y FTesting Lathes "228 Fig.7 IIIT POI IPOST SD EEE SS ESP EE DS OE ED ws |a ; ; "Tepe Ghar for Figap Turning Uaihes wp wo | Nott) | ten Ghar for Fialay Topaiag Lathes up to \ “Widionms Cabout IS} fad Tieigat of Centres | Chart | "i ms tabout 1St in) Height of Centres a -amaaedd fle slermeeiale| aa ie ‘Test to be Applied Ne | "Error ‘Test to be Applied Re Bed staieh in lone, te [oro bO% per| | Wark apindc poral wih bed Ta hor: | | ed sit in le recon; apron | ta JO 0.00% pee| | Work aindle pare wih bad ha a aes aad eet wind ice tad of mani | [0100 per a ace 500 me. Dino, oppose side > we | 002 pr mesare ‘eaneree ni) bom. | a re tf | | stovement of sep lide pret wich | 9 | 003 per Bed level in transverse direction . te “work spindic in vertical plane(hand feed) 130mm, | when ctu feds prone zw verter plane : 003 pee Swghas ofa ways for macines | 2 | OO2pe | F Sores itmoce’ Gm Sona surane | | 10 fan in boon plane ree Tenyth only; meazucements taken by ae ” | 300 ram, fi bat ate end seco |__| orinde Eat cle} a Tallsockpuidewaye parla wah oe "alae aot pw bed in| 100 019002 per sek dea WBE eh plane un en Pain | J | [Bike im horizontal plane (ont end | 108 [09 001 pe| ‘Work spindle: inclined towards. the direction of tool 100 mm, Cena pin 1 al in oot eh Centring sleeve for true running. 0-01 ‘Cone of sieeve parallel with bed in vertical | 11a | 0 eau per Work spindle for axial slip, measured at oO ae) mn, 2 points, displaced by 180" ‘Ditto, in horizontal plane (free end of | 11b_ Re per cama ne ne =| | Pian ete Stade Ueceton of ae Taper fk ae rare as tepdreinced oan 8 Soe oa ae oo. -—— G) ANT ace of 360mm. C203 | be Tizclecoica moaireibawcm papa) f 12 | Ove 02 | Worcspinale parted wisn bed in verseat | a [Ow 002 per] | Paella! whl bed in verieal lens | | | pl ising towards the Tree S00 mie % |-—| _| | anager eee em ot | i | stater + or on faTenah ner | Accuracy in pitch aad sere is amured 03 per 1 ied sua Seog | asi Chast for Finish Turning Usthen up © | No.1 Bia abo Sta Heats of Gensee © | Soe TABLE OF EQUIVALENTS eecimnicnn ‘Test to be Applied Ean 11, For Conesig Mi, Tolerances int leh Toleranes _ tT Lead screw for axial slip 13 oor Mr " i re obs oho Tend screw bering aligned wih eh | Ho | OT | aoe $8 hte ltd on Coos ae Gatentak pine Gresurements 0-03 00080 taken in positions I and 111) 1} | Bins iieraont pine ww [oa 2. Met Rfrnce Langs ne Inch Neerence Lanes | [rye ne aimee fe | OP Sim Ded i efi inanremen cess Rn cartage eae ey Inches Mm Inches nosition or halfway’along bed, position 13 ey ‘o fect cesabearne | | Ditto, in horizontal plane . ve | 1b Ons 2. Mew Tolerances Referred 16300, 00, and 1.000 tm. | | Wioring assy of machine I ne fa olerancs Reeecd wot Foss andS hee eles secures of machi cot 7 ~ Lathe turns cylindrically Mn Tock pet Foot | Inch par 3 Feet oF or eee irc winin 002 per 201 oe fiomm.| MD 8Gid ie Sook eel a Scant Seo (0) Work he in chuck within Oe ool 100 Saapl2 0036 vd Ba ee S581 ed San 7 “Sm Sooo Soon “aden ipo 805s. tase Soe “aco See 8802 Lote] Ger “Soo See e388 Teathe faze (holow or eomeave onl) | 15 [10002 per eal sao Sexes Coots “ine 28 mane eo 9 Sanies Sees ‘ion oot came Soot Je oo * om Samo Seige “Thread ex on 50mm, @ in) mgt o> p02 pee So 7 188 stare Soonte Sak 3 rarer bee tbr oad . 9 yponn as 7 : : + ” : a = :JIVE TVUIVI IE FE EFUCC CG UEC EFE ECU PES OOF "Toa Ghar for Fla Trang Cathet WTB yy Helght of Centzes trom over tb0 09800 ane | 2,12 ‘aboacSP 2S ia) (abou 13} 10°52 in) “Test tbe Applied | Fig | Pennisble “Test co be Applied Re sm, Work spindle parallel with bed in vercal | 64 | 010 605 per ed: lang (csng towards free end of an S00 me Bed straight in long. direction : apron | 1s |0%0003 per| | Gre) Tide (ehed or convex ony) 000mm f |S _________)_ X—=— |_| Dio, in horizontal plane (ree end of | fb | Oso 002 Dine, opposite side (concave ons) | 16070003 per| |" mandrelinclined tovards the direction 508 rane S00 ‘Strood pressure only Bed fiat or level in wanavene dircation | te | 2000 per Conca Novewiee permiced £900 mim] *] Movement of opper slide parallel wit] 9 | 009 per een ie |v] sodeapindle inertial pane (rand foe) somen, Surighiness of bed way (or machines | 2 | 002 per | | When mromatie fed proved ef more than 3m. (19) fuming 1,000, inverted plane 003 per fength oniys meanuremens uken by | fupiotaie dy 500 8m, imelauring tat wire and microscope 180.04) | in horizontal plane 02 per Sriong etait ge) over tse 005 300 “Tullock guide ways parallel with move. | 3 | O02 per Taieocks Tent of carnage” 14000 fam. | | Sieve pastel with bed in vertical plane | 104 | 040 003 per |—| (Ching toward the front ond) 100 ma ‘Work spindles Dina, in fovzonral plane (font, end | 100 [v0 O01 pee Cenie point orteve running + + | oars Inelince towards the dteetion of fol ot | Cones poi eee | resre onl ‘Ceniing sleeve or tue ranning = [cos | | eee’ ___j_|__| js ere eee} Cone of ieveparliewithbedin verical | 11a | to 003 per ‘Werk spindle for axial slip 3 2 poine, | 6 | 0015 Diane (fee tnd of manarel rag) 50 mt ipideed by 100" | Pine Cree end of mantel rng) __|_|_Ormm_ | Dist in horizontal plane (lee end of | 1b | Oto 002 per inandrel inclined towards direction of Sto “Teper of work spindle cuns tru: 1 tool pressure) “G5 Nearest spindle nose \ ois Tals of eenies (andre betwesn conrad | a 1G) Rey Sache of 300 mm. (2 in” | vos sah bed vee pe | HEs0 Cha for Figs Tara talker wilh |e yp ‘igor of Cenices fin over 200 to 890 mm. abou BF 0% ia) ‘Test to be Applied Lead sere Accuracy in lead of lead screw is asured “tha | Lead serew for eal dip aligned with each Chan 3 Fig.) Pergiaribie | Ne. | |" Eror 063 per 300 mv. 3 |— 0015 — O15 ‘other in verial plane (axes of bearing Parallel wath bed ways) (messurements Ee petitions if and iil) Ditto, in horizontal plane ois ‘Lead screw bearings aligned withhalfnat | Ma | 02 in vertical plane (memsurements taken ‘with clone Tale posicon or halfway along bed, nition! being the staring messing Paint) Dito, in horizontal plane Working accuracy of machine Bathe tuna round within 5 Lathe turn eylindeally (e) Between centres within (@) Work held in eck within | Lathe faces (Concave only) waka | isead eat on $0 ram. 300 ram, (12 in) we For Table of Equivalents s 2m) jena sf nut, carriage in. the | we | 02 ‘Brglth Meare ee page 54TS EES se) SSE Rog Se TS | ness | res of Accuracyjup to200 mm, abouttin) | N°. gree of Accuracy) up 10200 man, (about 8a, Welghr or Centeer Chant : Heigh at Centres Cha | ene lies Fig. | Permissible } Se Bae | Pile “Testo be Applied Fig | Permiel ‘Work spindle pailel with bed im hor | 66 | mm. wea a ont plane (ace end of atbor inclined | |0 w 0005 pr] ‘Bed straight in long. direction apron side | 1a | 0 to 0-02 per Seer ererne bt conve only) 1.600 re cman : eI Movement of Opper side parle. wit] 9 | 003 per Ditto, opposite side ‘work spindle in vertical 1€ (han mm. (concave only) rs spindle il plane (hand 100 ed fat or level in wanaverse direction, ‘When mcrae fad is provide cee ie penned . Sep eee Takes gor pelvis in tml pe ioe — ‘Tailstock: Work spinal Sleeve parle wih bein vera plane 010 002 Centrepoint Yor true running. ching towards frontend) per 00 mn, ‘Centing seve for tue ronal isto. in horizontal plane Gront end | 10b [Oe 001 per —_—_EE_- | inclined tomar aifecdon of cutlng 100 me Thera caper reeiving the ehuak for Presnaze) a __| “Taper of eecve parallel with bed in | He [Ow 001 per ‘Work spindle for axial clip mearured a 008 “ical plane (ang towards fee end Sbomne Sotnth pieced by 18 ot imandtel “Taper of work pine runs eet, Ditto, in horton plane (Gee end of | 1b [0 e900 per RY Nearest pind ges 7 | 0008 mandi acined Grande Uteion of Seem (3 Are dice of 300 mm. (12 inj ots iting pressure) Workpindle parle with bed in verical | fa [Oto 00) per| | Aino centres (mandrel boween cone) dwou lane (rain ward re end of see Soo mat eralel with bed im were. plane aay ng tod teach ch ead serew Accuray in esd of iad re is asured 003 pee ‘win Soo ee ‘ito, in horizontal plane Dito, in horizontal plane ‘Working accuracy of lathe: Tes Chater, Tpolroom, Taihes Highest jegree of Accuracy) up (0200 mn, (about in.) Hielghr of Centres a ‘Teat to be Applid Lead sere for axial slip arecwie ara oa ments taken in positions Itand TI) [Lead serew bearings aligned with half nat Tn vertical plane (meanurements taken closed halt nut, earrage in middle position or halfway along. bed, pos Hon T serving as starting point) athe turns rowad within Cathe turns eyindsically: |" (a) Work between centres within .. (8) Work held in chuck within Lathe faces (concave only) within "Thread cut on 50 mm, (Zin) length No. 13 ig. | Pecmissibie Ne |? "Error 13_| 0005 mm, va | on ie | oF Wa | o1s 7 | te [ons 0-005 9.01 per 5300 sem. 0.01 per 150 etm, Oa pert 15 | owSdis er 300 mm, nae 0-01 per omc ‘For Table of Equivalents in English Mearure vee page $4 — Pe ppp Pp ke VY DTP PP TPP IPI PP DD DDD ED ODBIII SEIT ISE LEE ES SSE TPE SSPE OS Testing Relieving Lathes 4" Relieving Lathes ‘The supplementary mensurements of acking-off to its intial position Soap Gauge Does the backing-olf side always | 2 itdvance tothe same point ? Deiving shaft for backing-off movement | 3 parallel with bed lathes are to be taken in conjunction ‘with the | No. 14 ‘measurements specified by he tant charts TT and 12, foe faihecurning lathes ‘Test wo be Applied Rig. | Permlsibte Does the bucking-of slide always cetuin | 1 | O05 oor 003 per 300 mn. ‘TABLE OF EQUIVALENTS ‘Mim, Tolerances into Inch Tolerances Me Taek 0s 6020 O10 0040 ous 6.0060, 020, 0080, os coos 2. Meurie Reference Length into Inch Reference Lengths Mes. Tnebes| Mi Tnches 20 ? 105 ‘ 33 1 130 é 38 n 300 2 50 2 1,000 0 3 5 3, Metre Tolerances Referred to Various Lengths into Inch Tolerances Referred to 1 Foot and 3 Feet Tnch per Foot | Inch per 3 Feet ‘odoons ‘Ob0002 ‘00086 00108 Ooo048 ooo 00080 0040 00120 ‘00360 e-00160 ‘00480 00240 0.00720, 001200 o-03600 00120, 0-00360 00240—} Fig.t “a Fig.5 Fig.6 Fig.? Fi9.8 “eat Chast for Facing Lathes ea “Fest Chart for Facing Ember [Oa 5 | Taree Artes Re | Pepi Tat be Ald Re | nse ‘Spindle headstock: a ae ! Faceplate fe feaion at coveave ony) | 1 Movemeat of upperside parallel wih ober | fis of faceplate ins vertical plane 500 mum. Thatta ected mandi Work vie for ala aps Dit, i borzenal pane w | out pe Sp BTN GOREN ve tuenea | 2 | aos Souk Shee done ace ates 30 |] Sec G8 pot glee By a0" | | Wosting scarey of machine | Foe ofthe fcel ane roe 7 Lape at toe ‘Up BONE in unin ds within cos OFcea to team earn wis bee Fegan ine Grmndin[ 4 Tabs sume pidsely (nly for ‘imchines eit heats an eps pod m (Odi tbe me 003 ‘oun oy cheer ase Sera GO‘) tobe red bs Opec HbR ie urlae de wihin 3 pe Carpe: (mo untedonsepartaseplate) (ver m. (10 en uring in within eo pet Sven oer outed = | 5 | 003 pee Seat 1100 im || _| |] Tages aap, zor macingy | | 0p9908 nr ‘Guide ways on compound slide square | 6 | 0-02 per ‘with Resdstocs and carsiage mounted 1,000 mn. ‘with ‘eth ‘other Gor alides without rm on conamon beseplate) within alee Tika pihe stip Sure of bapa at « zm (mound on common tase Core bg ‘with headstock) Movement dle pune plate (concave turning only) face For Table of Equivelen 71010005 per 000 | indir 38 English Meanure we page 57 a PELL IEP SP LIL oa fig] ts eee eo] ee] ff af Ly