AUTO-COLLIMATOR Used for straightness and flatness 1. Analyse the data recorded in the Ib, 2, Research and describe how and where the auto-collimator method would be used toassess flatness say ofthe granite table. 3, What other uses does the auto-collimator have? 623 Tests for Strnighmess and Flataess {Kt will be appreciated that for a carriage to move along a straight line in both Vertical and horizontal planes, the controling guide-ways mist themselves be stcaight. Tests for this condition may be earried out in several ways, the most convenient of which are by precision level and by the auto-collimavor. It is the latter method which will be diseussed here, but the method of tabulating and wsing the results of individual measurements is similar in each method. ‘The principle of measurement by the auto-colimator has teen dealt with in Chapter 4, but the method of determination of straightness and flaines is dealt ‘with now. ‘Assome that the straightness of « lathe bed 2 m in length is to be measured ‘The general arrangement of measurement would be as in Fig, 64, the auto. collimator being set up independenty of the lathe bed, about } m from ene end, ‘he parallel beam from the instrument being projected along the length of the bed. A particulary rigid suppor, preferably of the tipod type, is required for ths Assuming the bed to have flatways, the plane reflector i et onto the end of the bed nearer the instrument and a reflection obtained from it such thatthe image of the cross-wires of the collimator appear neater the centre of the field. The reflector is then moved 1o the other end of the bed, and provided the general line of movement of the reflector has been reasonably parallel to the optical axis of the instrument, then the image of the eross-wires will appear inthe Held of the ‘eyepiece at this position ofthe reflector also, This procedure ensures that refestions ‘at intermediate positions willbe within the Geld, and is thus an approximate check ‘onthe level of the bed in the horizontal plane. 126 . Machine Tool Metrology A straightedge should now be set down on the bed, to ensure thatthe reflector is stepped along it n a straight line, ‘Assume thatthe distance betwen the support fet of the reflector is 103-5 mm, and thatthe interval length at which measurements are taken is also 1035 mam Now, since I min of are radians 2 300 then, on a base length of 103-5 mm, 1 min of arc 103-5 mm, 2n 360 x80 =003 mm ‘Thats, each tlt of 1 min of ac ofthe reflector as it is stepped along the bed- ‘way corresponds very closely oa rise offal ofthe guide-Way surface of 0-03 mam ‘Having ensured that an image of the cross-wires will be received by the auto= collimator when the reflector i set at the end positions of the bed, the reflector fs now set at the forward end of the bed, nearest the instrument, to begin the series of readings. This condition, and those for subsequent readings, is shown in Fig. 64 in which the rise and fall ofthe bed surface i greatly exaggerated Mig. 64, Autocolimaor wed for cheking the sriehines of ate‘ auide-way With the reflector set at A-B, the siting wires in the auto-ollimator eyepiece fre moved to straddle symmetrically the image of the horizontal eross-wire, by the suitable rotation ofthe micrometer drum, ané the micrometer reading is noted ‘The reflector is then moved 103-5 mm to the position B-C and a second Tending taken on the micrometer drum, Successive readings at C-D, D-E, E-P, ete, are taken until the length ofthe bed has been stepped along. A stcond st of read ings should now be obtained by stepping the relecior in the reverse direction slong the bed, to reveal any serious erzors inthe fist act of readings. Assuming ‘one have occurred, the mean values ofeach set of readings may now be recorded, and these represent the angular positions of the reflector, in seconds relative to ‘the optical ais of the auto-collimator at each ofits postions along the bed. “The method of tabulation of the resulis of measurement are shown on p. 121 ‘Cokumn 1 gives the postion of the plane reflector at 1035 mm intervals the bed. Column 2 gives the mean reading of the auto-collimator to the nearest second. In practice itis possible to observe ubivisions of seconds, and thisshould eyMetrology for Engineers ’be done. Column 3 gives the diferences ofeach reading from the fst, In column 4 these differences are converted to the corresponding linear rise or fal, on the basis of 1 sec of arc—0-0005 mm per 1035 mm. The second zero introduced atthe head of column 4, when associated with the previous zero in this column, repe- sents the heights of the two feet of the reflector support mounting when in its ‘original position. Column 5 gives the heights of the support feet of the relector above the datum line drawa through their frst positon. That is, the values in column Sare obtained by suecesively adding, algebraically, the valves in column 4, ‘This is necessary because the individual heights obtained in column 4 are the ‘heights of the back feet ofthe support relative tothe front fet in a given postion ‘and not relative to the datum. 1 2 3 4 5 6 a ‘ise or “Adjusonent| Errors Dierence| Fallin | Corularve “to bring | from “fram Ist | interat | "Rise or | Bodh ends | Straight ‘Reading | “Length | Fall” | oZero. | Line (Gee) | (601 mom) | (0001 mn | (001 men) | (0001 mn ° ° © ° ° ° o | -20 42 | +10 | +10 40 Ys | iz | tas | -60 | 33s | t70 | = 80 38 | 340 | +10 | -100 | dss | tas | cao ts | das | tivo | liso 330] dts | dies | “160 | fos | tio | “180 2] sro | to | -20 ta | d20 | f210 | -220 46 | $30 | 4240 | -260 ‘The total rise in the surface of the bed over a 1}-m length from a datum, slong the line of the frst reading is,24 ja. Tn column 6 this total rise is pro- portioned over the twelve readings taken, Le, in inerements of 24/12=2 pm. ‘These values (eclumn 6) are subtracted from the values in column 5 to give the errors (column 7) in the bed from a straight lin joining the end points and within ‘which the series of readings were obtained Ge. itis as though a straight-edge were laid slong the bed profile and touching the end points of the test surface when they ‘are in a horizontal plane) The rise and fall ofthe surface relative to the straight- ‘edge would be the values given in column 7. ‘A graphical representation of ths is shown in Fig. 6.5 in which the values a8 Machine Too! Metrology siven in columns 5,6, and 7 are pled. In the graph of cumoatie errors Straightline has been Basel through teen pons ad rereants he sre emg th eno te a ath ap of ihe or hs fe ese the ai, and this he vies pled in the previow pap ave ‘the same relationship to it. z ne "is important Yo ‘ole thatthe increasing values forthe readings gen in column 2af the blends the creasing angi oft ofthe top of the eectr tovards te optial ax ofthe ast-coliator, Increasing readings have tetefore Indleted postive (+) vals forthe near ss nd fal ad vos ese The ate ted it thus both concave end convex slong i length lative to the data line joining end pons pale aes (CUMULATIVE ERROR (tam UNTS) PosTTON ow SURFACE POSITION OW sunFace ‘Engon FROM HoRizoNTat RTE ENE Gs Unt 4 Fig 65. Graphs of cumulative emor and acu eror in machine bed, determined ‘ing anautoeliator 19‘Metrology for Engineers ‘The test described relates to aflat-bed lathe, but the method applies also to 8 bed with vee guide-ways. In this ease, however, te plane reflector mount must be supported on a carriage having a vee accurately ground in its base, to suit the vee of the bed. The apex of the carriage vee should be relieved sa that contact is made only atthe sides ofthe vee. With this arrangement, the straightness of the bed in the horizontal plane can be determined, as well asin the vertical (i. the tlt about the vertical axis indicates changes in the angle of the reflector in the horizontal plane). . 'AS in the previous test, the reflector is stepped along the bed in interval lengths of 103-3 mm but in this ease the auto-colitator tube is rotated 9° in its housing, to a pre-set stop, so that the pair of seting wires in the eyepiece are vertical, Changes of position of the image of the vertical member of the cross- Wires are then read on the micrometer drum, and would be recoréed in column 2 ‘Associated withthe error inthe straightness ofa lathe bed may be any cross wind which exists due to each way of the bed having different errors in straightness, or, if straight, lying in non-parallel planes. This condition cannot be detected with an auto-collimator, since the reflector would be merely rotating in its own plane as it was stepped along the bed. The most practical and convenient ‘method of test isto step a precision level, nid transversely across the bed, eloag its length. If necessary, a bridge piece should be used as the level carriage, both to span the width of the bed, and to aecommodate the vee guideways, "A computer program for handling this typeof calculation is shown in Chapter M1, seetion 11.211 63. TESTS FOR SQUARENESS In many machine tools, for example, driling machines and vertical milling ‘machines, an essential accuracy lies m the squareness of the spindle axis withthe plane of the table, Fig. 6.6 illustrates the principle, in which a test bar supports a {ial est indicator ata suitable radi, say 150 mm, ‘With the measuring plunger bearing directly but lightly on the machine table, the spindle is rotated slowly by hand through 360", dil indicator readings being taken at 180° in planes perpendicular to each other. In the ease of drilling ‘machines, the permitted error is ofthe order of 0-05 mny300 mm, and in direction such thatthe front edge ofthe table is inclined upwards, That i, the force duc to the downward traverse ofthe dill tends to corres the errr, In the case of vertical milling machines, the fall tet would apply only to fixed cutting head machines. test ina direction perpendicular tothe longitudinal able axis only is applicable to swivlling ead machines, and an error of 0-02 mm300 mis applicable, the font edge ofthe tabe inclining upwards. ‘A test of this nature is known as the ‘turn round method’, and proves to be a very sensitive one. In some classes of machine tools, the accuracy of construction called for 130 Machine Tool Metrology requires optical methods for its testing. This applies especially to jig-boring ‘machines, buts also applicable to milling machines of both vertical and horizontal Fig. 6.7 ilustrates the conditions of tet for the squareness of the transverse table ways with th face ofthe column. mA Fig 66. Testing a dilngmachine spied for ‘oaenes whe ble ‘When using an optical method for such a test, and beating in mind thatthe axis of the incident beam from the auto-collimator forms the measuring daturs, itis clear that this most be turned accurately through 90°. Is doue by means of a optical square. This isa special ease of prism, such that, regardless of the angle fat which the incident beam strike the face ofthe prism, then by internal reflection the beam is tarned through 90° Fig. 67, Autocalitstor and optical auc being wed ‘ouareess of mache ses iL