CV Information - دانشگاه صنعتی امیرکبیر

Machine Tool Control & Test Systems

References: VDI/VGQ 3441 VDI/VDE 2617 part 3 International Standard ISO 230- part 1 to 5 International Standard ISO 10791-1,3,4,5,6,7 ISO/TC 39/SC2/WG3 BS4656-38 BS 3800-3
Machine Tools Testing and their Quality Control 1- Introduction 1.1- Factors affecting product quality Human Errors (this is decreasing by further automation) Machine Errors Material inconsistencies Manufacturing method and procedure
Ambient conditions (Temp.; Pres.; humidity; Magnetic, Electrical and electromagnetic Emissions; coolant; etc.)(better condition monitoring and compensations and also more perfection in protections are reducing the influences) Clamping and fixing of the tool and workpiece Tool preset and tool wear. 1.2-What is Machine Tool Calibration? 1.3-Why measure machine performance? 1.4-Statistics .
Ambient conditions (Temp.; Pres.; humidity; Magnetic, Electrical and electromagnetic Emissions; coolant; etc.)(better condition monitoring and compensations and also more perfection in protections are reducing the influences) Clamping and fixing of the tool and workpiece Tool preset and tool wear.
1.2-What is Machine Tool Calibration? 1.3-Why measure machine performance? 1.4-Statistics .
2- Factors Affecting Machine Performance 2.1-Monitoring and Controller Errors 2.1.1-Monitoring Errors: Linear scale and its installation Rotary encoder and its installation Speed sensor and its installation Accelerometer and its installation
2.1.2-Controller Errors: Hysteresis Servo mismatch Stick-Slip Feed rate Reversal spikes.
2.3- Environment 2.4-Geometry 2.5-Structure 2.6-Dynamic Behavior of Machine 2.7-Human Factors.
3- Machine Tool Testing Methods: 3.1-Static (No load or no process). 3.1.1-Positional
3.1.1.1-Linear axis positioning - Direct old Method using length bar, dial indicator, slip gage & rotation stop plate on screw - Indirect old Method using length bar, dial Indicator, slip gage & rotation stop plate on spindle - Microscope & Scale - Michelson Laser Interferometer (e.g. Renishaw) - Two frequency Laser Interferometer (e.g. HP)
3.1.1.1-Linear axis positioning - Direct old Method using length bar, dial indicator, slip gage & rotation stop plate on screw - Indirect old Method using length bar, dial Indicator, slip gage & rotation stop plate on spindle
- Microscope & Scale - Michelson Laser Interferometer (e.g. Renishaw) - Two frequency Laser Interferometer (e.g. HP)
3.1.1.2-Indexing or interpolating rotary axis positioning - Auto collimator & precision polygon - Laser straighter & precision polygon - Renishaw laser, angular reflector & Precision rotary table - Precision electronic level & precision rotary table.
3.1.2-Geometrical 3.1.2.1- Out of straightness of guides & motions 3.1.2.2- Angular deviations of straight motions 3.1.2.3- Out of flatness of tables 3.1.2.4- Out of alignment 3.1.2.5- Out of co-axiality
3.1.2.6- Out of parallelism 3.1.2.7- Out of squareness 3.1.2.8- Bed torsion 3.1.2.9- Axial play of spindle, center or rotary table 3.1.2.10- Run out of spindle, centre or rotary table
3.1.2.11- Caming of spindle or rotary table 3.1.2.12- Spindle cone run-out and angular deviations 3.1.2.13- Angular play 3.1.2.14- Leveling
3.2- Dynamic (Loaded or in process) 3.2.1-On-Line 3.2.1.1-Simulation of operation by static or dynamic load or by motion - Deflection under force and/or torque
- Induced vibrations - Dynamic geometrical simulation - Double ball bar of Telescopic LVDT or scale type (Renishaw or Heidenhain) - Laser ball bar (Optodyne) - Stanimuc Method
3.2.1.2-Actual operation - Repeatabilities in x, y & z directions: a- Tool change b- Spindle head change c- Tool adaptor change
d- Workpiece change e- Workpiece adaptor or pallet change f- Tool measuring probe g- Workpiece measuring probe
- Deflections measurement under force and/or torque - Vibrations a- Under no load while machine is on b- Under load of operation
- Noise a- Under no load while machine is on b- Under load of operation
- Feed rate a- Linear axis b- Rotary axis
- Feed acceleration and deceleration a- Linear axis b- Rotary axis - Spindle speed -Spindle acceleration and deceleration
-Field emissions a- Magnetic b- Electromagnetic c- Electric -Dust and particle generation
-Fume and chemical gas or vapor generation -Liquid and solid chemical residues -Dry run repeat cycles at least for 8 hours -Power test -Safety and limit switches operation
-Machine response to any failure 3.2.2-Off-Line 3.2.2.1- NAS test
3.2.2.2- Test Machined Part - Flatness - Roundness - Cylindercity
- Screwing - Parallelism 3.2.2.3- Actual Part Machined
Measuring Equipment Metrological Requirements