Machine Leveling and Testing

Turning
Turning is a form of machining, a material removal process, which is used to create
rotational parts by cutting away unwanted material. The turning process requires a
turning machine or lathe, workpiece, fixture, and cutting tool.

Equipment
Turning machines, typically referred to as lathes, can be found in a variety of sizes
and designs. While most lathes are horizontal turning machines, vertical machines
are sometimes used, typically for large diameter workpieces.
Milling
Milling is the most common form of machining, a material removal process, which
can create a variety of features on a part by cutting away the unwanted material.
The milling process requires a milling machine, workpiece, fixture, and cutter.

Equipment
Milling machines can be found in a variety of sizes and designs, yet they
still possess the same main components that enable the workpiece to be
moved in three directions relative to the tool.
Drilling
Hole-making is a class of machining operations that are specifically used to cut a
hole into a workpiece. Machining, a material removal process, creates features on a
part by cutting away the unwanted material and requires a machine, workpiece,
fixture, and cutting tool.

Equipment
In machining, a hole is a cylindrical feature that is cut from the workpiece by a
rotating cutting tool that enters the workpiece axially. The hole will have the same
diameter of the cutting tool and match the geometry (which may include a pointed
end).
Machine Testing

In most cases the production or machining of a given geometric surface is achieved

through a combination of work-tool movements. In other words, the machined
surface is generated, and the accuracy of the surface depends on the accuracy of
the mating elements present in the machine tool.
Machine tools are very sensitive to impact or shock, even heavy cast inn standards
are not always solid and rigid enough to withstand stresses due to falling during
transportation, and deformations may be set up. Although the machine is always
carefully adjusted and aligned when on the test stand or in the assembly
department of the manufacturer, it is well known from experience that erection in
the workshop of the user is not always done with sufficient care and thus
inaccuracies of the work may result from the faulty erection of the machine. So the
machine should be carefully levelled up by means of a spirit level before starting
with the actual trial tests.

Following instruments are required for conducting these tests: dial gauges, tests
mandrels, straight edges and squares, spirit levels, autocollimators, etc.
The dial gauges are more frequently used .The principle of dial indicator (dial gauge)
is that the linear mechanical movement of the stylus is magnified and transferred to
the rotation of pointer. The accuracy of dial indicator can be up to 0.001mm.
Turning machine
Aim:
To perform various tests on lathe machine.

Parallelism of quill axis of the tailstock with saddle motion

Setting:

(a)

(b)
To get the best performance from your lathe you need to check the accuracy of its
working parts. Modern lathes have accuracy built into them, but there may be some
parts that are not accurate or properly aligned

Before any testing is begun, the lathe should be carefully cleaned, all slides adjusted
and oiled to work smoothly but without any slackness, as it is easy to get false
readings due to swarf and grit.

Devices used:
Dial indicator, holder

This has to be checked in both vertical and horizontal planes.

Procedure:
Set the instrument as shown in figure ( holder on the carriage and the plunger
on the tailstock)
Rotate the carriage hand wheel
Take the maximum and minimum reading of the indicator

Readings:
(a)
Minimum reading Maximum reading
0.74 mm 0.79 mm

(b)
Minimum reading Maximum reading
0.18 mm 0.21 mm

Calculations:
= | | | |
(a)
= |0.79| |0.74| = 0.05
(b)
= |0.21| |0.18| = 0.03
Parallelism of tailstock slide way with saddle motion

Guide ways are used in machine tools to:

o Control the direction or line of action of the carriage or the table on which a
tool or a workpieces held
o To absorb all the static and dynamic forces

The flat or V-shaped bearing surfaces on a machining

tool that guide and align the parts which they
support.

Setting:
Devices used:
Dial indicator, holder

Procedure:
Set the instrument as shown in figure ( holder on the carriage and the plunger
on the v guide way)
Rotate the carriage hand wheel
Take the maximum and minimum reading of the indicator

Readings:
Minimum reading Maximum reading
0.45 mm 0.50 mm

Calculations:
= | | | |

= |0.50| |0.45| = 0.05

Milling Machine
Squareness of the feed motion with table surface:

Setting:

Devices used:
Dial indicator, holder, standard square (holder, base and straight edge)

Procedure:
Set the instrument as shown in figure ( holder on the quill and the plunger on
the straight edge of the standard square)
Rotate the feed handle (up and down movement)
Take the maximum and minimum reading of the indicator

Readings:
Minimum reading Maximum reading
0.63 mm 0.80 mm

Calculations:
= | | | |

= |0.80| |0.63| = 0.17

Squareness of spindle axis with table surface:

Setting:

Devices used:
Dial indicator, holder

Procedure:
Set the instrument as shown in
figure ( holder on the quill and the
plunger on the table)
Rotate the quill (take a reading and
then rotate it by 180 manually)
Repeat the last step on the other
axis of the table
Take readings of the indicator
Readings:
a\ Longitudinal axis of the table:
1st reading 2nd reading
0.03 mm 0.10 mm

b\ Transvers axis of the table:

1st reading 2nd reading
0.06 mm 0.20 mm

Calculations:
= | | | |

a\
= |0.10| |0.03| = 0.07

b\
= |0.20| |0.06| = 0.14
Run out and axial slip of the spindle:
Setting:

Devices used:
Dial indicator, holder

Procedure:
Set the instrument as shown in figure ( holder on the table and the plunger on
the quill surface))
Rotate the quill
Take the maximum and minimum reading of the indicator

Readings:
Minimum reading Maximum reading
0.09 mm 0.19 mm

Calculations:
= | | | |

= |0.16| |0.09| = 0.13

Milling Machine

Parallelism of the table with its guide way

Setting:
Devices used:
Dial indicator, holder,

Procedure:
Set the instrument as shown in figure ( holder on the machine and the
plunger on the table)
Rotate the longitudinal travers hand wheel
Take the maximum and minimum reading of the indicator

Readings:
Minimum reading Maximum reading
0.10 mm 0.20 mm

Calculations:
= | | | |

= |0.20| |0.10| = 0.10

Parallelism of Tee slot with the table motion

Setting:

Devices used:
Dial indicator, holder,

Procedure:
Set the instrument as shown in figure ( holder on the machine and the
plunger on the tee slot of the worktable)
Rotate the longitudinal travers hand wheel
Take the maximum and minimum reading of the indicator

Readings:
Minimum reading Maximum reading
0.03 mm 0.18 mm

Calculations:
= | | | |

= |0.19| |0.03| = 0.14