Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers

AN A MERICAN NA TIONAL S T AND ARD

ASME B5.54-2005

(Revision of ASME B5.54-1992)

Methods for Performance

Evaluation of Computer Numerically Controlled Machining Centers

AN AMERICAN NA TIONAL S T AND ARD

Three Park Avenue • New York, NY 10016

Date of Issuance: March 25, 2005

The 2005 edition of this Standard is being issued with an automatic addenda subscription service. The use of addenda allows revisions made in response to public review comments or committee actions to be published as necessary. This Standard will be revised when the Society approves the issuance of a new edition.

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The American Society of Mechanical Engineers Three Park Avenue, New York, NY 10016-5990

Copyright © 2005 by

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CONTENTS

Foreword viii

Committee Roster ix

Correspondence With the B5 Committee x

1. Scope 1

   1. General 1

   2. Performance Forms 1

2. References 18

3. Nomenclature 19

4. Definitions 23

   1. Glossary 23

   2. Machine Classifications 36

5. Environmental Specifications 43

   1. General 43

   2. Temperature 43

   3. Seismic Vibration 43

   4. Electrical 44

   5. Utility Air 44

   6. Other 45

6. Environmental Tests 46

   1. General 46

   2. Environmental Temperature Variation Error (ETVE) 46

   3. Relative Vibration Tests 51

   4. Electrical Tests 53

   5. Utility Air and Other Tests 53

7. Machine Performance 55

   1. General 55

   2. Machine Compliance and Hysteresis 56

   3. Positioning Accuracy and Repeatability 61

   4. Geometric Accuracy Tests 68

   5. Spindle Axis of Rotation 78

   6. Machine Thermal Tests 81

   7. Diagonal Displacement Test 87

   8. Subsystems Repeatability 88

   9. Machine Performance as a Measuring Tool 92

   10. CNC Performance Tests 95

   11. Contouring Performance Using Circular Tests 99

8. Machining Test Parts 102

   1. General 102

   2. Precision Contouring Machining Test: All Machining Centers 103

   3. Machining Tests for Four- and Five-Axis Machining Centers 105

   4. Production Parts 105

9. Cutting Performance Tests 108

   1. General 108

   2. Complete Set of Tests 108

   3. Machining Center Ranges 109

   4. Spindle Idle Run Loss Test 109

   5. Chatter Limits Tests and Full Torque Test 109

10. Multifunction Cycle Test 124

    1. General 124

    2. Procedure 124

    3. Functional Check 124

11. Test Equipment and Instrumentation 125

    1. General 125

    2. Temperature 125

    3. Relative Vibration 125

    4. Displacement 125

    5. Angle 126

    6. Pressure 126

    7. Humidity 126

    8. Utility Air 126

    9. Spindle Error Measurement 126

    10. Indicators for Straightness Measurements 127

    11. Test Part Measurement 127

Figures

1. Schematic Diagrams of the Six Basic Degrees of Freedom of an Axis of

   Rotation 24

2. Four Body Diagonals of a Rectangular Prism 25

3. Face Diagonals of a Rectangular Prism 27

4. Error Motion Polar Plot Showing Polar Chart (PC) Center, a Minimum Radial Separation (MRS) Center, and Error Motion Values About These

   Centers 31

5. Example of a Structural Loop Showing a Part, Spindle, Machine Frame, and

   Tool 33

6. Code Numbers for Spindle Types 38

7. Code Numbers for Column Types 39

8. Code Numbers for Column Traverse 39

9. Code Numbers for Spindle Head Traverse 40

10. Code Numbers for Table Traverse 41

11. Examples of Machining Centers Classified by Code Numbers 42

1. Typical Setup for Environmental Temperature Variation Error (ETVE)

   Measurement on a Vertical Machining Center 47

2. Temperature, Displacement, and Tilt Motion Results From a Typical ETVE

Test 48

1. Setup for Measuring the Compliance and Machine Hysteresis of a Linear

   Axis 57

2. Setup for Measuring the Compliance and Machine Hysteresis of a Linear

   Axis in a Vertical Direction 57

3. Typical Plot Showing Results of a Compliance and Axis Hysteresis Test 58

4. Setup for Angular Compliance Measurement on a Rotary Positioning Axis 59

5. Setup for Angular Compliance Measurement on a Tilt Table 59

6. Application of a Laser Interferometer to Test the Positioning Accuracy of a

   Linear Axis 61

7. Setup for Measuring the Positioning Accuracy of a Rotary Table With a

   Laser Angle Interferometer and a Calibrated Indexing Table 62

8. Setup for Adjusting the Alignment of an Indexing Table and a Laser Angle Interferometer 62

9. Setup for the Positioning Accuracy of a Rotary Axis Showing the Polygon, Autocollimator, and Rotary Table 63

10. Setup for Measuring the Positioning Accuracy of a Rotary Axis With a

    Calibrated Rotary Encoder 63

11. Standard Test Cycle 64

12. Full Data Set for the Positioning Deviations of an Axis, Bidirectional 65

13. Positioning Deviations of an Axis, Forward Direction Only 66

14. Setup for the Measurement of the Periodic Angular Error With a

    Displacement Indicator 68

15. Periodic Error, P, of a Linear Axis 69

16. Typical Linear Carriage Designed for Motion in the X Direction 70

17. Setup for Measuring Straightness Using an Electronic Indicator and a

    Mechanical Straightedge 70

18. Test Setup for Measuring Straightness Using Taut Wire 71

19. Straightness Setup Showing an Alignment Laser 71

20. Typical Straightness Interferometer of the Most Common Type 72

21. An Angular Interferometer Setup to Measure Pitch on a Machine Where

    the Spindle Moves Relative to the Table 72

22. Typical Setup Showing Differential Levels to Measure the Roll of a Horizontal

    Axis 73

23. Differential Straightness Measurement Used to Measure the Roll of a Vertical

    Axis 73

24. Diagram Showing the Effect of Cross-Axial Roll on the Measurement of

    Roll of a Vertical Axis Using Differential Straightness 74

25. Setup for Measuring Squareness With an Optical Square and a

    Straightness Interferometer: Line 1 74

26. Setup for Measuring Squareness With an Optical Square and a

    Straightness Interferometer: Line 2 74

27. Conceptual Diagram Showing the Angles Obtained in a Squareness

    Measurement 75

28. Analysis of Parallelism Between Two Linear Axes (Parallelism Is

    Calculated From the Differences in Best-Fit Slopes of Each Profile) 75

29. Measurement of Rotary Axis Squareness Using a Mechanical or Optical Straightedge 76

30. Measurement of Rotary Axis Squareness (or Parallelism) Using a Straightness Interferometer 77

31. Measurement of Parallelism of the Z-Axis With a Rotary Table 77

32. Schematic of the Test Setup for Radial Error Motion With a Rotating Sensitive Direction 78

33. Test Method for Radial Motion With a Rotating Sensitive Direction and

    the Ball Mounted Eccentric to the Spindle 79

34. Typical Total Error Motion Polar Plot Showing Asynchronous Error

    Motion and Average Error Motion Value as Utilized in This Standard 80

35. Five-Sensor Test System for Tilt Error Motion Test on a Machining Center 80

36. Setup for Axial Error Motion Measurement for Rotating Sensitive

    Direction 81

37. Sensor Data From a Typical Spindle Thermal Warm-Up Test 83

38. Tilts of the Axis Average Line, Spindle Warm-Up Test 84

39. Path for Measuring Thermal Distortion Caused by Moving Linear Axes 85

40. Position Error Versus Time for a Typical Test for Thermal Distortion

    Caused by a Moving Linear Axis 86

41. Typical Results From a Composite Thermal Error Test 87

42. Tool Holders Used for Tool Change Repeatability 88

43. Three-Sensor Nest Setup for Tool Change Repeatability 88

44. Test Setup for Pallet Change Repeatability 90

45. Tool Length Measurement With No Spindle Rotation 90

46. Tool Length Measurement With Rotating Spindle 91

47. Tool Diameter Measurement 91

48. Illustration of the Probing Pattern Used for Determining Three-Dimensional

    Probing Capability 93

49. Sample Results From the Small Increment Tests 96

50. Test Setup 97

51. Sample Acceleration Plot 99

52. Examples of Circle Test Setups 100

53. Typical Results From a 360 deg Circular Test 101

1. Precision Contouring Test Part Test Piece Blank 103

2. Precision Contouring Test Part Machining Dimensions 104

3. Precision Contouring Test Part Inspection Requirements 106

1. Typical Transfer Functions 110

2. Typical Plot of the Power Loss in the Spindle Idle Run Loss Test 111

3. Typical Face Mills 114

4. Typical End Mills 114

5. Typical End Mills With Carbide Inserts 115

6. Typical Test Parts for the Chatter Tests 116

7. Chatter Test for Face Mills 117

8. Chatter Test With End Mills 118

9. Typical Results of the Chatter Test in One Axis Direction 118

10. Plot of the Limit Cross-Sectional Area of Cut Versus the Radial Immersion

    for a Typical Chatter Test 119

11. Test Part and Test Procedure for the End Milling Deflection Test 120

12. Sample Measurements of the Part Profile in the End Milling Deflection

    Test 121

13. Face Milling Deflection Test 122

14. Sample Displacement Measurements for the Face Milling Deflection Test

When “Slotting” (Radial Immersion p 1) 123

Forms

1. General Form 2

2. Chapter 5 Environmental Specifications Guidelines 4

3. Chapter 6 Environmental Tests 6

4. Chapter 7 Machine Performance 7

5. Chapter 9 Cutting Performance Tests 15

6. Multifunction Cycle Test 17

8.1 Precision Contouring Test Part Inspection Results 107

1. Record of the Fill Torque Test 119

2. Deflection Errors in Face Milling 122

Tables

4.1 Key to Unit Code 37

1. Specification Zones Derated Due to an Excessive Expanded Thermal

   Uncertainty 51

2. Example Calculations for Derating of Specification Zones Due to Thermal Uncertainty 52

3. Specification Zones Derated Due to an Excessive Angular Expanded Thermal Uncertainty 53

4. Performance Parameters Derated Due to Excessive Environmental

Vibration 53

1. Suggested Maximum Loads for the Machine Compliance and Hysteresis

   Test (Not for Spindles With More Than 10,000 rpm) 57

2. Typical Test Results for the Positioning and Repeatability of a Linear Axis (Measured in m) 67

8.1 Types and Sizes of Test Parts 103

1. Metric to English Conversion Used in This Standard 108

2. Machining Center Ranges 111

3. Chip Loads for Cutting Performance Test 111

4. Standard Tools and Default Machine and Cutting Parameters for the Face

   Milling Chatter Test(s) 112

5. Standard Tools and Default Machine and Cutting Parameters for the

   Chatter Tests Using Solid (HSS or Carbide) End Mills 113

6. Standard Tools and Default Machine and Cutting Parameters for the

   Chatter Test for End Mills With Carbide Inserts 113

7. Record of the Chatter Test 117

8. Typical Results From an End Milling Deflection Test 120

9. Location of Measurements for the End Milling Deflection Test 120

   Nonmandatory Appendices

   
   

   A	Guide for Using This Standard...............................................	129
   B	Thermal Environment Verification Tests ......................................	131
   C	Seismic Vibration Verification Tests ...........................................	133
   D	Electrical Power Monitoring Tests ............................................	137
   E	Machine Functional Tests ....................................................	138
   F	Machine Leveling and Alignment ............................................	140
   G	Clarifications for Cutting Performance Tests ..................................	141
   H	Laser and Machine Scale Corrections .........................................	153
   I	Drift Checks for Sensors, Including Lasers....................................	154
   J	Example Ball Bar Patterns for Four- and Five-Axis Machining Centers.........	157
   K	Discussion of the UNDE and Thermal Uncertainty............................	165
   L	Straightedge Reversal Technique .............................................	170
   M	Calculation of Uncertainties ..................................................	172
   N	Sign Conventions for Error Values............................................	175
   O	Static Error Motion Measurement ............................................	176

   
   

   FOREWORD

   
   

   The primary purpose of this Standard is to provide procedures for the performance evaluation of computer numerically controlled (CNC) machining centers. The secondary purpose is to facilitate performance comparisons between machines and to provide for machine evaluation after refit. Definitions, environmental requirements, and test methods are specified. This Standard defines the test methods capable of yielding adequate results for most machines, but is not intended to supplant more complete tests that may be required for particular special applications. This first revision of this Standard provides consistency with the recently published standard for turning centers (ASME B5.57-1998) with respect to some definitions, data analysis, and reported parameters. To achieve consistency, uncertainty analysis was used to analyze data and report parameters for many of the procedures, deemed appropriate, within this Standard. Availability of improved measurement technology and increasing demand for greater accuracy require more robust procedures for assessing performance of machining centers, as provided within this revision

   of the B5.54 standard. This Standard does not address issues of machine safety.

   This revision was approved by the American National Standards Institute on July 7, 2003 and January 12, 2005.

   
   

   ASME B5 STANDARDS COMMITTEE

   Machine Tools — Components, Elements,

   Performance, and Equipment

   (The following is a roster of the Committee at the time of approval of this Standard.)

   
   

   OFFICERS

   
   

   C. Wax, Chair

   M. Lo, Secretary

   
   

   COMMITTEE PERSONNEL

   
   

   1. M. Bratkovich, The Association for Manufacturing Technology

D. M. King, Consultant

K. J. Koroncey, General Motors

D. L. Lewis, Consultant

M. Lo, The American Society of Mechanical Engineers

C. D. Lovett

C. J. Nuccitelli, Parlec, Inc.

J. A. Soons, NIST, U.S. Department of Commerce

R. C. Spooner, Powerhold, Inc.

C. Wax, CTW Advisors, Inc.

TECHNICAL COMMITTEE 52 — MACHINING CENTERS

1. D. Lovett, Chair

2. Ajao, GM, North America

A. M. Bailey, Renishaw, Inc.

1. G. Beracz, Beacon Metrology, Inc.

2. Bishop, Boeing Commercial Airplanes

3. Boyd, Northrup Grumman Corp.

A. M. Bratkovich, The Association for Manufacturing Technology

J. B. Bryan, Bryan Associates

R. P. Callaghan, Independent Quality Laboratories, Inc.

J. E. Crane, Hardinge, Inc.

A. Donmez, NIST, U.S. Department of Commerce

J. D. Drescher, United Technologies, Pratt & Whitney

R. Griffin, Optodyne, Inc.

Q. Ma, Automated Precision, Inc.

D. L. Martin, Lion Precision

M. Omari, GM, North America

B. Parry, Boeing Co.