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ASME B5.54 Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers , 2005
- CONTENTS
- FOREWORD
- COMMITTEE ROSTER
- CORRESPONDENCE WITH THE B5 COMMITTEE
- Chapter 1 Scope [Go to Page]
- 1.1 GENERAL
- 1.2 PERFORMANCE FORMS
- Chapter 2 References
- Chapter 3 Nomenclature
- Chapter 4 Definitions [Go to Page]
- 4.1 GLOSSARY
- 4.2 MACHINE CLASSIFICATIONS
- Chapter 5 Environmental Specifications [Go to Page]
- 5.1 GENERAL
- 5.2 TEMPERATURE
- 5.3 SEISMIC VIBRATION
- 5.4 ELECTRICAL
- 5.5 UTILITY AIR
- 5.6 OTHER
- Chapter 6 Environmental Tests [Go to Page]
- 6.1 GENERAL
- 6.2 ENVIRONMENTAL TEMPERATURE VARIATION ERROR (ETVE)
- 6.3 RELATIVE VIBRATION TESTS
- 6.4 ELECTRICAL TESTS
- 6.5 UTILITY AIR AND OTHER TESTS
- Chapter 7 Machine Performance [Go to Page]
- 7.1 GENERAL
- 7.2 MACHINE COMPLIANCE AND HYSTERESIS
- 7.3 POSITIONING ACCURACY AND REPEATABILITY
- 7.4 GEOMETRIC ACCURACY TESTS
- 7.5 SPINDLE AXIS OF ROTATION
- 7.6 MACHINE THERMAL TESTS
- 7.7 DIAGONAL DISPLACEMENT TEST
- 7.8 SUBSYSTEMS REPEATABILITY
- 7.9 MACHINE PERFORMANCE AS A MEASURING TOOL
- 7.10 CNC PERFORMANCE TESTS
- 7.11 CONTOURING PERFORMANCE USING CIRCULAR TESTS
- Chapter 8 Machining Test Parts [Go to Page]
- 8.1 GENERAL
- 8.2 PRECISION CONTOURING MACHINING TEST: ALL MACHINING CENTERS
- 8.3 MACHINING TESTS FOR FOUR- AND FIVE AXIS MACHINING CENTERS
- 8.4 PRODUCTION PARTS
- Chapter 9 Cutting Performance Tests [Go to Page]
- 9.1 GENERAL
- 9.2 COMPLETE SET OF TESTS
- 9.3 MACHINING CENTER RANGES
- 9.4 SPINDLE IDLE RUN LOSS TEST
- 9.5 CHATTER LIMITS TESTS AND FULL TORQUE TEST
- Chapter 10 Multifunction Cycle Test [Go to Page]
- 10.1 GENERAL
- 10.2 PROCEDURE
- 10.3 FUNCTIONAL CHECK
- Chapter 11 Test Equipment and Instrumentation [Go to Page]
- 11.1 GENERAL
- 11.2 TEMPERATURE
- 11.3 RELATIVE VIBRATION
- 11.4 DISPLACEMENT
- 11.5 ANGLE
- 11.6 PRESSURE
- 11.7 HUMIDITY
- 11.8 UTILITY AIR
- 11.9 SPINDLE ERROR MEASUREMENT
- 11.10 INDICATORS FOR STRAIGHTNESS MEASUREMENTS
- 11.11 TEST PART MEASUREMENT
- Figures [Go to Page]
- 4.1 Schematic Diagrams of the Six Basic Degrees of Freedom of an Axis of Rotation
- 4.2 Four Body Diagonals of a Rectangular Prism
- 4.3 Face Diagonals of a Rectangular Prism
- 4.4 Error Motion Polar Plot Showing Polar Chart (PC) Center, a Minimum Radial Separation (MRS) Center, and Error Motion Values About These Centers
- 4.5 Example of a Structural Loop Showing a Part, Spindle, Machine Frame, and Tool
- 4.6 Code Numbers for Spindle Types
- 4.7 Code Numbers for Column Types
- 4.8 Code Numbers for Column Traverse
- 4.9 Code Numbers for Spindle Head Traverse
- 4.10 Code Numbers for Table Traverse
- 4.11 Examples of Machining Centers Classified by Code Numbers
- 6.1 Typical Setup for Environmental Temperature Variation Error (ETVE) Measurement on a Vertical Machining Center
- 6.2 Temperature, Displacement, and Tilt Motion Results From a Typical ETVE Test
- 7.1 Setup for Measuring the Compliance and Machine Hysteresis of a Linear Axis
- 7.2 Setup for Measuring the Compliance and Machine Hysteresis of a Linear Axis in a Vertical Direction
- 7.3 Typical Plot Showing Results of a Compliance and Axis Hysteresis Test
- 7.4 Setup for Angular Compliance Measurement on a Rotary Positioning Axis
- 7.5 Setup for Angular Compliance Measurement on a Tilt Table
- 7.6 Application of a Laser Interferometer to Test the Positioning Accuracy of a Linear Axis
- 7.7 Setup for Measuring the Positioning Accuracy of a Rotary Table With a Laser Angle Interferometer and a Calibrated Indexing Table
- 7.8 Setup for Adjusting the Alignment of an Indexing Table and a Laser Angle Interferometer
- 7.9 Setup for the Positioning Accuracy of a Rotary Axis Showing the Polygon, Autocollimator, and Rotary Table
- 7.10 Setup for Measuring the Positioning Accuracy of a Rotary Axis With a Calibrated Rotary Encoder
- 7.11 Standard Test Cycle
- 7.12 Full Data Set for the Positioning Deviations of an Axis, Bidirectional
- 7.13 Positioning Deviations of an Axis, Forward Direction Only
- 7.14 Setup for the Measurement of the Periodic Angular Error With a Displacement Indicator
- 7.15 Periodic Error, P, of a Linear Axis
- 7.16 Typical Linear Carriage Designed for Motion in the X Direction
- 7.17 Setup for Measuring Straightness Using an Electronic Indicator and a Mechanical Straightedge
- 7.18 Test Setup for Measuring Straightness Using Taut Wire
- 7.19 Straightness Setup Showing an Alignment Laser
- 7.20 Typical Straightness Interferometer of the Most Common Type
- 7.21 An Angular Interferometer Setup to Measure Pitch on a Machine Where the Spindle Moves Relative to the Table
- 7.22 Typical Setup Showing Differential Levels to Measure the Roll of a Horizontal Axis
- 7.23 Differential Straightness Measurement Used to Measure the Roll of a Vertical Axis
- 7.24 Diagram Showing the Effect of Cross-Axial Roll on the Measurement of Roll of a Vertical Axis Using Differential Straightness
- 7.25 Setup for Measuring Squareness With an Optical Square and a Straightness Interferometer: Line 1
- 7.26 Setup for Measuring Squareness With an Optical Square and a Straightness Interferometer: Line 2
- 7.27 Conceptual Diagram Showing the Angles Obtained in a Squareness Measurement
- 7.28 Analysis of Parallelism Between Two Linear Axes (Parallelism Is Calculated From the Differences in Best-Fit Slopes of Each Profile)
- 7.29 Measurement of Rotary Axis Squareness Using a Mechanical or Optical Straightedge
- 7.30 Measurement of Rotary Axis Squareness (or Parallelism) Using a Straightness Interferometer
- 7.31 Measurement of Parallelism of the Z-Axis With a Rotary Table
- 7.32 Schematic of the Test Setup for Radial Error Motion With a Rotating Sensitive Direction
- 7.33 Test Method for Radial Motion With a Rotating Sensitive Direction and the Ball Mounted Eccentric to the Spindle
- 7.34 Typical Total Error Motion Polar Plot Showing Asynchronous Error Motion and Average Error Motion Value as Utilized in This Standard
- 7.35 Five-Sensor Test System for Tilt Error Motion Test on a Machining Center
- 7.36 Setup for Axial Error Motion Measurement for Rotating Sensitive Direction
- 7.37 Sensor Data From a Typical Spindle Thermal Warm-Up Test
- 7.38 Tilts of the Axis Average Line, Spindle Warm-Up Test
- 7.39 Path for Measuring Thermal Distortion Caused by Moving Linear Axes
- 7.40 Position Error Versus Time for a Typical Test for Thermal Distortion Caused by a Moving Linear Axis
- 7.41 Typical Results From a Composite Thermal Error Test
- 7.42 Tool Holders Used for Tool Change Repeatability
- 7.43 Three-Sensor Nest Setup for Tool Change Repeatability
- 7.44 Test Setup for Pallet Change Repeatability
- 7.45 Tool Length Measurement With No Spindle Rotation
- 7.46 Tool Length Measurement With Rotating Spindle
- 7.47 Tool Diameter Measurement
- 7.48 Illustration of the Probing Pattern Used for Determining Three-Dimensional Probing Capability
- 7.49 Sample Results From the Small Increment Tests
- 7.50 Test Setup
- 7.51 Sample Acceleration Plot
- 7.52 Examples of Circle Test Setups
- 7.53 Typical Results From a 360 deg Circular Test
- 8.1 Precision Contouring Test Part Test Piece Blank
- 8.2 Precision Contouring Test Part Machining Dimensions
- 8.3 Precision Contouring Test Part Inspection Requirements
- 9.1 Typical Transfer Functions
- 9.2 Typical Plot of the Power Loss in the Spindle Idle Run Loss Test
- 9.3 Typical Face Mills
- 9.4 Typical End Mills
- 9.5 Typical End Mills With Carbide Inserts
- 9.6 Typical Test Parts for the Chatter Tests
- 9.7 Chatter Test for Face Mills
- 9.8 Chatter Test With End Mills
- 9.9 Typical Results of the Chatter Test in One Axis Direction
- 9.10 Plot of the Limit Cross-Sectional Area of Cut Versus the Radial Immersion for a Typical Chatter Test
- 9.11 Test Part and Test Procedure for the End Milling Deflection Test
- 9.12 Sample Measurements of the Part Profile in the End Milling Deflection Test
- 9.13 Face Milling Deflection Test
- 9.14 Sample Displacement Measurements for the Face Milling Deflection Test When “Slotting” (Radial Immersion = 1)
- Forms [Go to Page]
- 1.1 General Form
- 1.2 Chapter 5 Environmental Specifications Guidelines
- 1.3 Chapter 6 Environmental Tests
- 1.4 Chapter 7 Machine Performance
- 1.5 Chapter 9 Cutting Performance Tests
- 1.6 Multifunction Cycle Test
- 8.1 Precision Contouring Test Part Inspection Results
- 9.1 Record of the Fill Torque Test
- 9.2 Deflection Errors in Face Milling
- Tables [Go to Page]
- 4.1 Key to Unit Code
- 6.1 Specification Zones Derated Due to an Excessive Expanded Thermal Uncertainty
- 6.2 Example Calculations for Derating of Specification Zones Due to Thermal Uncertainty
- 6.3 Specification Zones Derated Due to an Excessive Angular Expanded Thermal Uncertainty
- 6.4 Performance Parameters Derated Due to Excessive Environmental Vibration
- 7.1 Suggested Maximum Loads for the Machine Compliance and Hysteresis Test (Not for Spindles With More Than 10,000 rpm)
- 7.2 Typical Test Results for the Positioning and Repeatability of a Linear Axis (Measured in um)
- 8.1 Types and Sizes of Test Parts
- 9.1 Metric to English Conversion Used in This Standard
- 9.2 Machine Center Ranges
- 9.3 Chip Loads for Cutting Performance Test
- 9.4 Standard Tools and Default Machine and Cutting Parameters for the Face Milling Chatter Test(s)
- 9.5 Standard Tools and Default Machine and Cutting Parameters for the Chatter Tests Using Solid (HSS or Carbide) End Mills
- 9.6 Standard Tools and Default Machine and Cutting Parameters for the Chatter Test for End Mills With Carbide Inserts
- 9.7 Record of the Chatter Test
- 9.8 Typical Results From an End Milling Deflection Test
- 9.9 Location of Measurements for the End Milling Deflection Test
- NONMANDATORY APPENDICES [Go to Page]
- A GUIDE FOR USING THIS STANDARD
- B THERMAL ENVIRONMENT VERIFICATION TESTS
- C SEISMIC VIBRATION VERIFICATION TESTS
- D ELECTRICAL POWER MONITORING TESTS
- E MACHINE FUNCTIONAL TESTS
- F MACHINE LEVELING AND ALIGNMENT
- G CLARIFICATIONS FOR CUTTING PERFORMANCE TESTS
- H LASER AND MACHINE SCALE CORRECTIONS
- I DRIFT CHECKS FOR SENSORS, INCLUDING LASERS
- J EXAMPLE BALL BAR PATTERNS FOR FOUR- AND FIVE-AXIS MACHINING CENTERS
- K DISCUSSION OF THE UNDE AND THERMAL UNCERTAINTY
- L STRAIGHTEDGE REVERSAL TECHNIQUE
- M CALCULATION OF UNCERTAINTIES
- N SIGN CONVENTIONS FOR ERROR VALUES
- O STATIC ERROR MOTION MEASUREMENT [Go to Page]