ISO 10791-6 using QC20-W

Introduction
This document details the Renishaw solution for capturing data according to ISO 10791-6 using
a QC20-W ballbar, associated software and hardware.
ISO 10791-6 details tests which can be carried out using a QC20-W ballbar to verify the
performance of 4 or 5 axis machine tool centres.
Testing is carried out using the tool centre point style function within the machine controller. The
tool centre point function allows the machine to contour effectively between two set positions.
When contouring, the machine tool will maintain a constant separation between the tooltip and
workpiece using multi-axis movements. This makes QC20-W the perfect tool for verifying the
contouring performance of the machine tool by measuring any deviation along the specified tool
paths.

Machine requirements
The tests described in the ISO 10791-6 standard can be performed for the machine tools with
construction as below:

ISO 10791-6 reference = ‘AK’ ISO 10791-6 reference = ‘BK’ ISO 10791-6 reference = ‘CK’
Head - Head machines Table -Table machines CK: Head - Table machines
2 rotary axes in the spindle head 2 rotary axes in the workpiece Swivel head and/or rotary table
side of the machine

The function of enabling and disabling tool centre point in machine tool controllers will vary
depending on the manufacturer. The table below lists some common manufacturers and the
enable/disable codes for part program generation.

In the part program, it is critical that the tool length offset is applied when the tool centre
point function is enabled. Failure to do so could result in damage to the QC20-W ballbar
or to the machine tool.
Application note

Control type TCP control function Enable Disable

Fanuc 30 series Tool Centre Point (TCP) G43.4 G49
Siemens 840D TRAORI TRAORI TRAFOOF
Mazak Matrix 2 Tool Tip Point Control (TTPC) G43.4 G49
Heidenhain TNC530 Tool Centre Point Management (TCPM) M128 M129
Haas UMC-750 Tool Centre Point Management (TCPC) G234 G49

If you are using a part program or error correction parameters generated by the Renishaw
software, it is the responsibility of the user to validate these at low feedrate and be
prepared to operate the emergency stop button if necessary.
Hardware and software requirements
The following hardware and software will be required to carry out testing for all the machine variants detailed
above.
Further information on all of the hardware below, as well as software downloads, can be found at the
following page of the Renishaw website: www.renishaw.com/ballbar

QC20-W telescoping ballbar

Capture data from the machine tool

Ballbar Trace software

Capture data from the QC20-W

Ballbar spindle centring device

Remove errors caused by test set-up

XCal-View data analysis software

OMP40 & OMP60 shanks Analyse QC20-W data to ISO 10791-6 standard
Mount and adjust the spindle centring device

Test process

Apply tool
Machine Adjust tool cup Measure the
length to
set-up tip to spindle tool length
centreline machine

Machine Generate part Set up QC20-W

Verify program
preparation program hardware

Capture Analyse
Data capture data using data using
Ballbar Trace XCal-View
1 – Machine set-up
Assemble the tool centre cup/shank
Insert the Ballbar spindle centring device into the shank and hold in place by tightening the screws in the
shank as outlined below.

2.0 mm
A/F x 2

2.0 mm
A/F x 4
0.5 Nm - 1.5 Nm 0.5 Nm - 1.5 Nm
(0.4 lb ft - 1.1 lb ft) (0.4 lb ft - 1.1 lb ft)

2 – Prepare the machine

Using the setting ball, align the centre pivot and tool cup and set a work offset.

Set centre pivot Set work offset Move to start

G54
Z-
X100.0
Z XX.XXX
Y0.0
Z0.0

G54
Z-
X0.0
Z XX.XXX
Y0.0
Z0.0
3 – Adjust tool cup to spindle centreline

Insert QC20-W Start Ballbar 20 Alignment check

360°

Coarse adjust Tighten Alignment check

100 mm ± 10 µm

2.0 mm 360°
A/F x 2
2.0 mm
A/F x 4
1.5 Nm - 2.2 Nm
(1.1 lb ft - 1.6 lb ft)

Fine adjust Move to centre Reset work offset

100 mm ± 1 µm

2.0 mm
A/F x 4

1.5 Nm - 2.2 Nm
(1.1 lb ft - 1.6 lb ft)
Measure the tool length
Before carrying out any tool centre point style function, it is critical that the tool length is accurately known.
The tool length is defined as the distance from the gauge line to the centre of the setting ball from the
QC20-W kit. The process for measuring is as follows:
Manual method
• Measure a reference position using a ‘calibrated length bar’

Overall length (1) =

Z position from machine control - Calibrated length bar

• Measure the same reference position with the ‘centred tool cup’ and ‘setting ball’

Overall length with toolcup =

Overall length (1) - new Z position from machine control

• Remove the radius of the ball from the measured length (6.35 mm)
Apply tool length to machine
Applying the tool length will vary depending on the control manufacturer for your machine. Please refer to
your user guides for exact details. The instructions below are for guidance only:
Fanuc 30 series - select the ‘Offset setting’ hard key, then the ‘Offset’ soft key; this will direct you to
the tool page - select the tool number with the centred tool and enter the tool length. There are also
options for tool length wear, Radius geometry and Radius wear - these do not need to be populated.
Siemens 840D - select the ‘Offset’ hard key, then the ‘Tool list’ soft key; this will direct you to the tool
page - select the tool name or tool number with the centred tool and enter the tool length. There are
also options for Tool Diameter and Tool Type - these do not need to be edited.
Mazak Matrix 2 - Select left arrow soft key, then press position soft key and then tool data soft key.
Cursor down to the relevant Tool which will then show all of the info on the right hand side of the
screen. Select Edit, cursor to length, enter the length and then press Input.
Heidenhain TNC 530 - In manual or hand mode, cursor the soft keys right and select the ‘Tool Table’
soft key; this will direct you to the tool page - switch on edit by selecting the ‘Edit Off/On’ soft key, then
select the tool name or tool number with the centred tool and enter the tool length (L). There is also an
option for Tool Radius (R) which does not need to be edited.
HAAS UMC 750 - Press the ‘Offset’ hardkey. Next navigate to the ‘Tool’ tab (will most likely be the
default tab selected). Cursor down to the correct tool number, type in the tool length and press the
‘Write/Enter’ hardkey. Other tool geometries are available on this screen, but only the tool length needs
to be populated.

Machine preparation
Generate part program
Ballbar Trace software does not curently produce a part program. There are program examples available on
the Renishaw website which can be ‘edited’ to suit all test details in the standard.
The programs can be downloaded from www.renishaw.com/ballbar-ISO-testing
Each program contains variables which must be edited before running to suit your machine.

Caution should be observed when initially running the program and it is recommended that the ballbar
is not inserted on first run.

Hints and tips:

Ballbar Trace data capture is activated and deactivated by a linear Feed-in and Feed-out move of the ballbar.
This can lead to a spike in the data plot at Feed-in and Feed-out which is not representative of the 5-axis
error in the machine tool.
XCal-View overcomes this by allowing the Start/End of the data to be manually ‘cropped’ by the user.
To identify a clear difference between Feed-in and 5 axis moves, it is recommended that you add a machine
dwell after the Feed-in and before activating Tool centre point function.

• A simple example of a part program is shown below:

G Code Description
X101.5 Liner start position from G54
X100.0 Feed-in 1.5 mm
G04X2 Dwell 2 seconds
G43.4H1 Enable TCP and call tool length
B90 Rotate B axis 90 degrees
G49 Disable TCP
G04X2 Dwell 2 seconds
X101.5 Feed-out
Test set-up
The set-up for each test should be as recommended in the ISO 10791-6 standard. The guidelines outlined in
this document are as follows:
• Feedrate
• Minimum stroke of rotary axis
• Clockwise and counterclockwise data capture
• The offset of the sphere from the rotary axis
• Ballbar length (diameter of test)
For further information of any of the above, refer to the latest edition of the ISO 10791-6 standard document.

Machine precautions
Precautions must also be taken into consideration for carrying out the tests:

• Rotation of an A or B axis does not cause a collision with the machine spindle - more likely to occur on a
‘trunnion’ stye machine.
• Feedrate with TCP enabled is often the feedrate of the rotary axis. As a result linear moves can be much
higher than expected.

Data capture (Ballbar Trace)

Ballbar Trace software allows a ‘free-run’ method of data capture using a simple feed in/feed out move of the
ballbar to start and stop data capture.

Full details of the software functionality can be found in the Ballbar Trace help manual.
Data analysis (XCal-View)
Ballbar Trace software saves data in a ‘.ballbar’ file format. The files can only be analysed to the
ISO 10791-6 standard using XCal-View software.
Data in ‘.ballbar’ format can be analysed in ISO 10791-6 or in its raw format using the tabs to the left of the
main plot. When ISO 10791-6 is selected, data can be manually ‘cropped’ by the user to remove any spikes
as a result of ‘Feed in/Feed out’.
Full details of the software functionality can be found in the XCal-View help manual.

Factors affecting accuracy

Precaution should be observed to the following areas when carrying out initial set-up of the hardware.
These areas can influence the data captured directly and give a result that does not reflect that of the
machine performance.

• Tool tip mis-alignment - the tool cup tip is not aligned to the centre of the spindle
◦◦ This will cause a direct maximum to minimum deviation error caused by the set-up, not an error in the
machine tool
◦◦ The level of this affect will vary depending on which test is being carried out

• Incorrect tool length applied - the tool length value in the controller is incorrect
◦◦ This can cause the toolpath to increase or decrease
◦◦ In extreme circumstances, this can lead to the QC20-W being dropped

• Damage to tool cup/centre cup

◦◦ Damage to the kinematic mounts in the tool cup/centre cup will result in a loose fit of the ball into the
cup giving a test error

• Loose tool cup/centre pivot cup

◦◦ A loose tool cup or centre cup will cause the ballbar to change length during the toolpath resulting in
a test error
Renishaw plc T +44 (0) 1453 524524
F +44 (0) 1453 524901
New Mills, Wotton-under-Edge
E [email protected]
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United Kingdom www.renishaw.com

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