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Machine Alignment Test

Machine alignment tests are necessary to ensure machine tools can manufacture components within specified tolerances. The accuracy of a component depends on the accuracy of the machine tool's movements. Alignment tests examine the manufacturing accuracy of machine tools by testing the position and relative displacement of machine components while static. Common alignment tests for lathes include leveling the machine, ensuring the spindle runs true, and checking the parallelism of the spindle axis and guide-ways. Precise instruments like dial gauges and test mandrels are used to perform the alignment checks.

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Sudhanwa Kulkarni
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409 views

Machine Alignment Test

Machine alignment tests are necessary to ensure machine tools can manufacture components within specified tolerances. The accuracy of a component depends on the accuracy of the machine tool's movements. Alignment tests examine the manufacturing accuracy of machine tools by testing the position and relative displacement of machine components while static. Common alignment tests for lathes include leveling the machine, ensuring the spindle runs true, and checking the parallelism of the spindle axis and guide-ways. Precise instruments like dial gauges and test mandrels are used to perform the alignment checks.

Uploaded by

Sudhanwa Kulkarni
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Necessity of Alignment Tests

To manufacture a component, various operations are carried out on various machine tools like
lathe, milling machine, drilling machine etc.

We can not manufacture a component to exact size because of various factors like human
errors, machine errors, material errors, time etc.

So, generally tolerance is applied on every dimension of a component.

In order to manufacture a component within its specified tolerance, machine tools that are used
to manufacture it, must be accurate because the dimensional accuracy of the component
depends on the accuracy of various movements of machine tools.

Thus, to examine the grade of manufacturing accuracy of the machine tools, machine alignment
tests are carried out.

Various geometrical tests that are carried out in order to inspect position and relative
displacement of machine components when machine is at static condition are called as ‘machine
alignment tests’
Dr. Georg Schlesinger (1874-1949) from Technical University Berlin, Germany was the first person
to establish certain acceptance test charts for alignment of various machine tools.

Various alignment tests carried out on various machine tools are –

1) Tests for ensuring leveling of the machine tool in both horizontal and vertical planes

2) Tests for ensuring flatness of machine bed and straightness as well as parallelism of bed ways
3) Tests for ensuring perpendicularity of guide-ways with respect to other guide-ways

4) Tests for ensuring true running of the machine spindle and its axial movements

5) Tests for ensuring parallelism of spindle axis with respect to guide-ways

6) Tests for line of movements for slides, cross-slides, and carriages


Instruments required to carry out alignment tests
1) Dial Gauge: LC = 0.01 mm, Range = 0 – 10 mm
2) Magnetic base to hold the dial gauge
3) Test mandrels: Length = 100 – 300 mm, hardened and stress relieved solid rods, two types of test
mandrels
a) Mandrels with cylindrical surface and tapered shank that can be inserted in to
the taper bore of main spindle
b) Mandrels with cylindrical surface that can be held between live and dead centres
4) Spirit Level

Cylindrical Mandrel Cylindrical Mandrel


with tapered shank
Alignment tests on lathe machine

Leveling of the lathe True running of the main Axial slip of the True running of the
Max. permissible error = 0.01 – spindle main spindle headstock centre
0.02 mm over length of 500 mm, Main spindle should not have any main spindle surface must be Headstock centre must run
can be corrected by using wedges perpendicular to axis, true with spindle axis,
radial deviation from its axis, Work-piece will develop
under supporting leg of lathe can be corrected by finishing difference between the two
reading will give the axial slip eccentricity if headstock
locating cylinder of main spindle centre is not true with
spindle centre.
Must be less than 0.03 mm

Parallelism of the main True running of spindle taper Parallelism of the tailstock
spindle bore sleeve
If spindle axis is not parallel to Axis of taper hole and main spindle hole Job centre should coincide with tailstock
guide ways then taper results, must be concentric otherwise eccentric centre otherwise job will develop taper,
Max. permissible error = 0.02 and taper jobs will be produced, Max. permissible error = 0.02 mm per
mm per 300 mm in both Max. permissible error = 0.02 mm at
both the locations 100 mm in both directions
horizontal and vertical plane

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