MANUFACTURING ENGINEERING, NITW

143511

NATIONAL INSTITUTE OF TECHNOLOGY

WARANGAL, TELANGANA-506004

A report
On

ALIGNMENT TESTS
Submitted By

SHARATH CHANDRA PALLE

ROLL NO.143511
MANUFACTURING ENGINEERING

Submitted To

Dr. VENKAIAH N
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING

CONTENTS
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1. Introduction
2. Types of Geometric checks
2.1 straightness
2.2 flatness
2.3 parallelism, equidistance and coincidence
2.4 rotations
2.5 squareness
3. Instruments required for alignment tests
4. Alignment test on lathe

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Introduction :
The dimensions of a gauge, its surface finish and geometry are dependent upon the inherent
quality and accuracy of the machine tool for its manufacture. Also in mass production the various
components produced must be of such accuracy that they may be assembled on a non-selective
basis. The accurate production of the component parts depends upon the accuracy of the machine
tools.
The continuously increasing demand for highly accurate machined components has led to
considerable research towards means by which the geometric accuracy of machines may be
improved and maintained. It is very important, therefore, that under static conditions, the
alignment accuracy of the machine tools is checked by some geometric tests. The tests which
check the alignment accuracy of the various parts of a machine tool are called static rests.
A machine tool, at the same time must be able to display the desired behaviour and
characteristics under normal operating conditions as operator is concerned with the actual
working of machine tool. Therefore, some alignment tests are performed under dynamic loading
conditions and these are referred to as dynamic tests. Thus it is obvious that the satisfactory
working of a machine under static loading only is not sufficient but account should be taken of
the vibration and deflection of various machine parts under actual dynamic loading also. In
dynamic tests, the various members are actually loaded and alignment tests are carried out. Also
various parts are excited at working frequency and behaviour of machine observed. In other
words it could be said that machine tools for the workshop must be able to produce work-pieces
of given accuracy within prescribed limits consistently and without requiring artistic skill on the
part of the operator and that the quality of workpieces depends upon :
(i) Stiffness and rigidity of the machine tool and its components parts.
(ii) The alignment of various machine parts in relation to one another. This is very important
because the geometry of various shapes is based on the relative motion between various machine
parts and hence on alignment of various parts.
(iii) The quality and accuracy of the control devices and the driving mechanism.
Stiffness and rigidity are a matter for designer and once tests on a prototype of a certain design
have given satisfactory results, there is no need to test the machine of same design over and over
again. The accuracy of manufacture, the precision of control devices and driving mechanisms
such as lead screw of lathe, all should have relative alignment as accurate as possible. This
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depends upon the quality of manufacture and may vary from machine to machine. Therefore,
each machine is subjected to an acceptance test concerning items {ii) and (iii).
The accuracy of machine tools (which cut metal by removing chips or swarfs) is tested by means
of
geometrical
checks
and
practical
tests.
Geometrical checks include checking of dimensions of forms and positions of components as
well as checking of their displacement relative to one another. These comprise all the operations
which affect the components of the machine and concern only sizes, forms, positions and relative
movements which may affect the accuracy of the machine. It may be appreciated that the
geometrical definitions are abstract and relate only to imaginary lines and surfaces. In practice,
therefore, metrological definitions are followed which are concrete and take account of real lines
and surfaces accessible to measurement. Metrological definitions cover in a single result all
macro and micro-geometrical errors and allow a result to be reached covering all causes of errors
without distinguishing them from one another. Practical tests include the machining of test pieces
appropriate to the fundamental purposes for which the machine has been designed and having
predetermined limits and tolerances.The results of practical tests and geometrical checks may be
compared only in so far as these two kinds of tests have the same object; in case both do not give
the same result, the results obtained by carrying out practical tests are accepted as valid. In case
where it is expensive or difficult to conduct both types of tests, the accuracy of a machine may be
checked only by geometrical checks or only by practical tests.

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3. MEASURING INSTRUMENTS USED FOR TESTING:

The accuracy of the machine tools employed should be higher than the accuracy of
the components that it produces. Similarly the quality of the measuring equipment used
for machine tool testing should be commensurate with the quality expected from such
testing. A few commonly used equipments are

Dial Indicators

Test mandrels

Straight edges

Spirit levels

Alignment Tests on Lathe

16.3.
16.3.1.

Levelling of the Machine.

Before the various tests on any machine tool are carried out, it is very essential that it should be
installed in truly horizontal and vertical planes. In horizontal plane, both longitudinal and
transverse directions are equally important. If, say, any long lathe bed is not installed truly
horizontal the bed will undergo a deflection, thereby producing a simple bend and undesirable
stresses will be introduced. If the bed is not installed truly horizontal in transverse direction,
twist will be introduced. Thus the movement of the saddal cant be in a straight line and true
geometric
cylinder
cant
be
generated.
For proper installation and maintenance of its accuracy, a special concrete foundation of
considerable depth must be prepared. Also this must be insulated from the surrounding floor by
introducing
some
form
of
damping.
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The level of the machine bed in longitudinal and transverse directions is generally tested by a
sensitive spirit level. The saddle is kept approximately in the centre of the bed support
feet. The spirit level is then placed at a-a (Fig. 16.1), the ensure the level in the longitudinal
direction. It is then traversed along the length of bed and readings at various places noted down.
For test in transverse direction the level is placed on a bridge piece to span the front and rear
guideways and then reading is noted. It is preferable to take two readings in longitudinal and transverse directions simultaneously so that the effect of adjustments in one
direction may also be observed in the other. The readings in transverse direction reveal any

Fig.
16.1
twist or wind in the bed. It may be noted that the two guideways may be perfectly levelled in
longitudinal direction, but might not be parallel to each other. This is revealed by the test in
transverse
direction.
The straightness of bed in longitudinal direction for the long beds can also be determined by
other methods, e.g., using straight edges, autocollimators or by taut wire method. But the test in
transverse
direction
can
be
carried
out
only
by
spirit
level.
It is desired that the front guideway should be convex only as the cutting forces and the weight of
carriage act downward on it. If the front guideways are concave, then the effect will be
comulative. The tendency of the carriage, under cutting forces is to lift upwards from the rear
and this is prevented by a gib placed underneath the guideways. With the result, an upward force
acts on the rear guideways ; which must, therefore, be made concave.Transverse level may be in
any direction, but no twist can be tolerated.16.3.2.

True Running of Locating Cylinder of Main Spindle.

Locating cylinder is provided to locate the chuck or face plate. However locating surface
cant be threaded one as threads get worn out soon and thus introducing play in face
plate or chuck. Thus locating surface is cylindrical and this must run truly; for only then
the face plate etc., can run truly. The dial indicator is fixed to the carriage (or any other
fixed member) and the feeler of the indicator touches the locating surface. The surface
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is then rotated on its axis and indictor should not show any movement of needle.

Fig.
16.3.3.

16.2

Axial Slip of Main Spindle and True Running of Shoulder

Face of Spindle Nose.
Let us first distinguish between the axial play and the axial slip. Axial play means the
indispensable freedom of spindle movement in axial direction to prevent it from
seizing by heating. The spindle is supported between two bearings. Due to running of
spindle, there will be a rise in temperature and thermal expansion of spindle would be
there. If no axial play is allowed, it would try to bend. Thus there will be no adverse
effect of axial play if the direction of cutting forces remains same. If the direction of
cutting force changes, there would be some error introduced due to movement of
spindle axially in either direction. Under such conditions, therefore, it is advisable to cut
threads
in
one
direction
only.
Axial
slip
is
defined
as
the
axial
spindle
movement
which

Fig.
16.3
follows the same pattern and is due to the manufacturing error. Actually this test is
meant to check this error. To test this the feeler of the dial gauge rests on the face of the
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locating spindle shoulder and the dial gauge holder is clamped to the bed (Fig. 16.3).
The locating cylinder is then rotated and the change in reading noted down. The
readings are taken at two diametrically opposite points. The total error indicated by the
movement of the pointer includes three main sources of errors.
(i) Axial slip due to error in bearings supporting the locating shoulder, i.e., the bearings
are not perpendicular to the axis of rotation and due to it a point on the shoulder will
move axially in and out at diametrically opposite points.
(ii) Face of the locating shoulder not in a plane perpendicular to axis of rotation. (Hi)
Irregularities of front face.Due to axial slip, in screw cutting, the pitch will not be uniform
due to periodic movement of the spindle. This, however, is not important while
turning.16.3.4.

True Running of Headstock Centre.

Headstock centre is live centre and the workpiece has to rotate with this centre. If it is
not true with the axis of movement of the spindle, eccentricity will be caused while
turning a work, as the job axis would not coincide with the axis of rotation of main
spindle. For testing this error, the feeler of the dial indicator is pressed perpendicular to
the taper surface of the centre (Fig. 16.4), and the spindle is rotated. The deviation
indicated
by
the
dial
gauge
gives
the
trueness
of
the
centre.

16.3.5.

Parallelism of the Main Spindle to Saddle Movement.

This has to be checked in both vertical and horizontal planes. In this we require the use
of mandrel. An important precaution in the use of mandrels and dial indicator is
mentioned here. The mandrel must be so proportioned that its overhang does not
produce appreciable sag, or else the sag must be calculated and accounted for. The
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rigidity indicator set up is also very important and must be carefully watched. Otherwise
variations in readings are recorded by pointer may be solely due to deflection of the
indicator mounting in different positions and it becomes very difficult to detect and
isolate
the
spurious
deflection
from
the
true
variations.
If axis of the spindle is not parallel to bed in horizontal direction, a tapered surface is
produced.
Any deviation from parallelism of spindle axis from bed in vertical axis will produce a
hyperboloid surface. For this test, a mandrel is fitted in the taper socket of the spindle.
Mandrel has a concentric taper shank which is close fit to the spindle nose taper. The
feeler of the dial indicator is pressed on the mandrel and the carriage is moved. The
indication in horizontal plane is given by dial (b) and in vertical plane by dial (a) (Fig.
16.5).
In
vertical
plane
the
mandrel
should
be
rising
towards

Fig.
16.5
the free end in order to counteract the weight of mandrel and job. But for counter-acting
cutting forces, it should be lower towards free end. In horizontal plane, mandrel should
be inclined in a direction opposite to the direction of tool pressure.
16.3.6.

True running of taper socket in main spindle.

If the axis of tapered hole of the socket is not concentric with the main spindle axis,
eccentric and tapered jobs will be produced. To test it, a mandrel is fitted into the
tapered hole and readings at two extremes of the mandrel are taken by means of a dial
indicator
as
shown
in
Fie.
16.6.

Fig.
16.3.7.

16.6

Parallelism of tailstock guideways with the movement of

carriage.
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Sometimes the job is held between head-stock and tail stock centre for turning. In that
case the job axis must coincide with the tailstock centre. If the tailstock guideways are
not parallel with the carriage movement there will be some offset of the tailstock centre
and this results in taper turning.
To check the parallelism of tailstock mideways in both the planes i.e., horizontal and
vertical, a block is placed on the guideways as shown in Fig. 16.7 and the feeler of the
indicator is touched on the horizontal and vertical surfaces of the block. The dial
indicator is held in the carriage and carriage is moved. Any error is indicted by the
pointer
of
dial
indicator.
16.3.8.

Movement of upper slide parallel with main spindle in vertical

plane.
The dial indicator if fixed in the tool post. A mandrel is fitted in the spindle. The feeler

Fig.
16.7
of the dial gauge is pressed against the mandrel in vertical plane and the upper slide is
moved longitudinally. This error is not tested in horizontal plane because there is
swivelling arrangement for taper turning.
Parallelism of tailstock sleeve to saddle movement. If the tailstock sleeve is not parallel
to the saddle movement, the height of dead centre would vary as varying lengths of
sleeve are taken out. For the jobs held between two centres, it is necessary that the
central axis of the dead centre be coaxial with the job axis in both the planes. If it is not
so,
the
job
may be tilted up or down or in sideways due to the support of the dead centre. The test
is carried out by fixing the dial indicator on the tool post and pressing the plunger
against the sleeves first in vertical and then in horizontal plane (Fig. 16.9). The carriage
is moved along the full length of the sleeve and deviations as indicated by dial indicator
are noted down. Tailstock sleeve should be rising towards the free end in vertical plane
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and should
16.3.10.

be

inclined

towards

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the

tool

pressure

in

horizontal

plane.

Parallelism of tailstock sleeve taper socket to saddle movement.

A mandrel is put in the sleeve socket. The dial gauge is fixed on the tool post and
plunger is pressed against the mandreland saddle is moved from one side to the other.
This test is carried out in both the horizontal and vertical planes.16.3.11.

Alignment of both the centres in vertical plane.

Besides testing the parallelism of the axes individually (main spindle axis and tailstock
axis) it is-necessary to check the relative position of the axes also. Both the axes may
be parallel to carriage movement but they may not be coinciding. So when a job

Fig.16.10
is fitted between the centres, the axis of the job will not be parallel to the carriage
movement. This test is to be carried out in vertical plane only. A mandrel is fitted
between the two centres and dial gauge on the carriage. The feeler of the dial gauge is
pressed
against
the
mandrel
in
vertical
plane
as

Fig.16.11

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Alignment
Tests
on
Pillar
Type
Drilling
Machine
(Metrology)
Before carrying out the alignment tests, the machine is properly levelled in
accordance
with the manufacturers instructions. The various tests performed are :
1. Flatness of clamping surface of base. (Refer Fig. 6.17).
The test is performed by placing a straight edge on two gauge blocks on the base plate
in various positions and the error is noted down by inserting the feeler gauges. This
error should not exceed 0.1/1000 mm clamping surface and the surface should be
concave only.
2. Flatness of clamping surface of table.
This test is performed in the same manner as test (1), but on the table. The permissible
error is also same.
3. Perpendicularity of drill head guide to the base plate.
The squareness (perpendicularity) of drill head guide to the base plate is tested :
(a) in a vertical plane passing through the axes of both spindle and column, and
(b) in
a
plane
at
90
to
the
plane
at
(a).
The test is performed by placing the frame level (with graduations from 0.03 to 0.05
mm/m)
on
guide

Fig.
16.17.
Checking
flatness
of
clamping
surface
of
base.
column and base plate and the error is noted by noting the difference between the
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readings of the two levels. This error should not exceed 0.25/1000 mm guide column for
(a) and the guide column should be inclined at the upper end towards the front only, and
0.15/1000 mm for (b).
(Please note that Fig. 16.18 shows the similar test for the squareness of drill head guide
with table, the only difference being that the frame level is to be placed on the base
instead of table).

4. Perpendicularity of drill head guide with table.

This test is performed exactly in the same way as (b). (Refer Fig. 16.18) and the
permissible error is also same.
5. Perpendicularity of spindle sleeve with base plate.
This test is performed in both the planes specified in test (3) and in the similar manner
with the difference that the frame levels are to be placed on spindle sleeve and base
plate. The error (i.e., the difference between the readings of the two levels) should not
exceed 0.25/1000 mm for plane (a) and the sleeve should be inclined toward column
only ; and 0.15/1000 mm for plane (b).
6. True running of spindle taper.
For this test, the test mandrel is placed in the tapered hole of spindle and a dial indicator
is fixed on the table and its feeler made to scan the mandrel. The spindle is rotated
slowly and readings of indicator noted down. The error should not exceed 0.03/100 mm
for machines with taper upto Morse No. 2 and 0.04/300 mm for machines with taper
larger than Morse No. 2.
7. Parallelism of the spindle axis with its vertical movement.
This test is performed into two planes CA) and (B at right angles to each other. The test
mandrel is fitted in the tapered hole of the spindle and the dial indicator is fixed on the
table with its feeler touching the mandrel. The spindle is adjusted in the middle position
of its travel. The readings of the dial indicator are noted when the
spindle is moved in upper and lower directions of the middle position with slow vertical
feed
mechanism.

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Fig.

16.18.

Test

for

Fig.

perpendicularity

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of

drill

head

with

table.
16.19

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Fig.
For
For

machines
machines

with
taper
upto
Morse
with
taper
larger
than
Morse

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16.20
No.
2.
No.
2.

(Lower end of mandrel can be inclined towards column only).

8. Squareness of clamping surface of table to its axis.
For performing this test, the dial indicator is mounted in the tapered hole of the spindle
and its feeler is made to touch the surface of table (Refer Fig. 16.21). Table is slowly
rotated and the readings of dial gauge noted down, which should not exceed 0.05/300
mm diameter.
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9. Squareness of spindle axis with table.

For this test a straight edge is placed in positions AA and BB. Work table is arranged in
the middle position of its vertical travel. The dial indicator is mounted in the spindle
tapered hole and its feeler made to touch the straight edge first say at A and reading
noted down. The spindle is rotated by 180 so that the feeler touches at point A and
again reading is noted down. The difference of two readings gives the error in
squareness of spindle axis with table. Similar readings are noted down by placing the
straight
edge
in
position
BB.

The permissible errors are 0.08/300 mm with lower end of spindle inclining
towards column only for set up AA and 0.05/300 mm for set up BB.

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