ASME B5.

54-2005
(Revision of ASME B5.54-1992)

Methods for
Performance
Evaluation of Computer
Numerically Controlled
Machining Centers

A N A M E R I C A N N AT I O N A L STA N DA R D

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ASME B5.54-2005
(Revision of ASME B5.54-1992)

Methods for
Performance
Evaluation of Computer
Numerically Controlled
Machining Centers

A N A M E R I C A N N AT I O N A L S TA N D A R D

Three Park Avenue • New York, NY 10016

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Copyright ASME International

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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
THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS
All rights reserved
Printed in U.S.A.

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CONTENTS

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Committee Roster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Correspondence With the B5 Committee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.2 Performance Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Machine Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3 Seismic Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Utility Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.6 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6 Environmental Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Environmental Temperature Variation Error (ETVE) . . . . . . . . . . . . . . . . . . . . 46
6.3 Relative Vibration Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4 Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5 Utility Air and Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7 Machine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2 Machine Compliance and Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.3 Positioning Accuracy and Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.4 Geometric Accuracy Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.5 Spindle Axis of Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.6 Machine Thermal Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.7 Diagonal Displacement Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.8 Subsystems Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9 Machine Performance as a Measuring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.10 CNC Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.11 Contouring Performance Using Circular Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8 Machining Test Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.2 Precision Contouring Machining Test: All Machining Centers . . . . . . . . . . . 103
8.3 Machining Tests for Four- and Five-Axis Machining Centers . . . . . . . . . . . . 105
8.4 Production Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

9 Cutting Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2 Complete Set of Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.3 Machining Center Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.4 Spindle Idle Run Loss Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.5 Chatter Limits Tests and Full Torque Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

10 Multifunction Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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10.3 Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

11 Test Equipment and Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.3 Relative Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.4 Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.5 Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.6 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.7 Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.8 Utility Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.9 Spindle Error Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.10 Indicators for Straightness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11.11 Test Part Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Figures
4.1 Schematic Diagrams of the Six Basic Degrees of Freedom of an Axis of
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Four Body Diagonals of a Rectangular Prism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Face Diagonals of a Rectangular Prism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Error Motion Polar Plot Showing Polar Chart (PC) Center, a Minimum
Radial Separation (MRS) Center, and Error Motion Values About These
Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Example of a Structural Loop Showing a Part, Spindle, Machine Frame, and
Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.6 Code Numbers for Spindle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Code Numbers for Column Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8 Code Numbers for Column Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.9 Code Numbers for Spindle Head Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.10 Code Numbers for Table Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.11 Examples of Machining Centers Classified by Code Numbers . . . . . . . . . . . . . . . . . 42
6.1 Typical Setup for Environmental Temperature Variation Error (ETVE)
Measurement on a Vertical Machining Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Temperature, Displacement, and Tilt Motion Results From a Typical ETVE
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1 Setup for Measuring the Compliance and Machine Hysteresis of a Linear
Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2 Setup for Measuring the Compliance and Machine Hysteresis of a Linear
Axis in a Vertical Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3 Typical Plot Showing Results of a Compliance and Axis Hysteresis Test . . . . . . . 58
7.4 Setup for Angular Compliance Measurement on a Rotary Positioning Axis . . . . 59
7.5 Setup for Angular Compliance Measurement on a Tilt Table . . . . . . . . . . . . . . . . . . 59
7.6 Application of a Laser Interferometer to Test the Positioning Accuracy of a
Linear Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.7 Setup for Measuring the Positioning Accuracy of a Rotary Table With a
Laser Angle Interferometer and a Calibrated Indexing Table . . . . . . . . . . . . . . . . 62
7.8 Setup for Adjusting the Alignment of an Indexing Table and a Laser Angle
Interferometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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7.9 Setup for the Positioning Accuracy of a Rotary Axis Showing the Polygon,
Autocollimator, and Rotary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.10 Setup for Measuring the Positioning Accuracy of a Rotary Axis With a
Calibrated Rotary Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.11 Standard Test Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.12 Full Data Set for the Positioning Deviations of an Axis, Bidirectional . . . . . . . . . . 65
7.13 Positioning Deviations of an Axis, Forward Direction Only . . . . . . . . . . . . . . . . . . . 66
7.14 Setup for the Measurement of the Periodic Angular Error With a
Displacement Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.15 Periodic Error, P, of a Linear Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.16 Typical Linear Carriage Designed for Motion in the X Direction. . . . . . . . . . . . . . . 70
7.17 Setup for Measuring Straightness Using an Electronic Indicator and a
Mechanical Straightedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.18 Test Setup for Measuring Straightness Using Taut Wire . . . . . . . . . . . . . . . . . . . . . . . 71
7.19 Straightness Setup Showing an Alignment Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.20 Typical Straightness Interferometer of the Most Common Type . . . . . . . . . . . . . . . . 72
7.21 An Angular Interferometer Setup to Measure Pitch on a Machine Where
the Spindle Moves Relative to the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.22 Typical Setup Showing Differential Levels to Measure the Roll of a Horizontal
Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.23 Differential Straightness Measurement Used to Measure the Roll of a Vertical
Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.24 Diagram Showing the Effect of Cross-Axial Roll on the Measurement of
Roll of a Vertical Axis Using Differential Straightness . . . . . . . . . . . . . . . . . . . . . . . 74
7.25 Setup for Measuring Squareness With an Optical Square and a
Straightness Interferometer: Line 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.26 Setup for Measuring Squareness With an Optical Square and a
Straightness Interferometer: Line 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.27 Conceptual Diagram Showing the Angles Obtained in a Squareness
Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.28 Analysis of Parallelism Between Two Linear Axes (Parallelism Is
Calculated From the Differences in Best-Fit Slopes of Each Profile) . . . . . . . . . . 75
7.29 Measurement of Rotary Axis Squareness Using a Mechanical or Optical
Straightedge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.30 Measurement of Rotary Axis Squareness (or Parallelism) Using a Straightness
Interferometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.31 Measurement of Parallelism of the Z-Axis With a Rotary Table . . . . . . . . . . . . . . . . 77
7.32 Schematic of the Test Setup for Radial Error Motion With a Rotating Sensitive
Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.33 Test Method for Radial Motion With a Rotating Sensitive Direction and
the Ball Mounted Eccentric to the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.34 Typical Total Error Motion Polar Plot Showing Asynchronous Error
Motion and Average Error Motion Value as Utilized in This Standard. . . . . . . 80
7.35 Five-Sensor Test System for Tilt Error Motion Test on a Machining Center . . . . . 80
7.36 Setup for Axial Error Motion Measurement for Rotating Sensitive
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Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.37 Sensor Data From a Typical Spindle Thermal Warm-Up Test . . . . . . . . . . . . . . . . . . 83
7.38 Tilts of the Axis Average Line, Spindle Warm-Up Test . . . . . . . . . . . . . . . . . . . . . . . . 84
7.39 Path for Measuring Thermal Distortion Caused by Moving Linear Axes . . . . . . . 85
7.40 Position Error Versus Time for a Typical Test for Thermal Distortion
Caused by a Moving Linear Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.41 Typical Results From a Composite Thermal Error Test . . . . . . . . . . . . . . . . . . . . . . . . 87
7.42 Tool Holders Used for Tool Change Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.43 Three-Sensor Nest Setup for Tool Change Repeatability . . . . . . . . . . . . . . . . . . . . . . . 88
7.44 Test Setup for Pallet Change Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.45 Tool Length Measurement With No Spindle Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 90

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7.46 Tool Length Measurement With Rotating Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.47 Tool Diameter Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.48 Illustration of the Probing Pattern Used for Determining Three-Dimensional
Probing Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.49 Sample Results From the Small Increment Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.50 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.51 Sample Acceleration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.52 Examples of Circle Test Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.53 Typical Results From a 360 deg Circular Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.1 Precision Contouring Test Part Test Piece Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.2 Precision Contouring Test Part Machining Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 104
8.3 Precision Contouring Test Part Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . 106
9.1 Typical Transfer Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2 Typical Plot of the Power Loss in the Spindle Idle Run Loss Test . . . . . . . . . . . . . . 111
9.3 Typical Face Mills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.4 Typical End Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.5 Typical End Mills With Carbide Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.6 Typical Test Parts for the Chatter Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9.7 Chatter Test for Face Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.8 Chatter Test With End Mills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9.9 Typical Results of the Chatter Test in One Axis Direction . . . . . . . . . . . . . . . . . . . . . 118
9.10 Plot of the Limit Cross-Sectional Area of Cut Versus the Radial Immersion
for a Typical Chatter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.11 Test Part and Test Procedure for the End Milling Deflection Test . . . . . . . . . . . . . . 120
9.12 Sample Measurements of the Part Profile in the End Milling Deflection
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
9.13 Face Milling Deflection Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.14 Sample Displacement Measurements for the Face Milling Deflection Test
When “Slotting” (Radial Immersion p 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Forms
1.1 General Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Chapter 5 Environmental Specifications Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Chapter 6 Environmental Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Chapter 7 Machine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Chapter 9 Cutting Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Multifunction Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Precision Contouring Test Part Inspection Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.1 Record of the Fill Torque Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.2 Deflection Errors in Face Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Tables
4.1 Key to Unit Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1 Specification Zones Derated Due to an Excessive Expanded Thermal
Uncertainty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2 Example Calculations for Derating of Specification Zones Due to Thermal
Uncertainty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.3 Specification Zones Derated Due to an Excessive Angular Expanded Thermal
Uncertainty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.4 Performance Parameters Derated Due to Excessive Environmental
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1 Suggested Maximum Loads for the Machine Compliance and Hysteresis
Test (Not for Spindles With More Than 10,000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2 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
9.1 Metric to English Conversion Used in This Standard. . . . . . . . . . . . . . . . . . . . . . . . . . 108

vi
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9.2 Machining Center Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3 Chip Loads for Cutting Performance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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9.4 Standard Tools and Default Machine and Cutting Parameters for the Face
Milling Chatter Test(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
9.5 Standard Tools and Default Machine and Cutting Parameters for the
Chatter Tests Using Solid (HSS or Carbide) End Mills . . . . . . . . . . . . . . . . . . . . . . 113
9.6 Standard Tools and Default Machine and Cutting Parameters for the
Chatter Test for End Mills With Carbide Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.7 Record of the Chatter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.8 Typical Results From an End Milling Deflection Test . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.9 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

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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.

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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

A. 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

C. D. Lovett, Chair
D. Ajao, GM, North America
A. M. Bailey, Renishaw, Inc.
K. G. Beracz, Beacon Metrology, Inc.
L. Bishop, Boeing Commercial Airplanes
M. 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
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R. Griffin, Optodyne, Inc.

Q. Ma, Automated Precision, Inc.
D. L. Martin, Lion Precision
M. Omari, GM, North America
B. Parry, Boeing Co.
B. B. Seth, Ford Motor Co.
S. C. Shivaswamy, Cincinnati Machine
L. Somerville, Renishaw, Inc.
J. A. Soons, NIST, U.S. Department of Commerce
N. Srinivasan, Caterpillar, Inc.
M. R. Stallings, Northrup Grumman Marine Systems
D. E. Stapley, S & S Machine Dynamics
W. Taylor, Northrup Grumman Marine Systems
C. P. Wang, Optodyne, Inc.
R. Winfough, Bourn & Koch

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CORRESPONDENCE WITH THE B5 COMMITTEE

General. ASME Standards are developed and maintained with the intent to represent the
consensus of concerned interests. As such, users of this Standard may interact with the
Committee by proposing revisions, and attending Committee meetings. Correspondence
should be addressed to:
Secretary, B5 Standards Committee
The American Society of Mechanical Engineers
Three Park Avenue
New York, NY 10016-5990
Proposing Revisions. Revisions are made periodically to the Standard to incorporate
changes that appear necessary or desirable, as demonstrated by the experience gained from
the application of the Standard. Approved revisions will be published periodically.
The Committee welcomes proposals for revisions to this Standard. Such proposals should
be as specific as possible, citing the paragraph number(s), the proposed wording, and a
detailed description of the reasons for the proposal, including any pertinent documentation.
Attending Committee Meetings. The B5 Standards Committee regularly holds meetings,
which are open to the public. Persons wishing to attend any meeting should contact the
Secretary of the B5 Standards Committee.
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ASME B5.54-2005

METHODS FOR PERFORMANCE EVALUATION OF COMPUTER

NUMERICALLY CONTROLLED MACHINING CENTERS

Chapter 1
Scope

1.1 GENERAL be the subject of contractual agreement between the Sup-

plier and the User. This Standard is rather comprehen-
This Standard establishes methodology for specifying sive; therefore, for smaller and less expensive machines
and testing the performance of CNC machining centers. the conformance to specifications could be based on a
In addition to clarifying the performance evaluation, this recommended subset of tests to evaluate machine per-
Standard facilitates performance comparisons between formance.
machines by unifying terminology, general machine
classification, and the treatment of environmental 1.2 PERFORMANCE FORMS
effects. It provides a series of tests that should be used Any performance forms described, as complying with
to perform acceptance testing (runoff) of new and recon- this Standard, shall include at least those items specified
ditioned machines and could be used to verify continued in Forms 1.1 through 1.6. Other forms shall be included,
capability of production machines, already in operation, depending on the acceptance tests agreed between the
through periodic testing. The set of acceptance tests and Supplier and the User. The form for machining test parts
the specification limits for machine conformance shall is included in Chapter 8 as Form 8.1.

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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

Form 1.1 General Form

Machine Classification (Para. 4.2): A code number classifying the machining center configuration, axis designation, and directions of positive
travel shall be specified as described in para. 4.2.

Code number

In addition, a schematic of the machine with axis directions should be provided.

Linear Axes

Full Travel Control Resolution Minimum Programming Increment

Axis Name mm in. mm in. mm in.

X
Y
Z

Maximum Programmable Feed Rate Rapid Traverse Speed Acceleration/Deceleration

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Axis Name mm/min in./min mm/min in./min mm/s2 in./sec2

X
Y
Z

Rotary Machining Axes

Minimum Maximum Time to Rotate, sec

Control Programming Programmable Rapid Traverse Acceleration/
Full Travel, Resolution, Increment, Feed Rate, Speed, Deceleration,
Axis Name deg deg deg deg/min deg/min deg/sec2 90 deg 180 deg

A
B
C

Rotary Positioning Axes

Full Travel, Minimum Index Increment, Time to Index, sec

Axis Name deg deg 90 deg 180 deg

A
B
C

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METHODS FOR PERFORMANCE EVALUATION OF COMPUTER ASME B5.54-2005
NUMERICALLY CONTROLLED MACHINING CENTERS

Form 1.1 General Form (Cont’d)

Principal Spindle Parameters (for Each Spindle)

Rotation Speed Spindle Power Continuous Duty

Spindle Range Min., rpm Max., rpm kW hp

1
2

Minimum programmable speed: rpm

Supplier shall furnish torque/power curves for each spindle range. Intermittent duty cycle details for each spindle range shall be supplied if
applicable.

Tool holder type:

Machine Tool Probes (for Each Probe)

Probe type: 3 Part probe 3 Tool setting probe

3 Contact 3 Noncontact
3 Switching 3 Proportional 3 Nulling
3 1D 3 2D 3 3D
Operating parameters: Probe approach rate mm/s in./sec

Probe approach distance mm in.

Settling time (proportional probes only) sec

Software: 3 Allows only 1D Measurements

3 Allows only 2D measurements
3 Allows 3D measurements
List of Compensation Tables in the Controller: Supplier shall provide a technical description of the machine compensation system (where
applicable), as well as a statement describing User access to compensation system parameters.

Accessible by User Information Attached

Compensation Description (Y/N) (Y/N)

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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

Form 1.2 Chapter 5 Environmental Specifications Guidelines

Thermal Information (Para. 5.2)

Temperature °C °F

Mean ambient temperature

Minimum safe operating temperature
Maximum safe operating temperature
Daily (24 hr) temperature cycling amplitude, plus or minus

Superimposed cycle(s)
Amplitude: ± °C ± °F
Frequency: cycles/hr

Maximum temperature gradients

Vertical: °C/m °F/ft
Horizontal: °C/m °F/ft

Maximum mean air speed surrounding the machine: m/s ft/sec

Additional guidelines on machine component placement and special flow parameters, such as mean flow rate, are to be specified if appro-

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priate.

Nominal Coefficient of Thermal Expansion of Linear Machine Feedback Device Axis

Nominal Coefficient of Thermal Expansion

Axis 10−6 /°C 10−6 /°F

X
Y
Z

Seismic Vibration Allowances (Para. 5.3)

3 Option 1 (response function data):

(detailed permissible vector vibration spectra shall be attached as a part of this specification)
3 Option 2 (broadband data):

Frequency Range Peak-to-Peak Amplitude

Minimum, Hz Maximum, Hz mm in.

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METHODS FOR PERFORMANCE EVALUATION OF COMPUTER ASME B5.54-2005
NUMERICALLY CONTROLLED MACHINING CENTERS

Form 1.2 Chapter 5 Environmental Specifications Guidelines (Cont’d)

Electrical (Equivalent Specification Required for Each Electrical Supply; Para. 5.4)

Steady state requirements:

Voltage V Frequency Hz Amperage A

Allowable short duration RMS voltage variations (instantaneous):

Voltage sag (8.3 msec to 500 msec) percent of nominal
Voltage swell (8.3 msec to 500 msec) percent of nominal

Allowable long duration RMS variations:

Overvoltages (>1 min) percent of nominal
Undervoltages (>1 min) percent of nominal

Allowable transient voltage (0.5 to 800 ␮sec) percent of nominal

Utility Air (if Applicable; Para. 5.5)

Pressure MPa psi

Flow rate dm3/s scfm
Dew point °C °F

Particulate removal requirements:

Maximum particulate size ␮m ␮in. % removal

Other Services (if Applicable; Para. 5.6)

Foundation/installation specifications (must be included by Supplier)

Construction drawings: 3 Yes 3 No

Suppliers shall provide a technical description of the coolant system

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Coolant through spindle: 3 Yes 3 No

GENERAL NOTE: The parameters listed here are based on assumptions regarding normal air-conditioned rooms. Another
set, if provided as part of the machine specification and agreed on between Supplier and User, shall be acceptable for the
purposes of this Standard. In some cases, other fluids (rather than air) are used to provide thermal stability. In those
cases, separate guidelines should also be provided.

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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

Form 1.3 Chapter 6 Environmental Tests

Environmental Temperature Variation Error (Para. 6.2)

Date: Time: Operator:

Location for ETVE Test

(Machine Coordinates)
Axis mm or deg in. or deg

X
Y
Z

A
B
C

Range Drift
Reported Result mm or s in. or sec

ETVEX
ETVEY
ETVEZ
ETVEXX
ETVEYY

Relative Vibration Test (Para. 6.3)

If the nominal location for this test is different from that of environmental temperature variation test, the nominal location shall be
recorded on this sheet.

Date: Time: Operator:

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Relative Vibration
Direction mm in.

X
Y
Z

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Form 1.4 Chapter 7 Machine Performance

Machine Compliance and Hysteresis (Para. 7.2)

Date: Time: Operator:

Location for Tests (Machine Coordinates)

Location of Test (Machine Coordinates)

X Y Z
A, B, C,
Compliance mm in. mm in. mm in. deg deg deg

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
X
Y
Z
A
B
C

Machine Compliance and Hysteresis Measured Between Machine Spindle and Workpiece

Axis That Compliance Hysteresis

Direction of Distance Generates
Measured From Table, Clamped or the Force
Compliance Rotary Axis R Servo Held [Note (1)] mm/N in./lb mm in.

X N/A N/A
Y N/A N/A
Z N/A N/A

3 X or 3 Y A
3 X or 3 Z B
3 Y or 3 Z C

NOTE:
(1) Enter “N/A” if the force is applied using an external actuator such as a differential screw or hydraulic jack.

Positioning Accuracy and Repeatability (Para. 7.3): Linear Axes

Date: Time: Operator: Compensated: 3 Yes 3 No

Maximum Unidirectional Bidirectional Systematic Bidirectional Accuracy

Systematic Deviation of Positioning, Deviation of Positioning, of Positioning, Periodic Error,
E↑ or E↓ E A P
Axis mm in. mm in. mm in. mm in.

X
Y
Z

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Maximum Unidirectional
Repeatability, Bidirectional Repeatability, Reversal Deviation,
R↑ or R↓ R B
Axis mm in. mm in. mm in.

X
Y
Z

Min. ambient temperature °C °F Max. ambient temperature °C °F

Ambient air pressure mm Hg in. Hg Relative humidity %
Feed rate of testing mm/min in./min Machine temperature °C °F

Positioning Accuracy and Repeatability (Para. 7.3): Rotary Axes

Date: Time: Operator: Compensated: 3 Yes 3 No

Maximum Unidirectional Bidirectional Systematic Bidirectional

Systematic Deviation of Positioning, Deviation of Positioning, Accuracy of Positioning, Periodic Error,
E↑ or E↓, E, A, P,
Axis sec sec sec sec

A
B
C

Maximum Unidirectional Repeatability, Bidirectional Repeatability, Reversal Deviation,

R↑ or R↓, R, B,
Axis sec sec sec

A
B
C

Min. ambient temperature °C °F Max. ambient temperature °C °F

Rotary feed rate deg/min

Geometric Accuracy Tests (Para. 7.4)

Geometric Errors of Linear Axes (Para. 7.4.2)

Date: Time: Operator: Compensated: 3 Yes 3 No

X Straightness Y Straightness Z Straightness Roll, Pitch, Yaw,

E, E, E,
Axis mm in. mm in. mm in. sec sec sec
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

X N/A N/A
Y N/A N/A
Z N/A N/A

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Geometric Errors of Rotary Axes (Para. 7.4.3)

Date: Time: Operator: Compensated: 3 Yes 3 No

Error Motion Error Motion Error Motion

in X in Y in Z
Tilt Around X, Tilt Around Y, Tilt Around Z,
Axis mm in. mm in. mm in. sec sec sec

A N/A
B N/A
C N/A

Squareness Errors (Para. 7.4.4.1)

Date: Time: Operator: Compensated: 3 Yes 3 No

Squareness Error Error Magnitude, sec

XY squareness
XZ squareness
YZ squareness
AZ squareness

Parallelism (Para. 7.4.4.2)

Date: Time: Operator: Compensated: 3 Yes 3 No

Parallelism Error Error Magnitude, sec

ZW parallelism in XZ plane
ZW parallelism in YZ plane

Spindle Axis of Rotation (For Each Spindle; Para. 7.5)

Date: Time: Operator: Spindle: Compensated: 3 Yes 3 No

Structural Motion, Spindle OFF (Para. 7.5.2)

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Machine Drives OFF Machine Drives ON
Direction mm in. mm in.

Along X or Y direction
Along Z direction

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Spindle Tests, Rotating Sensitive Direction (Para. 7.5.3)
Date: Time: Operator: Spindle:

Asynchronous
Percentage of Spindle Average Radial Radial Total Axial Average Tilt Asynchronous
Error Motion Error Motion Error Motion
Maximum Speed, Error Motion, Tilt Error Motion,
Speed rpm mm in. mm in. mm in. sec sec

10%
50%
100%

Machine Thermal Tests (Para. 7.6)

Spindle Warm-Up and Transient Shut-Off Test (for Each Spindle; Para. 7.6.2)

Date: Time: Operator: Compensated: 3 Yes 3 No

Spindle: Duration of test: Spindle speed: Coolant: 3 On 3 Off

Displacement and Tilt of the Axis of Rotation

Drift During Warm-Up Drift During Transient Shut-Off

Error Motion mm or s in. or sec mm or s in. or sec

Displacement in X, DX
Displacement in Y, DY
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Displacement in Z, DZ
Tilt around X, DXY
Tilt around Y, DYZ

Thermal Distortion Caused by Moving Linear Axes (for Each Axis; Para. 7.6.3)

Date: Time: Operator: Duration of Test: Compensated: 3 Yes 3 No

Range of the Drift at Position 1 in Axis Direction Range of the Drift at Position 2 in Axis Direction
Forward Direction ↑ Reverse Direction ↓ Forward Direction ↑ Reverse Direction ↓
Axis mm in. mm in. mm in. mm in.

X
Y
Z

Composite Thermal Error (Para. 7.6.4)

Date: Time: Operator: Compensated: 3 Yes 3 No

Duration of test: Distance between indicator 1 and indicator 2: mm in.

Drift After 30 min Drift After min

Location mm in. mm in.

X Indicator 1
X Indicator 2
Y Indicator 1
Y Indicator 2
Z Indicator 1
Z Indicator 2

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Diagonal Displacement Test (Para. 7.7)

Date: Time: Operator: Compensated: 3 Yes 3 No

Body or Face Length of Diagonal Bidirectional Systematic Deviation, E Reversal Deviation, B

Diagonal mm in. mm in. mm in.

#1
#2
#3
#4

Subsystems Repeatability (Para. 7.8)

Tool Change Repeatability (Para. 7.8.2)

Date: Time: Operator:

Length from gage line for short tool: mm in. Length from gage line for long tool: mm in.

Tool Change Repeatability

Short Tool Long Tool
Error Direction mm in. mm in.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
X
Y
Z

Pallet Change Repeatability (Para. 7.8.3)

Date: Time: Operator:

X Position Y Position Z Position

A Angle, B Angle, C Angle,
mm in. mm in. mm in. sec sec sec

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Tool Setting Repeatability (Para. 7.8.4)

Date: Time: Operator:

Can measure tool diameter? 3 Yes 3 No
Measured while rotating spindle? 3 Yes 3 No
Tool setting repeatability length measurement: mm in.
Tool setting repeatability diameter measurement: mm in.

Machine Performance as a Measuring Tool (Para. 7.9)

Feature Location Repeatability

1D 2D 3D
Axis mm in. mm in. mm in.

X
Y
Z

2D feature measurement accuracy: mm in. 2D probe lobing range: mm in.

3D feature measurement accuracy: mm in. 3D probe lobing range: mm in.

Linear measurement accuracy in X: mm in. Y: mm in. Z: mm in.

Volumetric measuring performance: mm in.

Workpiece Location

Workpiece Location Working Tolerance

Axis mm in.

X
Y
Z

CNC Performance Tests (Para. 7.10)

Date: Time: Operator:

Minimum Block Execution Time (Para. 7.10.2)

Maximum steady feed rate (Vmax): mm/min in./min Minimum block execution time (MBET): sec

Varying Segment Feed Rate (Para. 7.10.3)

Varying segment feed rate (VSFR) mm/min in./min

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Least Increment Test (Para. 7.10.4)

Least Increment Step Reversal Error

Axis mm in. mm in.

X
Y
Z

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Linear and Rotary Axes Feed Rate and Acceleration Tests (Para. 7.10.5)

Mean Actual Time to

Nominal Feed Rate Feed Rate Reach Acceleration Deceleration
Range of 63.2% of
mm/min mm/min Variation, Nominal mm/s2 mm/s2
Direction, or or % Feed Rate, or or
Axis ↑ or ↓ % max. rpm in./min rpm in./min Nominal sec rev/s2 in./sec2 rev/s2 in./sec2

X ↑ 10
X ↓ 10
X ↑ 100
X ↓ 100
Y ↑ 10
Y ↓ 10
Y ↑ 100
Y ↓ 100
Z ↑ 10
Z ↓ 10
Z ↑ 100
Z ↓ 100

A ↑ 10
A ↓ 10
A ↑ 100
A ↓ 100
B ↑ 10
B ↓ 10
B ↑ 100
B ↓ 100
C ↑ 10
C ↓ 10
C ↑ 100
C ↓ 100

Average acceleration: mm/s2 in./sec2 rev/sec2

Average deceleration: mm/s2 in./sec2 rev/sec2 --```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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Form 1.4 Chapter 7 Machine Performance (Cont’d)

Contouring Performance Using Circular Test (Para. 7.11)

Date: Time: Operator: Compensated: 3 Yes 3 No

Circular Circular Radial Radial Radial Radial

Nominal Deviation, Deviation, Deviation, Deviation, Deviation, Deviation,
Radius Feed Rate G↑ (cw) G↓ (ccw) Fmin↑ (cw) Fmin↓ (ccw) Fmax↑ (cw) Fmax↓ (ccw)
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

% mm/ in./
Plane mm in. max. min min mm in. mm in. mm in. mm in. mm in. mm in.

XY 10
XY 80
YZ 10
YZ 80
XZ 10
XZ 80

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Form 1.5 Chapter 9 Cutting Performance Tests

Date: Time: Operator:

Spindle Idle Run Losses (Para. 9.4)

Maximum spindle speed: rpm

Percentage of Maximum Speed Lost Power, kW

20
40
60
80
100

Chatter Limits Test (Para. 9.5)

NOTE: A table of values is required for each cutting performance chatter test. A minimum of three tests are to be performed: a face milling
and an end milling test in 4340 steel (300–350 Brinell hardness number) and an end milling test in 7075-T6 aluminum. In one case,
where the Supplier gives limited information on the machine dynamics, each of these tests is to be conducted at two spindle speeds,
which yields six tests.

Date: Time: Operator:

Machine range (para. 9.3): Test material (para. 9.5.1): Cutting tool (para. 9.5.5):
Spindle speed (para. 9.5.4): rpm Feed rate (para. 9.5.6): mm/min

Radial Immersion, Limit Axial Depth of Cut, Limit Cross-Sectional Area of Cut,
Direction i, mm Milling Direction blim, mm a ⴛ blim, mm2

X 0.25 Up
X 0.50 Up
X 1.00 N/A
X 0.50 Down
X 0.25 Down
Y 0.25 Up
Y 0.50 Up
Y 1.00 N/A
Y 0.50 Down
Y 0.25 Down

Full Torque Test (Para. 9.5.8)

Date: Time: Operator:

Test material: 4340 steel (300–350 Brinell hardness number)

Machine range (para. 9.3): Cutting tool (para. 9.5.5):
Spindle speed (para. 9.5.4): rpm Feed rate (para. 9.5.8): mm/min

Direction: 3x 3y 3 Up 3 Down

Radial depth of cut a: mm Axial depth of cut b: mm Expected torque, Tev: N·mm
Measured power, Pmeas: W Measured torque, Tmeas: N·mm

15 --```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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Form 1.5 Chapter 9 Cutting Performance Tests (Cont’d)

End Milling Deflection Test (Para. 9.5.9)

Date: Time: Operator:

Test material: 7075-T6 aluminum

Machine range (para. 9.3): Cutting tool (para. 9.5.5):
Spindle speed (para. 9.5.9): rpm Feed rate (para. 9.5.9): mm/min

Radial Depth of Cut, a Maximum Error, Error Range,

emax, ⌬e,
Direction Milling Direction mm in. mm mm

X Up 0.05 0.002
X Up 0.50 0.020
X Up 1.50 0.060
X Down 0.05 0.002
X Down 0.50 0.020
X Down 1.50 0.060
Y Up 0.05 0.002
Y Up 0.50 0.020
Y Up 1.50 0.060
Y Down 0.05 0.002
Y Down 0.50 0.020
Y Down 1.50 0.060

Face Milling Deflection Test (Para. 9.5.10)

Date: Time: Operator:

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Test material: 4340 steel (300–350 Brinell hardness)
Machine range (para. 9.3): Cutting tool (para. 9.5.5):
Spindle speed (para. 9.5.9): rpm Feed rate (para. 9.5.9): mm/min

1 mm (0.04 in.) Axial Depth 2 mm (0.08 in.) Axial Depth

Maximum Error, Error Range, Maximum Error, Error Range,
emax, ⌬e, emax, ⌬e,
Direction Case mm mm mm mm

X Slot
1
X /2 up
1
X /2 down
Y Slot
1
Y /2 up
1
Y /2 down

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Form 1.6 Multifunction Cycle Test

Date: Time: Operator:

Duration of test: min Number of failures: Maximum time required for correction: min

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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ASME B5.54-2005

Chapter 2
References

The following is a list of publications referenced in IEST-RP-CC024.1, Measuring and Reporting Vibration
this Standard. in Microelectronics Facilities
Publisher: Institute of Environmental Sciences and Tech-
ASME B5.57-1998, Methods for Performance Evaluation nology (IEST), 5005 Newport Drive, Rolling Meadows,
of Computer Numerically Controlled Lathes and IL 60008
Turning Centers ISO Guide to the Expression of Uncertainty in Measure-
ASME B89.3.4M-1985 (R1992), Axes of Rotation ment, 1993
ASME B89.4.1-1997, Methods for Performance Evalua- ISO 1:2002, Standard Reference Temperature for Geo-
tion of Coordinate Measuring Machines metrical Product Specification and Verification
ASME B89.6.2-1973 (R1995), Temperature and Humidity ISO 230-2:1997, Test Code for Machine Tools — Part
Environment for Dimensional Measurement 2: Determination of Accuracy and Repeatability of
Positioning Numerically Controlled Axes
Publisher: The American Society of Mechanical Engi- ISO 230-3:2001, Test Code for Machine Tools — Part 3:
neers (ASME International), Three Park Avenue, New Determination of Thermal Effects
York, NY 10016; Order Department: 22 Law Drive, ISO 230-4:1996, Test Code for Machine Tools — Part 4:
Box 2300, Fairfield, NJ 07007 Circular Tests for Numerically Controlled Machine
Tools
EIA-267-C-1990, Axis and Motion Nomenclature for ISO 554:1976, Standard Atmospheres for Conditioning
Numerically Controlled Machines and/or Testing Specifications
Publisher: Electronic Industries Alliance (EIA), 2500 Wil- ISO 841:2001, Industrial Automation Systems and Inte-
son Boulevard, Arlington, VA 22201 gration — Numerical Control of Machines — Coordi-
nate System and Motion Nomenclature
IEC 60212:1971, Standard Conditions for Use Prior to ISO 3205:1976, Preferred Test Temperatures
and During the Testing of Solid Electrical Insulating ISO 10791-7:1998, Test Conditions for Machining Cen-
Materials ters — Part 7: Accuracy of a Finished Test Piece
ISO VIM 1993, International Vocabulary of Basic and
Publisher: International Electrotechnical Commission General Terms in Metrology
(IEC), 3 rue de Varembé, Case Postale 131, CH-1211, Publisher: International Organization for Standardiza-
Genève 20, Switzerland/Suisse tion (ISO), 1 rue de Varembé, Case Postale 56, CH-
1211, Genève 20, Switzerland/Suisse
IEEE 1159-1995, Recommended Practice on Monitoring
NAS 938, Machine Axis and Motion Nomenclature
Electrical Power Quality
NAS 979, Uniform Cutting Tests
Publisher: Institute of Electrical and Electronics Engi- Publisher: Aerospace Industries Association (AIA), 1000
neers (IEEE), 445 Hoes Lane, Piscataway, NJ 08854 Wilson Boulevard, Arlington, VA 22209

18
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--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`--- ASME B5.54-2005

Chapter 3
Nomenclature

A p bidirectional accuracy of positioning of DZ p spindle thermal drift, Z direction

an axis1 1D p one-dimensional
A↑ p unidirectional accuracy of positioning of 2D p two-dimensional
an axis, forward direction 3D p three-dimensional
A↓ p unidirectional accuracy of positioning of d p tool diameter
an axis, reverse direction E p bidirectional systematic deviation of
Aae p bidirectional total angular error position of an axis
Aae↑ p unidirectional total angular error, for- E↑ p unidirectional systematic deviation of
ward direction position of an axis, forward direction
Aae↓ p unidirectional total angular error, reverse E↓ p unidirectional systematic deviation of
direction position of an axis, reverse direction
a p radial depth of cut ETVE p environmental temperature variation
a+ p upper limit of a uniform distribution error
a− p lower limit of a uniform distribution ETVEA p thermal drift of tilt about a nominal axis
B p maximum of the absolute reversal values direction
at all target positions along an axis1 ETVEX p thermal drift in X direction
B p mean reversal value of an axis ETVEXX p thermal drift of tilt about the X direction
Bae p reversal deviation of angular error ETVEY p thermal drift in Y direction
Bi p reversal value at target position, i, along ETVEYY p thermal drift of tilt about the Y direction
or around an axis ETVEZ p thermal drift in Z direction
b p axial depth of cut E(X) p bidirectional systematic deviation of
bcr p estimated chatter limit depth of cut for positioning, X-axis
slot milling E(Z) p bidirectional systematic deviation of
blim p axial depth of cut for which chatter occurs positioning, Z-axis
C p a programmable spindle axis1 Eae p bidirectional systematic angular error
CD p corrected diameter Eae↑ p unidirectional systematic angular error,
CLR p corrected laser reading forward direction
CMR p corrected machine reading Eae↓ p unidirectional systematic angular error,
CPMA p circular profile measurement accuracy reverse direction
CXn p mean X circle center at position n p 1, 2, e(xn↑) p range of thermal drift, target position n, X
two-sphere axis alignment direction, forward, thermal distortion test
CYn p mean Y circle center at position n p 1, 2, e(xn↓) p range of thermal drift, target position n, X
two-sphere axis alignment direction, reverse, thermal distortion test
c p chip load e(zn↑) p range of thermal drift, target position n, Z
DIA p diameter of a circle or part direction, forward, thermal distortion test
Dc p diameter of a test cylinder e(zn↓) p range of thermal drift, target position n, Z
Dg p distance between two gages direction, reverse, thermal distortion test
Di p gage reading during spindle warm-up F p linear axis feed rate
test (i p 1 to 5) F p out-of-squareness angle between a
DX p spindle thermal drift, X direction straightedge and a spindle axis
DXZ p spindle angular thermal drift of axis aver- FLRX p feature location repeatability
age line, XZ plane FMAX p feature measurement accuracy
DY p spindle thermal drift, Y direction FM(X) p feature measurement accuracy, X
DYZ p spindle angular thermal drift of axis aver- direction
age line, YZ plane FM(Z) p feature measurement accuracy, Z
1 direction
Capital letters such as A, B, C, X, Y, Z, and W are also used to
designate linear and rotary machine tool axes. (See ISO 841:2001 Fmax↑ p radial deviation, maximum, clockwise
for axis nomenclature.) direction, circular test

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NUMERICALLY CONTROLLED MACHINING CENTERS

Fmax↓ p radial deviation, maximum, counter- m p number of target points on an axis

clockwise direction, circular test N p newton, unit of force
Fmin↑ p radial deviation, minimum, clockwise NDE p nominal differential expansion
direction, circular test NE p nominal thermal expansion of the object
Fmin↓ p radial deviation, minimum, counter- to be measured or calibrated
clockwise direction, circular test NEs p nominal thermal expansion of the
fn p natural frequency of the dominant mode standard
G↑ p circular deviation, clockwise, circular test n p number of measurements of the same
G↓ p circular deviation, counterclockwise, cir- quantity
cular test nmax p maximum spindle speed for chatter limits
H p circular hysteresis, circular test and spindle torque test
Hc p dynamic compliance at the natural fre- nmin p minimum spindle speed for chatter test
quency of the dominant mode nrpm p spindle speed
INCR p segment length used to test block execu- ns p stable spindle speed for chatter test
tion time nT p maximum spindle speed for acceptable
Im(G) p imaginary part of the transfer function G tool life
i p index of target position P p periodic error of a linear or rotary axis
j p index for number of measurements Pi p target position in the positioning tests, ith
k p coverage factor position
L p dimension of the workpiece at 20°C Pidle p electrical power consumed by a rotating
LDR p laser display reading spindle cutting air
LMA(X) p linear measurement accuracy, X direction Pij p measured position at the jth approach to
LMA(Z) p linear measurement accuracy, Z direction the target position, Pi
LSC p least-squares circle center of a polar Pmeas p electrical power consumed by a rotating
profile spindle cutting metal
LUTM p length uncertainty due to temperature Ps p air pressure
measurement Pw p electrical power
Lc p length of a test cylinder q p a quantity to be measured (i.e., a meas-
Lcte p distance between the displacement indi- urand)
cators in the composite thermal error test q p mean of a set of measurements of a quan-
Ld p distance between two measurement tity, q
points used to calculate angle qj p the jth measurement of a quantity, q
Ls p dimension of the reference and/or work- R p bidirectional repeatability of a measure-
ing standard at 20°C ment or axis
LT p dimension of an object at temperature T R↑ p unidirectional repeatability for an axis,
≠ 20°C forward direction (maximum value)
LX p traverse length of the X-axis R↓ p unidirectional repeatability for an axis,
LZ p traverse length of the Z-axis reverse direction (maximum value)
L1,2 p distance between indicator 1 or 2 and the RH p relative humidity
spindle face, spindle thermal stability test RA p radius of an artifact
M p range of the mean bidirectional positional Rae p bidirectional repeatability of angular
deviations of an axis error
MBET p minimum block execution time Rae↑ p unidirectional repeatability of angular
MCC p minimum circumscribed circle center of error, forward direction
a polar profile Rae↓ p unidirectional repeatability of angular
MD p measured diameter error, reverse direction
MDR p machine display reading Ri p bidirectional repeatability of positioning
MIC p minimum inscribed circle center of a at position i
polar profile R i↑ p unidirectional repeatability of position-
MR(R) p measurement repeatability of a radius ing in the forward direction at position i
MRS p minimum radial separation center of a R i↓ p unidirectional repeatability of position-
polar profile ing in the reverse direction at position i
MR(X) p measurement repeatability, X direction Rpcx p pallet change repeatability along the
MR(Z) p measurement repeatability, Z direction X-axis
Max[q] p maximum value of a quantity, q Rpcxy p pallet surface tilt motion repeatability in
Min[q] p minimum value of a quantity, q the XY plane

20
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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NUMERICALLY CONTROLLED MACHINING CENTERS

Rsphere p radius of a sphere linear axis repeatability, probe system

Rxts p the tool-change repeatability for the short repeatability, and the pallet change
tool length in the X direction repeatability
rpm p revolutions per minute upc␤xy p standard uncertainty for the pallet tilt
r(␪) p radial error motion of a spindle motion error in the XY plane that includes
SMTC p significant mean temperature change the combined effect of machine’s linear
SOTR p safe operating temperature range axis repeatability, probe system repeat-
SZ p specification zone for a quantity specified ability, and the pallet change repeatability
in this Standard upx2 p standard uncertainty for the pallet linear
si p estimator of the standard uncertainty of positioning error along the X-axis that
a quantity measured at the ith position includes the combined effect of machine’s
si↑ p estimator of the standard uncertainty in linear axis repeatability and probe system
the forward direction at position i repeatability
si↓ p estimator of the standard uncertainty in up␤xy p standard uncertainty for the pallet tilt
the reverse direction at position i motion error in the XY plane that includes
T p temperature of workpiece the combined effect of machine’s linear
TEI p thermal error index axis repeatability and probe system
Ta p mean air temperature repeatability
Tex p expected spindle torque calculated based uq p standard uncertainty of a quantity, q
on part material properties, cutting con- usub p standard uncertainty of a measurement,
ditions, and the number of teeth on the denoted by the subscript “sub”
cutter utcx p standard uncertainty for combined effect
Tmeas p spindle torque calculated from measured of machine linear axis repeatability, test
spindle power instrument repeatability, and tool change
Tq p torque repeatability
TR p rated spindle torque utx p standard uncertainty for combined effect
Ts p temperature of reference and/or working of machine linear axis repeatability and
standard test instrument repeatability
t p time VMA p volumetric measurement accuracy
UNDE p uncertainty of nominal differential VSFR p varying segment feed rate
expansion Vmax p maximum steady feed rate observed,
UNE p uncertainty of nominal thermal minimum block execution time test
expansion W p out-of-squareness angle1
UNEs p uncertainty of nominal thermal expan- xi p mean bidirectional deviation of axis posi-
sion of a standard tioning at position i
UT(A) p angular expanded thermal uncertainty xi↑ p mean deviation of axis positioning in the
UT(L) p expanded thermal uncertainty
forward direction at the ith position
upr p undulations per revolution
xi↓ p mean deviation of axis positioning in the
u(T) p uncertainty of temperature of the object
reverse direction at the ith position
being measured or calibrated
xij p positional deviation for the jth measure-
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

u(Ts) p uncertainty of temperature of the refer-

ment at the ith position
ence and/or working standard
xij↑ p jth positional deviation at the ith position
u(␣) p uncertainty of the coefficient of thermal
along an axis, forward direction
expansion of the object being measured
xij↓ p jth positional deviation at the ith position
or calibrated
u(␣s) p uncertainty of the coefficient of thermal along an axis, reverse direction
expansion of reference standard and/or xp2 p average of the ten readings for measure-
working standard ment point 2 in the X direction
ucT(A) p combined angular standard thermal xp2j p jth reading in the X direction for measure-
uncertainty ment point 2
ucT(L) p combined standard thermal uncertainty xtcx p average of the ten readings in the X
uETVE p standard uncertainty due to the environ- direction
mental temperature variation xtcxj p jth reading in the X direction
upcx2 p standard uncertainty for the pallet linear xtx p average of the ten readings in the X
positioning error along the X-axis that direction
includes the combined effect of machine’s xtxj p jth reading in the X direction

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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

␣ p coefficient of thermal expansion of the ⌬X(␪) p output of the X-axis gage in spindle
object being measured or calibrated testing
␣s p coefficient of thermal expansion of the ref- ⌬Y(␪) p output of the Y-axis gage in spindle
testing
erence and/or working standard
␪ p angular position of a rotary axis (spindle
␤(␪) p tilt degree of freedom for a rotary axis in
axes included) or the angle between
the sensitive direction
two lines
␤pxy p average tilt motion of the pallet in the ␬ p thermal conductivity of a material
XY plane ␮m p micrometer (one millionth of a meter),
␤pxyj p jth reading of the tilt motion of the pallet unit of length
in the XY plane ␮rad p microradian (one millionth of a radian),
␥(␪) p tilt degree of freedom for a rotary axis in unit of angle
the nonsensitive direction ␶ p time constant of a physical quantity

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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ASME B5.54-2005

Chapter 4
Definitions

4.1 GLOSSARY artifact: generic term used to describe a stable, physical

object used as a master in machine testing. Particularly
Abbe error: measurement error resulting from angular
used to describe a ball, a set of balls, or a mandrel, in
motion of a movable component and an Abbe offset.
many tests in this Standard.
Abbe offset: instantaneous value of the perpendicular dis-
aspect ratio: ratio of the travel of the longest linear axis
tance between the line where the displacement is mea-
to the shortest linear axis. A large aspect ratio machine
sured and the line where the displacement is to be
is defined as having an aspect ratio greater than 3.
determined.
autocollimator: optical instrument that allows measure-
Abbe principle: displacement-measuring system should
ment of the angle between its optical axis and a mirror
be in line with the functional point whose displacement
whose calibration is independent of the distance
is to be measured. If this is not possible, either the
between the instrument and the mirror.
slideways that transfer the displacement must be free
of angular motion or angular-motion data must be used auxiliary spindle: see accessory spindle.
to calculate the consequences of the offset. average: average value of a series of measurements. Used
accessory spindle: a spindle supplied with a machine, not synonymously with mean.
the main spindle, which was not manufactured by the axial depth of cut: depth of cut in the spindle axis direction
Supplier of the base machine and is, by the machine when milling.
Supplier, considered an “add-on.”
axial error motion: error motion collinear with the Z refer-
accuracy: quantitative measure of the degree of confor- ence axis of an axis of rotation. See Fig. 4.1, illustra-
mance to recognized national or international physical tion (d).
standards and methods of measurement.1
axis acceleration/deceleration: rate at which the machine
accuracy (of measurement): closeness of the agreement drive systems control the transition between different
between the result of a measurement and a true value programmed axis feed rates.
of the measurand.
axis average line: average axis of rotation of a rotating
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

NOTES: spindle. The axis average line is obtained by least-

(1) The term accuracy is a qualitative concept.1 squares fitting a line through the centers of several aver-
(2) The term precision should not be used for accuracy. age error motion polar plots at different distances from
actual path: path produced by the machine tool when the spindle face.
programmed to move along a nominal path. axis direction, linear axes: direction of any line parallel to
actual position, Pij (i p 1 to m; j p 1 to n): measured the motion direction of a linearly moving component.
position reached by the moving component on the jth Due to straightness errors, squareness, parallelism, and
approach to the ith target position. angular errors, the direction of a linear axis can best be
defined by a least-squares fit of a straight line to the
ambient temperature: temperature of the ambient air (or appropriate straightness data.
other working fluid, such as oil on an oil-showered
machine) surrounding a machine. See also mean ambient axis direction, rotary axes: direction of rotation of a rotary
temperature. axis. Such rotation shall be either clockwise or counter-
clockwise around a positive axis of rotation. For exam-
angular drift of axis average line: change in angle of a ple, the direction of axis rotation shown in Fig. 4.1,
spindle’s axis average line caused by thermal effects due illustration (g) is counterclockwise.
to spindle rotation.
axis of rotation: line about which rotation occurs.
1 axis travel: maximum travel, linear or rotary, over which
ISO defines accuracy (of measurement) as the “closeness of the
agreement between the result of a measurement and the true value the movable component of a machine can move under
of the measurand,” with the conditions that “accuracy is a qualita- numerical control.
tive concept” and “the term precision should not be used for accu-
racy.” This ASME Committee does not concur that “accuracy is a backlash: a relative movement between interacting
qualitative concept.” mechanical parts, resulting from looseness.

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NUMERICALLY CONTROLLED MACHINING CENTERS

Y (θ )
C
A A
C Z (θ )
C A D

Y B B
B D
X(θ ) D
X (b) (c) (d)

(a) C θ C C
D
A γ (θ ) A A θ
B D
B B
β (θ )
D
(e) (f) (g)

Fig. 4.1 Schematic Diagrams of the Six Basic Degrees of Freedom of an Axis of Rotation

ball bar (magnetic, telescoping): a gage with two high- where

precision ball and magnetic socket pairs held at the Bi p reversal deviation at position i
end of a telescoping rod, with an integral displacement Ri↑ p 4si↑
sensor to measure the change of distance between the Ri↓ p 4si↓
balls/sockets. si↑, si↓ p estimators of the standard uncertainty at
bearing error motion: error motion of a rotary axis due to that position
imperfect bearings.
bidirectional systematic angular error, E ae : difference
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

bidirectional: refers to a parameter derived from a series

between the maximum and minimum of the mean unidi-
of measurements in which the approach to a target posi-
rectional angular motions for both directions of
tion is made in either direction along or around an axis.
approach at any position along the linear axis being
bidirectional accuracy of positioning of an axis, A: range measured. Computed the same as bidirectional system-
derived from the combination of the bidirectional sys- atic deviation of positioning of an axis, E.
tematic deviations and the estimator of the standard
bidirectional systematic deviation of positioning of an axis,
uncertainty of bidirectional positioning, obtained using
E: difference between the maximum and minimum of
a coverage factor of 2.
the mean unidirectional positional deviations for both
A p max. [xi↑ + 2si↑; xi↓ + 2si↓] approach directions (i.e., E↑ and E↓ at any position along
− min. [xi↑ − 2si↑; xi↓ − 2si↓] (4-1) or around the axis).

bidirectional repeatability for an axis, R: maximum value E p max. [xi↑; xi↓] − min. [xi↑; xi↓] (4-3)
of the bidirectional repeatability of positioning at any
position for an axis; that is, R p max. [Ri]. bidirectional total angular error, Aae: range derived from
the combination of the bidirectional systematic angular
bidirectional repeatability of angular error, Rae: maximum error and the estimator of the standard uncertainty of
value of the bidirectional repeatability of angular error bidirectional angular error, obtained using a coverage
at any position for an axis. factor of 2. Computed the same as the bidirectional accu-
bidirectional repeatability of positioning at a position, Ri: racy of an axis, A.
maximum range representing the expanded uncertainty
block look-ahead limit: maximum number of part program
of bidirectional positional deviations, including the
blocks ahead of the block being executed that a CNC
reversal deviation, obtained using a coverage factor of
controller uses to plan motion.
two or four times the standard uncertainty in either
direction at the position, whichever is larger; that is, body diagonal: space diagonal of a rectangular prism
within the working volume of the machine tool as shown
Ri p max. [2si↑ + 2si↓ + 冨Bi冨; Ri↑; Ri↓] (4-2) in Fig. 4.2.

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NUMERICALLY CONTROLLED MACHINING CENTERS

circular deviation: minimum radial separation of two con-

centric circles enveloping the actual path (minimum
zone circles) in the circular test and that may be evalu-
ated as maximum radial range around the least-squares
circle. It is equivalent to the total error motion value
(see also error motion value). Values are denoted G↑ for
clockwise rotations and G↓ for counterclockwise rota-
tions.
coefficient of thermal expansion: the true coefficient of
expansion, ␣, at a temperature, T, of a body is the rate
of change of length of the body, L, with respect to temper-
Fig. 4.2 Four Body Diagonals of a Rectangular ature at the given temperature divided by the measured
Prism length at the given temperature, LT.

冢 冣
1 dL
␣p (4-4)
LT dT
broadband vibration amplitude: the amplitude of vibration T

allowed over a specified frequency band, usually speci-

cold machine: a machine at a stable operating temperature
fied as the maximum vibration from a low frequency
where during the last 2-hr period, (1) the hydraulic sys-
(e.g., 1 Hz) to an upper frequency of several thousand
tems and servos have been on, (2) the spindle has not
hertz.
been rotated above 10% of the maximum rotations per
Bryan principle: the straightness-measuring system minute, and (3) the axes’ motions have been restricted
should be in line with the functional point whose to only those necessary to set up measurement equip-
straightness is to be measured. If this is not possible, ment. A secondary definition is that the machine has
either the slideways that transfer the straightness must been allowed to stabilize thermally for a Supplier-speci-
be free of angular motion or angular-motion data must fied or User-specified soak-out time.
be used to calculate the consequences of the offset.
combined angular standard thermal uncertainty: for the pur-
canned cycle: see fixed cycle. poses of this Standard, the combined angular standard
cap test: a check for electrical noise and drift of a trans- thermal uncertainty for angle measurement is given by
ducer, most commonly applied to displacement trans-
冪ETVE
2
A
ducers, sensors, or indicators (see Appendix I). In this ucT(A) p (4-5)
Standard the check is normally performed by placing a 12
stable “cap” on a displacement indicator and monitoring combined standard thermal uncertainty: for the purposes
its output over time. See also transducer drift check. of this Standard, the combined standard thermal uncer-
capacitance (“cap”) gage: a displacement measuring tainty for a length measurement made at a temperature
device of relatively short range and high resolution that other than 20°C in a changing environment is given by
functions by measuring the electrical capacitance

冪
between the probe tip and the surface being displaced. ucT(L) p u2ETVE + L2s (Ts − 20)2u2(␣s) (4-6)

catenary: curve formed by a flexible string, wire, band, + L (T − 20) u (␣) +

2 2 2
L2s ␣2s u2(Ts) + L ␣ u (T)
2 2 2

or cable suspended between two spatially separated

points of equal height in a gravitational field. The form command: operative order to initiate a movement or a
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

of the curve is determined primarily by the tension in function.

the suspended element and its mass per unit length. In command mode: mode of operation of the command or
the context of this Standard, a catenary correction refers data entry device and display device in which entries
to the difference between this curve and a straight line are interpreted as functions to be executed.
between the two suspension points, measured in a verti-
comparator: any device used to perform the comparison
cal direction.
of the part and the master is called a comparator. For
chatter: self-excited relative vibrations between the tool the purposes of this Standard, the comparator can be a
and the workpiece during the cutting process that may simple short-range indicating device, such as a gage
damage the cutting tool, the machine, or the part in block comparator, or a complex comparator, such as a
roughing cuts and degrade the surface finish in finish- coordinate measuring machine.
ing cuts. compensation: the practice of using prerecorded error
chip load: relative motion of the feed axis of the tool tables and in-process sensing of variables such as tem-
with respect to the workpiece, per tooth pass, usually perature for correcting the position of a CNC machine
measured in millimeters per tooth. using the CNC controller.

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NUMERICALLY CONTROLLED MACHINING CENTERS

compliance: displacement per unit static force between difference between the actual and programmed cutter
two objects, specified with respect to the structural loop, radius or diameter.
the location and direction of the applied forces, and the cutter diameter (radius) offset: a displacement normal to
location and direction of the displacement of interest. the cutter path to adjust for the difference between the
The following terms can be applied when the structural actual and programmed cutter radius or diameter.
loop contains an axis of rotation or a linear axis:
(a) radial compliance: applicable when the force and cycle time: period of time from starting one set of machine
displacement directions are at 90 deg to the reference operations to starting another (in a pattern of continuous
axis. repetition).
(b) axial compliance: applicable when the force and the deviation: in general, the difference between an actual
displacement are collinear with the reference axis. value and the desired value, or commanded value, of a
(c) tilt compliance: applicable for a pure moment and a quantity. In this Standard, this word will be used synon-
tilt displacement in a plane containing the reference axis. ymously with error and will refer to the difference
(d) face compliance: applicable when the force and dis- between an actual value and the desired value, unless
placement are parallel to the reference axis and at a otherwise specified. See also error.
specified radial location. deviation of position; positional deviation, xij: actual position
(e) linear compliance: applicable when the force and reached by the moving component minus the target
displacement are applied to a machine axis designed for position,
linear motion. Linear compliance can be in the direction
of the slide axis or perpendicular to that direction. xij p Pij − Pi (4-7)
(f ) angular compliance: applicable when a pure
diagonal displacement: displacement of the “tool” of a
moment is applied to a rotary axis in the direction of
machine tool along a diagonal in its work zone. The
the designed angular displacement.
diagonal may be either a face diagonal; that is, in a plane
computer numerical control (CNC): numerical control sys-
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

defined by two machine axes, or, in the general case,

tem in which the data handling sequence, control func- along a body diagonal defined by the displacement of
tions, and response to data input are determined three machine axes.
primarily by a control program executed by a computer.
differential expansion: difference between the expansion
contouring control system: system of control in which two of the part and the expansion of the master from 20°C
or more machine axes move in a coordinated fashion so to their time-mean temperatures at the time of the mea-
that the desired angular path or contour is generated. surement.
contouring mode: mode of operation of a CNC system displacement indicator: any one of a family of devices that
that operates in one of the defined modes of interpola- measures displacement between a datum and a moving
tion (e.g., linear, circular, parabolic). element. Such instruments could be, for example, capaci-
control program: ordered set of instructions in a computer tance gages, linear variable differential transformers
language and a format that provide a computer-based (LVDTs), dial gages, laser interferometers, or eddy cur-
control system with the capability of properly executing rent probes.
system functions and commands of the machine drift test: experiment conducted to determine the actual
program. drift inherent in a system under normal operating condi-
cosine error: measurement error in the motion direction tions. The test usually consists of simultaneous
caused by angular misalignment between a linear dis- recordings of drift and environmental temperatures. The
placement measuring system and the displacement recommended procedure for the conduct of a drift test is
being measured. given in para. 6.2 for the measurement of environmental
temperature variation error (ETVE).
coverage factor: numerical factor used as a multiplier of
the standard uncertainty to obtain an expanded uncer- drifts of axis average line: positional drifts of a spindle’s
tainty, normally denoted k. axis average line caused by spindle thermal effects. For
the purposes of this Standard, these drifts are defined as
critical depth of cut: axial depth of cut in milling where close to the chuck, part-holding device, or tool-holding
chatter will begin to occur if the spindle speed is such device as is practical (see para. 7.6.2).
that a minimum in the lobing diagram is encountered.
environmental temperature variation error, ETVE: an esti-
critical speed: a spindle speed which is such that at that mate of the maximum possible position uncertainty
speed and tool combination a minimum in the lobing induced solely by deviation of the environment from
diagram would be encountered. average conditions. For the purposes of this Standard,
cutter diameter (radius) compensation: a displacement com- it is assumed that the errors due to temperature variation
pensation normal to the cutter path to adjust for the are uniformly distributed with a total range equal to the

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measured ETVE. Since the ETVE is a total range, it must

be converted to a standard uncertainty as is discussed
in para. 6.2.3.3.1.
error: difference between the actual response of a
machine to a command issued according to the accepted
protocol of that machine’s operation and the response
to that command anticipated by that protocol. See also
deviation.
error motion: change in position relative to the reference
coordinate axes of the surface of a perfect tool or work-
piece with its centerline coincident with the axis of rota-
Fig. 4.3 Face Diagonals of a Rectangular Prism
tion. Error motions are specified as to location and
direction as shown in Fig. 4.1, illustration (a), and do
not include motions due to thermal drift. uncertainty of the positional deviations obtained by a
error motion measurements: a measurement record of error series of n unidirectional approaches at a position Pi,
motion that should include all pertinent information n

冪
1
regarding the machine, instrumentation, and test condi- si↑ p
n−1 兺 (xij↑ − xi↑)2
jp1
(4-8)
tions.
n

冪
error motion polar plot: polar plot of error motion made 1
in synchronization with the rotation of the spindle. The
si↓ p
n−1 兺 (xij↓ − xi↓)2
jp1
(4-9)
following terms apply to the error motion polar plot
and its components: expanded thermal uncertainty: in the case where the effec-
(a) total error motion polar plot: the complete error tive number of degrees of freedom for each of the uncer-
motion polar plot as recorded. tainties in the combined standard thermal uncertainties
(b) average error motion polar plot: the mean contour of (see para. 4.1) is known, the expanded uncertainty
the total error motion polar plot averaged over a number should be computed following the example given in the
of revolutions that can be divided into: ISO Guide, para. H.1.6 (ISO, 1993). In the absence of
such information, it is the recommendation of this Stan-
(1) fundamental error motion polar plot: the best-fit
dard that a coverage factor of k p 2 be used to yield an
reference circle fitted to the average error motion
expanded uncertainty of length measurement at approx-
polar plot.
imately the 95% confidence level, due to temperature,
(2) residual error motion polar plot: deviation of the
UT(L), given by:
average error motion polar plot from the fundamental
error motion polar plot. ±UT(L) p ±kucT(L) p ±2ucT(L) (4-10)
(c) asynchronous error motion polar plot: deviation of
the total error motion polar plot from the average error expanded uncertainty: quantity defining an interval about
motion polar plot. the result of a measurement that may be expected to
(d) inner error motion polar plot: contour of the inner encompass a large fraction of the distribution of values.
boundary of the total error motion polar plot. face diagonal: diagonal in a plane of a rectangular prism
(e) outer error motion polar plot: contour of the outer within the working volume of the machine tool as shown
boundary of the total error motion polar plot. in Fig. 4.3.
error motion value: a magnitude assessment of error face error motion: error motion parallel to the Z reference
motion. axis at a specified radial location.
(a) asynchronous error motion value: maximum scaled
feed function: command defining a feed rate.
width of the error motion polar plot, measured along a
radial line through the polar chart center. feed hold: action of the controller to temporarily suspend
(b) average error motion: average (mean) error motion all axis motion and machine program execution, in
in the spindle performance test. At least 20 revolutions response to some condition or command that is not part
are required by this Standard. of the machine program.
(c) average error motion value: scaled difference in radii feed rate: rate of motion of the feed axis of the tool relative
of two concentric circles from a least-squares motion to the workpiece, measured in millimeters per minute
center just sufficient to contain the average error motion (mm/min) or millimeters per revolution (mm/rev).
polar plot. fixed cycle: a preset series of operations that directs the
estimator of the unidirectional standard uncertainty of posi- machine axis movement and/or causes spindle opera-
tioning at a position, si↑ or si↓: estimator of the standard tion to perform a complex function (e.g., boring, drilling,

27
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tapping, probing, facing, and a combination thereof). NOTE: This is typically used for start-up.

fixed zero: a reference position of the origin of the coordi- initialization: sequence of operations establishing the
nate system not readily movable. starting point of a machine.
NOTE: This is typically a characteristic of a machine having abso- intermittent duty: with respect to motors, a measure of
lute feedback elements. the time that the motor is operated as a fraction of 100%
floating zero: a characteristic of a numerical control sys- operation, continuous duty.
tem permitting the zero point on an axis to be established laser interferometer: fringe-counting interferometer for
readily at any point; the control retains no information displacement measurement that uses a laser as a light
on the location of any previously established zeroes. source.
functional point: point on the machine tool where a cut- laser scales: machine scales that are based on laser inter-
ting tool would contact a part for the purposes of mate- ferometric principles.
rial removal.
lathe: any one of a class of machine tools where the part
fundamental error motion: in spindle testing, a sinusoidal
to be machined is rotated in a spindle to provide the
error motion that is at the spindle rotation frequency.
surface speed necessary for material cutting.
gage: a mechanical artifact, often of high precision, used
length uncertainty due to temperature measurement: the use
either for checking a part or for checking the accuracy
of this Standard requires that the measured length of a
of a machine, or a measuring device with a proportional
body be corrected to 20°C. This requires a measurement
range and some form of displacement indicator. When
of the temperature of the body and an estimate of its
referring to a measuring device, the term gage is synony-
thermal expansion coefficient. The uncertainty that the
mous with a displacement indicator or sensor, as used in
temperature measurement induces in the calculated
this Standard.
length is called the length uncertainty due to tempera-
grid encoder: a type of two-axis positioning readout sen- ture measurement (LUTM). In the case where there is a
sor which, through the use of a two-dimensional grid mechanical part and a mechanical master, it is given by
or grating and an electronic read head, allows the posi-
tion of the read head with respect to the grid to be LUTM p冪␣2L2u(T)2 + ␣2s L2s u(Ts)2 (4-11)
accurately measured in two dimensions.
high-speed spindle: for the purposes of this Standard, a where u(T) and u(Ts) are the standard uncertainties in
high-speed spindle is any spindle that can operate at temperature measurement of the part and the standard.
continuous duty at over 10,000 rpm. In the case where the standard is a laser interferometer,
hysteresis: a component of bidirectional repeatability ␣s should be taken as 0.93 x 10−6/°C.
caused by mechanisms such as drive train clearance, level: the condition of perpendicularity between a surface
guideway clearance, mechanical deformations, friction, and the local gravitational field vector, or an instrument
and loose joints. For the purposes of this Standard, two used to measure such perpendicularity.
types of hysteresis are defined:
load cell: transducer that is used to measure force. Nor-
(a) setup hysteresis: hysteresis of the various elements
mally a load cell has the capability to convert a force
in a test setup, normally due to loose mechanical connec-
into a proportional electrical signal.
tions.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
(b) machine hysteresis: hysteresis of the machine struc- lobing diagram (or stability lobing diagram): diagram that
ture when subjected to specific loads. relates the effects of spindle speed and axial depth of
cut on stability in machining. These diagrams are con-
identification of axes: the identity of an axis moved to
structed from computations for all the values of radial
produce an actual path during machine testing.
immersion, workpiece material, tool/tool holder combi-
incremental dimension: dimension expressed with respect nations, and structural modes of interest.
to the preceding point in a sequence of points.
LVDT (linear variable differential transformer): electromag-
incremental feed: manual or automatic input of a preset netic device used for displacement measurement. Nor-
motion command for a machine axis. mally an LVDT has the capability to convert a
indicator: device used to measure displacements between displacement into a proportional electrical signal.
a surface and a reference point. For the purposes of this machine coordinate system: coordinate system that corres-
Standard, an indicator could be a dial gage, an LVDT, ponds to the axes of the machine on which a part is to
or a capacitance gage. The term displacement transducer be manufactured. The coordinate system usually
will be considered synonymous with the term indicator. includes one or more linear axes designated X, Y, or Z
initial position: a fixed point along an axis referenced (see EIA 267). (The machine may also include rotary
with respect to a machine datum. axes usually designated A, B, and C.)

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METHODS FOR PERFORMANCE EVALUATION OF COMPUTER ASME B5.54-2005
NUMERICALLY CONTROLLED MACHINING CENTERS

machine datum: built-in zero position of the machine ele- mean gage temperature: mean temperature of a gage used
ments used to establish the origin of the machine coordi- for machine testing as computed from at least two read-
nate system. ings taken on the gage during the interval required for
a test.
machine home: condition in a machine coordinate system
where all machine elements are at home position (i.e., mean reversal value of an axis, B: arithmetic mean of the
at the machine datum). reversal values, Bi, at m target positions along or around
the axis,
machine program: an ordered set of instructions in auto-
m
matic control language and format sufficiently complete 1
m i兺
Bp Bi (4-13)
to affect the direct operation of an automatic control p1
system.
mean scale temperature: mean temperature of a machine
machine tool duty rating (MTDR): power level that a scale as computed from at least two temperature read-
machine tool’s spindle motor can operate above its con- ings taken on that scale during the interval spanning
tinuous power rating for a short period of time (intermit- the time required for a test.
tent duty). This rating is supplied by the machine tool mean temperature: average temperature computed from a
Supplier. stated number of temperature measurements at equally
machine zero: origin of the coordinates in the machine spaced time intervals at a specified location.
system. mean unidirectional positional deviation at a position, xi↑ or
xi↓: arithmetic mean of the positional deviations
machining center: computer numerically controlled
obtained by a series of n unidirectional approaches to
machine tool with at least one main spindle equipped
a position Pi,
for holding rotating tools. The purpose of this spindle(s)
shall be to generate sufficient surface speed between 1
n

n j兺
tool and part to allow effective material removal by xi↑ p xij ↑ (4-14)
p1
cutting. Such a machine shall also have automatic tool-
changing capabilities and be capable of automatically and
performing multiple operations, including milling, drill-
n
1
n j兺
ing, tapping, and boring. xi↓ p xij ↓ (4-15)
p1
master: standard against which the desired dimension
of the part is compared. The standard may be in the measurement line: line in the work zone of a machine
form of the wavelength of light, length of a gage block, along which measurements are taken.
line standard, lead screw, etc. measurement point: point in the work zone of a machine
maximum steady feed rate, Vmax: maximum steady feed at which measurements are taken.
rate measured (less than 5% fluctuation) for a given measurement travel: part of the axis travel that is used
part program segment length during the minimum block for data capture. It is selected so that the first and last
execution time test. target positions may be approached bidirectionally (see
para. 7.3.1).
mean: the mean (arithmetic average) of a physical quan-
tity in this Standard is defined as the average value of minimum block execution time, MBET: minimum time
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

that quantity and denoted with a bar over the symbol. required by a CNC controller to execute one program
Both terms, average and mean, are used in this Standard block.
synonymously. movable component: major structural component that is
movable relative to the machine base during mea-
mean ambient temperature: mean temperature of the ambi-
surement.
ent environment surrounding a machine as computed
from at least two readings taken at the center of the nominal coefficient of thermal expansion: estimate of the
machine’s work zone during the interval required for coefficient of thermal expansion of a body. For the pur-
the test. poses of this Standard and in reference to the nominal
coefficient of expansion of machine scales, it shall mean
mean bidirectional positional deviation at a position, xi: arith- the effective coefficient of the scale and its mounting to
metic mean of the mean unidirectional positional devia- the machine as measured in line with the scale for typical
tions xi↑ and xi↓, obtained from the two directions of machines of the given design. Since the true coefficient
approach at a position Pi, for a given machine is not known, an uncertainty must
be applied when making nominal differential expansion
xi ↑ + x i ↓ corrections (see para. 6.2.3.3.2). Following ISO practice,
xi p (4-12)
2 this Standard does not differentiate between the

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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

expected value of a quantity and its actual value. There- for which a dimension is to be determined. This object
fore, the nominal coefficient of expansion in this Stan- is called the part or workpiece.
dard will be denoted ␣. part programming, computer-aided: preparation of a part
nominal differential expansion (NDE)2: difference between program to obtain a machine program using a computer
the nominal expansion of the object to be calibrated and and appropriate processor and post-processor.
the standard: performance test: any of a number of test procedures that
are used to measure machine performance.
NDE p NE − NEs (4-16)
periodic error: error in the positioning of a machine axis
When measuring at temperatures other than 20°C, cor- that is periodic over an interval that normally coincides
rections for the NDE must always be made. The NDE with the natural periodicity of the machine scales or
is a systematic error and cannot be considered to be an their equivalent. For example, in a lead screw driven
uncertainty. machine with rotary encoders, the periodicity is usually
synchronous with the pitch of the lead or ball screw.
nominal expansion (NE): estimate of the expansion of an
object from 20°C to its time-mean temperature. It shall pitch: angular motion of a carriage, designed for linear
be determined from the following relationship: motion, about an axis perpendicular to the motion direc-
tion and perpendicular to the yaw axis.
NE p ␣L(T − 20) (4-17)
play: condition of low or zero stiffness over a limited
nominal path: numerically controlled and programmed range of displacement due to clearance between mem-
path defined by the machine’s appropriate program- bers of the structural loop.
ming protocol. For the purposes of the circular tests, polar chart (PC) center: center of the polar chart.
this path would be defined by its diameter or radius, polar profile center: center derived from the polar profile.
the position of its center, and its orientation in the work In this Standard, the least-squares circle center, LSC, is
zone of the machine. Nominal paths for the circular tests used. The list of possible centers follows:
may be either full circles or partial arcs. (a) minimum radial separation (MRS) center: center that
nonsensitive direction: any direction perpendicular to any minimizes the radial difference required to contain the
sensitive direction. See also sensitive direction. error motion polar plot between two concentric circles
numerical control system: special purpose computer that (see Fig. 4.4).
processes primarily numeric data to control the move- (b) least-squares circle (LSC) center: center of a circle
ments and functions of a machine to which it is con- that minimizes the sum of the squares of a sufficient
nected. number of equally spaced radial deviations measured
from it to the error motion plot.
optical polygon: optical element composed of a number
(c) maximum inscribed circle (MIC) center: center of the
of plane surface mirrors arranged to form a regular
largest circle that can be inscribed within the error
polygon.
motion plot.
outlier: a measured value that is greater than +2 times (d) minimum circumscribed circle (MCC) center: center
the repeatability or less than −2 times the repeatability of the smallest circle that will just contain the error
from the average of all data values for the same quantity motion polar plot.
in the sample, where the repeatability of the machine
positional deviation: see deviation of position.
is as defined in para. 7.3.4 of this Standard.
positioning control system: numerical control in which
parametric: for the purposes of this Standard, parametric (a) each numerically controlled motion operates in
is defined as referring to the measurement of any of accordance with instructions that specify only the next
the geometrical errors of a machine. These include, for required position
example, positioning errors, angular errors, straightness (b) the movement in the different axes of motion are
errors, error motions of spindle, and alignment errors not necessarily coordinated with each other and may be
such as parallelism and squareness. executed simultaneously or consecutively
part coordinate: the Cartesian (X, Y, Z) coordinate system (c) velocities are not specified by the input
in which the part is defined and in which the tool coordi- positioning mode: mode of operation of NC or CNC sys-
nates are specified. tem that performs in accordance with the definition of
part or workpiece: in every dimensional or geometric mea- a positioning control system.
surement process, there is usually some physical object probe: in this Standard, a device that establishes the loca-
tion of the movable components of a machine tool rela-
2
It is a requirement of this Standard that nominal differential tive to a measurement point. Three types of probes are
expansion corrections always be made. See para. 7.3.2.1 for details. discussed in this Standard. They are

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NUMERICALLY CONTROLLED MACHINING CENTERS

Error motion value quadrant photodiode: photodetector, used for measuring

for MRS center Error motion value
for PC center displacements in 2D, composed of four separate photo-
detectors arranged in a form that resembles the quad-
rants of a circle.
radial depth of cut: depth of cut perpendicular to the
spindle axis direction when milling.
radial deviation: deviation in radial direction between the
actual path and the nominal circular path, where the
center of the nominal path is obtained from either one
MRS
of the following:
(a) from the centering of the measuring instruments
on the machine tool
PC (b) from the least-squares centering analysis for a full
circle only.
radial error motion: error motion of a rotary axis normal
to the Z reference axis and at a specified angular orien-
tation.
radial immersion: ratio of the actual width of the cut to
the cutter diameter in milling.
radian: natural unit of angle. For small angles, the radian
is often represented by “rise over run.” Radians can be
converted to decimal degrees by multiplying by 57.29
Fig. 4.4 Error Motion Polar Plot Showing Polar
or to arc seconds by multiplying by 206,265. The microra-
Chart (PC) Center, a Minimum Radial Separation
dian (␮rad) is a millionth of a radian.
(MRS) Center, and Error Motion Values About
These Centers range: difference between the maximum and minimum
values of a set of measurements of nominally the same
quantity.

(a) switching probe: probe that gives a binary signal as reference coordinate axes: mutually perpendicular X-, Y-,
a result of contact with or in proximity to a workpiece. and Z-axes fixed with respect to an object.
(b) proportional probe: probe that gives a signal propor- relative vibration: for the purposes of this Standard, rela-
tional to a displacement of the probe from its free tive vibration refers to nonzero frequency relative
position. motion between the position of a nominal tool and a
(c) nulling probe: probe that, in reference to a work- nominal workpiece.
piece, gives a signal that causes the machine to be driven repeatability: for the purposes of this Standard, repeat-
to a position that will null the probe reading. ability is defined as a measure of the ability of a machine
probe approach distance: distance of approach to the part to sequentially position a tool with respect to a work-
at which the machine traverse speed is reduced to the piece under similar conditions. Repeatability is defined
probe approach rate for measurement. on a per-axis basis (see para. 7.3).

probe approach rate: nominal speed of approach of the resolution: least increment of a measuring device. On a
probe toward the part during the acquisition of data. digital instrument, the least significant bit.

probe cycle: fixed cycle using a probe. retroreflector: optical element with the property that an
input light beam is reflected to return along the same
probe lobing: systematic error in the measuring accuracy angle as it was incident.
of probing systems such that a measured value depends
on the displacement direction of the probe tip. reversal deviation of angular error, Bae: maximum of the
absolute reversal values at all target positions along a
process damping: condition in milling where the wave- linear axis when measuring angular error. Computed
lengths of undulations created by chatter on the cut similarly to the reversal value of an axis.
surface decrease, the slope of these waves increases, and
reversal value (error) at a position, Bi: value of the difference
the damping component of the cutting force strongly
between the mean unidirectional deviations obtained
increases, thus attenuating the regeneration of waviness.
from the two directions of approach,
pure radial motion: concept of radial motion in the absence
of tilt motion. Bi p xi↑ − xi↓ (4-18)

31
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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

reversal value of an axis, B: maximum of the absolute (b) rotating sensitive direction: the workpiece is fixed
reversal values, 冨B i 冨, at all target positions along or and the point of machining or gaging rotates with the
around the axis spindle.

B p max. 关冨Bi冨兴 (4-19) NOTE: A lathe has a fixed sensitive direction; a jig borer and a
machining center have a rotating sensitive direction. With a fixed
roll: angular motion of a carriage, designed for linear sensitive direction, the reference coordinate axis is fixed; with a
rotating sensitive direction, the reference coordinate system rotates
motion, about the linear motion axis.
with spindle.
rotary axis: any motion axis of a machine whose function
is to provide a rotary motion either for the purposes of sensor: generic term used for an indicator that senses a
positioning or for moving a part or a tool to provide particular physical quantity. In this Standard the term
sufficient surface speed for cutting (i.e., a spindle). In sensor is normally used to mean a displacement indica-
this Standard, three types of rotary axes are defined. tor. See displacement indicator.
They are sensor nest: group of more than one sensor assembled
(a) rotary machining axis: rotary axis where the axis together in a stable fixture to allow displacement mea-
can be used to provide continuous-path contour cutting surements in more than one direction.
in a rotary direction.
sequence number: number identifying blocks or group of
(b) rotary positioning axis: rotary axis that allows the
blocks in a machine program.
rotation of a part into a new position for the purposes
of cutting only; that is, this axis is not used to provide settling time: time required between contact of a propor-
continuous, contour cutting, but only to reposition dif- tional probe with the workpiece and the time at which
ferent faces of the part for the purpose of metal removal. valid data may be taken.
(c) spindle: see spindle. significant mean temperature change: change in the mean
runout: total range of displacements measured by an ambient temperature surrounding a machine that, in the
instrument sensing against a moving surface or moved Supplier’s judgment, will cause sufficient degradation in
with respect to a fixed surface. machine performance such that performance evaluation
safe operating temperature range: temperature range in (Chapter 7) should be repeated.
which a machine tool may be expected to operate with- soak out: one of the characteristics of an object is that it
out physical damage to the machine or its support sys- has a thermal “memory.” When a change in environment
tems (i.e., computers, controllers, etc.). is experienced, such as occurs when an object is trans-
scale: part of a transducer system that provides the linear ported from one room to another, there will be some
or rotary position of a machine axis. For the purposes period of time before the object completely “forgets”
of this Standard, the transducer system could be a line about its previous environment and exhibits a response
scale, inductive scale, shaft encoder, or any type of linear dependent only on its current environment. The time
or rotary positional measuring device. Where tempera- elapsed following a change in environment until the
ture is mentioned in this Standard with respect to a object is influenced only by the new environment is
scale, it refers to the temperature of the material that called soak out time. After soak out, the object is said to
comprises the portion of the scale that establishes the be in equilibrium with the new environment. In cases

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
unit of length. That is, in a line scale it refers to the where an environment is time variant, the response of
matrix on which the lines have been deposited; for a the object is also a variable in time.
lead or ball screw it refers to the temperature of the socket: spherical cup that allows for accurate reposition-
material composing the screw itself, etc. ing of one end of a telescoping ball bar.
segment length (chordal length): distance between two specific power or specific force: the power or force required
points in a part program. for the removal of a unit volume of a particular material
seismic vibration: for the purposes of this Standard, seis- per unit time in cutting.
mic vibration is defined as vibration of the support sur-
specification zone: value specified in a machine specifica-
face on which the machine tool is mounted that is
tion for the result of a particular test, as defined in this
induced as the result of external forces in the sur-
Standard, shall be called the specification zone for that
rounding area.
test and denoted SZ.
sensitive direction: direction where relative motion
between the tool and the workpiece causes one-for-one spindle: device which provides an axis of rotation for the
form errors to be cut into the workpiece. Two types of purpose of rapidly rotating a part or a tool to provide
sensitive directions are recognized: sufficient surface speed for cutting operations.
(a) fixed sensitive direction: the workpiece is rotated by spindle speed: rate of rotation of a machine spindle, usu-
the spindle and the point of machining or gaging is fixed. ally expressed in revolutions per minute.

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NUMERICALLY CONTROLLED MACHINING CENTERS

spindle speed function: command defining the spindle Structural

loop
speed.
squareness: a plane surface is “square” to an axis of rota-
tion if coincident polar profile centers are obtained for
an axial and face motion polar plot at different radii.
Also, for linear axes, the angular deviation from 90 deg,
measured between the best-fit lines drawn through two
sets of straightness data derived from two orthogonal
axes in a specified work zone.
staging: the moving of a gage from a first position to a
second position such that a series of measurements
started in the first position may be continued in the
second position.
standard uncertainty due to the environmental temperature
variation error: the environmental temperature variation
error (ETVE) is measured as the range of the total drift
of the instrument/master/part system as described in Fig. 4.5 Example of a Structural Loop Showing a
Chapter 6. To convert this to a standard uncertainty Part, Spindle, Machine Frame, and Tool
according to ISO guidelines, it is assumed that this envi-
ronmental error is uniformly distributed within this
range for a given measurement. The resulting standard straightness error: slide straightness error is the deviation
uncertainty, uETVE, is then given by from straight line movement that a displacement indica-
tor positioned perpendicular to a slide direction exhibits
when it is either stationary and reading against a perfect
straightedge supported on the moving slide, or moved
冪
ETVE2
uETVE p (4-20) by the slide along a perfect straightedge that is sta-
12
tionary.
standard uncertainty (of a quantity, q), uq or u(q): given a NOTE: In some documents the moving indicator against the sta-
set of n measurements of a quantity, q, the standard tionary straightedge is called lateral deviation.
uncertainty in q is given as
structural loop: assembly of mechanical components that
n maintain relative position between specified objects. A
冪n − 1 兺 (q − q)
1 2
uq p u(q) p j (4-21) typical pair of specified objects is the cutting tool and
jp1
the workpiece; the structural loop would include the
spindle shaft, the bearings and housing, the slideways
where the qj denote the individual measurements and
and frame, possibly the foundation, and the tool and
q is the mean of the set of measurements. This quan- work-holding fixtures (see Fig. 4.5).
tity is also sometimes called the estimator of the stan-
dard deviation and commonly symbolized by sq. Supplier: party who contracts, or indicates readiness to
contract, to supply a machine tool to a User (also called
static error motion measurement: special case of error a vendor in some ISO documents).
motion measurement in which the error motion is sam-
synchronous error motion: another term for average error
pled with the spindle at rest at a series of discrete rota-
motion, used in axis of rotation testing.
tional positions.
systematic error: mean that will result from an infinite
steering mirror: mirror used to steer the laser beam to
number of measurements of the same measurand carried
the appropriate angle in the diagonal displacement mea-
out under repeatability conditions, minus the true value
surement test. of the measurand.
step gage: gage comprising a rigid bar with calibrated NOTE: Systematic error is equal to error minus random error; like
steps used for determining accuracy of distance mea- true value, systematic error and its causes cannot be completely
surements in a direction of linear motion. known; for a measurement instrument, systematic error is often
called bias.
stiffness: the reciprocal of compliance. Usually defined
statically as a ratio of the applied force to the displace- target position, Pi (i p 1 to m): position to which the
ment of a machine element. For the purposes of this moving component is programmed to move. The sub-
Standard, stiffness is defined with respect to the struc- script “i” identifies the particular position among other
tural loop. selected target positions along or around the axis.

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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

temperature of a body: tilt error motion: error motion in the angular direction
(a) temperature at a point: when discussing a body that relative to a linear axis. [See Fig. 4.1, illustrations (e)
does not have a single uniform temperature, it is neces- and (f).]
sary to refer in some manner to the distribution of tem- tolerance: for the purposes of this Standard, the tolerance
perature throughout the body. Temperature at a point is a range on either side of a desired dimension of a
in a body is assumed to be the temperature of a very manufactured part or a gage. In some cases, tolerances
small volume of the body centered at that point. The are expressed as plus (+) or minus (−) a single value.
material of which the body is composed is assumed to That value is called the tolerance.
form a continuum.
tool change under program control: process on a machining
(b) temperature of a body: when the differences between
center or work center where the cutting tool is
the temperatures at all points in a body are negligible,
exchanged, usually with its tool holder, for another tool
the body is said to be at a uniform temperature. This
under control of the part program (i.e., without human
temperature is then the temperature of the body.
intervention).
(c) instantaneous average temperature of a body: when
the body is not at a uniform temperature at all points, tool (fixture) offset: a relative displacement that is applied
but it is desirable to identify the thermal state of the to an axis of a machine for a specified portion or the
body by a single temperature, the temperature that rep- whole of a program and causes a displacement in that
resents the total heat stored in the body may be used. axis only in the direction determined by the sign of the
When the body is homogeneous, this is called the aver- offset value (may not apply for some 5-axis machines).
age temperature of the body. (This temperature is the NOTE: For example, the tool offset is typically applied in pairs of
average, over the volume of the body, of all point temper- independent values for X, Y, and Z for the tool tip location on
atures.) turning machines, individually or in combination on milling
machines.
(d) time-mean temperature of a body: the average of the
average temperature of a body, over a fixed period of tool function: command identifying a tool or a tool offset.
time, is called the time-mean temperature of the body. tool (length) offset: incremental displacement in the axial
The fixed period is selected as appropriate to the mea- direction of the tool.
surement problem.
NOTE: This is typically used on milling and drilling machines.
thermal error index (TEI): in some cases, particularly in
factories, dimensional measurements are made at tem- tool-setting probe: see tool-setting system.
peratures other than 20°C, corrections are not made for tool-setting system: instrument supplied with a machin-
the nominal differential expansion between standard ing center that allows for the measurement of tool offsets
and part, and the environment is constantly changing. or tool diameter as part of a computer-controlled cycle.
In this case, there is a systematic error that is coupled Also sometimes called a tool-setter, a tool-gage, or a
with the thermal uncertainty index to give an overall tool-setting probe(s).
estimate of the error made in manufacturing or measure-
tow-along carriage: machine carriage that is positioned
ment. Since the nominal differential expansion correc-
with the mechanical assistance of another machine car-
tion is a systematic error, it is not subject to statistical
riage; thus the term tow-along.
analysis. This Standard defines, in this particular case,
a thermal error index that estimates the maximum possi- transducer: any device that converts a measurand of one
ble percentage error that would be made in these condi- physical quantity into another physical parameter. For
tions as the sum of the absolute value of the uncorrected example, a strain gage that converts strain to an electrical
differential expansion and the expanded thermal uncer- signal would be considered a transducer. For the pur-
tainty, divided by the specification zone. That is, poses of this Standard, most transducers discussed are
displacement transducers. The term displacement trans-
冨NDE冨 + UT(L) ducer will be used synonymously with the term displace-
TEI p 100% (4-22)
SZ ment indicator.
Here SZ is the desired specification zone (see para. transducer drift check: experiment conducted to determine
4.1) on the measurement. the drift in a displacement transducer and its associated
amplifiers and recorders when it is subjected to a thermal
thermal expansion: the difference between the length (or environment similar to that being evaluated by the drift
volume) of a body at one temperature and its length (or test itself. The transducer drift is the sum of the “pure”
volume) at another temperature is called the linear (or amplifier drift and the effects of the environment on the
volumetric) thermal expansion of the body. transducer, amplifier, etc. The transducer drift check is
thermally induced drift: drift caused by variations in the performed by blocking the transducer and observing
thermal environment or internal heat sources of the the output over a period of time at least as long as the
machine. duration of the drift test to be performed. Blocking a

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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NUMERICALLY CONTROLLED MACHINING CENTERS

transducer involves making a transducer effectively same direction along or around the axis. The symbol ↑
indicate on its own frame, base, or cartridge. In the case signifies a parameter derived from a measurement made
of a cartridge-type gage head, this is accomplished by after an approach in the forward or clockwise direction,
mounting a small cap over the end of the cartridge so and ↓ signifies one in the reverse or counterclockwise
the plunger registers against the inside of the cap. Fin- direction (e.g., xij↑ or xij↓).
ger-type gage heads can be blocked with similar devices. unidirectional accuracy of positioning of an axis, A↑ or A↓:
Care must be exercised to see that the blocking is done range derived from the combination of the unidirec-
in such a manner that the influence of temperature on tional systematic deviations and the estimator of the

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
the blocking device is negligible. standard uncertainty of unidirectional positioning using
transfer function: for the purposes of this Standard, the a coverage factor of two.
transfer function is the ratio of the relative vibration
between tool and workpiece to the input variable force A↑ p max. [ xi↑ + 2si↑] − min. [ xi↑ − 2si↑] (4-25)
acting between tool and workpiece as a function of fre-
quency. The transfer function has both amplitude and and
phase (or a real and imaginary part). A↓ p max. [ xi↓ + 2si↓] − min. [ xi↓ − 2si↓] (4-26)
type test: machine performance test that is likely to yield
nearly the same results for all machines of the same unidirectional repeatabilities of angular error, Rae↑ and Rae↓:
model or type, as long as the machine has been assem- maximum value of repeatability of angular error at any
bled to specification. position along a linear axis. Computed similarly to uni-
directional repeatability of positioning.
uncertainty of nominal coefficient of expansion: the uncer-
tainty in the nominal thermal expansion coefficient of a unidirectional repeatability of positioning at a position, Ri↑
body shall be denoted u(␣) for the object being calibrated or Ri↓: range derived from the expanded uncertainty of
or measured and u(␣s) for the standard. This value, like unidirectional positional deviations at a position, using
that of ␣ itself, must be an estimate. (See para. 6.2.3.3.2 a coverage factor of 2,
for further explanation.)
Ri↑ p 4si↑ (4-27)
uncertainty of nominal differential expansion (UNDE): the
square root of the sum of the squares of the uncertainties and
of nominal expansion of the object to be calibrated or
measured and the standard, Ri↓ p 4si↓ (4-28)

UNDE p 冪(UNE)2 + (UNEs )2 (4-23) unidirectional repeatability of positioning, R↑ or R↓, of an

axis: maximum value of the unidirectional repeatabilities
uncertainty of nominal expansion (UNE): the uncertainty of positioning at any position along or around an axis,
in the value chosen for the nominal expansion. It is
determined as R↑ p max. [Ri↑] (4-29)

UNE p L(T − 20)u(␣) (4-24) and

uncertainty of temperature measurement: when the temper- R↓ p max. [Ri↓] (4-30)

ature of a body or the ambient environment is measured,
there is an uncertainty associated with this measure- unidirectional systematic angular error, Eae↑ and Eae↓: differ-
ment. This uncertainty comes from the calibration of the ence between the algebraic maximum and minimum of
thermometer, thermometer mounting procedures, and the mean unidirectional angular errors for both
instrumental variations. (See para. 6.2.3.3.3 for further approach directions, at any position along a linear axis,
explanation.) computed similarly to unidirectional systematic devia-
tion of positioning of an axis.
undulations per revolution (upr): term commonly used
when referring to spindle error testing. It refers to the unidirectional systematic deviation of positioning of an axis,
highest order (frequency) sine wave detected in a spindle E↑ or E↓: difference between the algebraic maximum
error analysis (highest harmonic of the spindle speed). and minimum of the mean unidirectional positional
The bandwidth of a sensor used for spindle error detec- deviations for both approach directions (i.e., xi↑ or xi↓
tion should be several times higher than the product of at any position along or around the axis).
the upr and the revolutions per second of the spindle
being tested (see ASME B89.3.4M for a more detailed E↑ p max. [ xi↑] − min. [ xi↑] (4-31)
explanation).
and
unidirectional: refers to a series of measurements in which
the approach to a target position is always made in the E↓ p max. [ xi↓] − min. [ xi↓] (4-32)

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NUMERICALLY CONTROLLED MACHINING CENTERS

unidirectional total(s) angular error, Aae↑ and Aae↓: range pallet configurations or pallet change mechanisms; thus
derived from the combination of the unidirectional sys- a specification should include details regarding such
tematic angular error and the estimator of the standard devices in equivalent detail. A position is provided in
uncertainty of unidirectional angular error, using a cov- the machine performance form (Form 1.1), which should
erage factor of 2. Computed similarly to unidirectional be used to designate the machine classification as
accuracy of positioning of an axis. described below.
User: party who contracts to accept a machine tool from If a machine is to be supplied that does not conform
a Supplier. to one of the described machines, a drawing similar in
content to those shown in this classification paragraph
vibration amplitude: the size (amplitude) of a given fre- with axis designation and directions of positive travel
quency component of a vibration spectrum. Common should be provided as part of the machine specification.
practice is to express the vibration amplitude in either Axis and motion nomenclature should be consistent
displacement or acceleration units. In some cases, broad-
with EIA 267, ISO 841, ASME B89.3.4M, and NAS 938.
band vibration amplitude is also used (see broadband
For the purposes of classifying machining center con-
vibration amplitude).
figurations, the machine structure is divided into five
volumetric performance: ability of a machine tool to per- major units. The units are further subdivided into types
form the intended multiaxis functions anywhere within and each assigned a code number. The order in which
the volume defined by the maximum travel of the these major units shall be specified is:
machine linear axes.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Major Units
wobble plate: mechanical device that allows the tilting
(wobbling) of a test fixture by adjustment screws.
work zone: working (machining) volume of a machine Spindle Column Column Spindle Head Table
as specified by the Supplier. More than one work zone Type Type Traverse Traverse Traverse
may be specified for a given machine, and specification
zones may be specified separately for each work zone.
Code no: 01 11 21 301 401
workpiece: object to be turned, machined, or measured. and up and up and up and up and up
yaw: angular motion of a carriage, designed for linear
motion, about a specified axis perpendicular to the Specific code numbers corresponding to the various
motion direction. In the case of a carriage with horizontal spindle, column, and table configurations are given in
motion, the specified axis shall be vertical unless explic- Table 4.1 and Figs. 4.6 through 4.11. A machining center
itly specified. For a carriage that does not have horizontal configuration can therefore be identified by reference to
motion, the axis must be explicitly specified. the assigned code numbers in the specified sequence.
For example, a machining center classification of 01-
11-23-302-402.4 would describe a 4-axis horizontal spin-
4.2 MACHINE CLASSIFICATIONS
dle machining center having a single column travelling
The following classifications of different types of in the X-axis direction with spindle head moving in
machining centers are provided for ease of machine the vertical Y-axis direction on column and a rotary
specification. This Standard does not seek to standardize machining table mounted on an X-axis table base.

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Spindle Type Column Type Column Traverse Spindle Head Traverse Table Traverse
(See Fig. 4.6) (See Fig. 4.7) (See Fig. 4.8) (See Fig. 4.9) (See Fig. 4.10)
(Spindle Code Code Direction(s) Direction(s) Direction(s)
Attitude) Number Number of Travel of Travel of Travel

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(Depending (Depending (Depending
Horizontal 01 Single 11 on Spindle Code on Spindle Code on Spindle Code
Vertical 02 Attitude) Attitude) Attitude)
Fixed 12 Number Number Number
Tilt 03
bridge None 21 Y 301 None 401
Multispindle Heads Moving 13 X 22 X 402
bridge Y or Z 302
Z or Y 23 Y or Z 403
Multispindle heads can X over Z 24 Z 303 Z or Y 404
be specified by adding or X over Y 405
Z over Y 304
a suffix to the spindle X over Y or
type code number X over Z
NUMERICALLY CONTROLLED MACHINING CENTERS

Z over X 25 Z over X 305

corresponding to the X over Z 406
or
number of spindles or
required. Y over X None 306
X over Y
METHODS FOR PERFORMANCE EVALUATION OF COMPUTER

Example: Code number X 26 Z over X 407

02.3 would specify a three Y over X 307
Z over X 408
spindle vertical head.
Z over Y 308 or
If no suffix is attached
to the code number, a over X Y over X
X over Z

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
single spindle head is 409
Z 309

37
assumed. over Y
For identification or
Z over Y 310
purposes, the spindles X over Y
shall be numbered 1, 2, over Z
A spindle head can be Tilt head XXX.1
3, etc., starting from Trunnion Pos. XXX.1
converted into a tilting
the left when facing table Mach. XXX.2
head spindle or gimbal Gimbal XXX.2
the spindle heads. Pos. XXX.3
head by adding a suffix head Rotary table
to an appropriate spindle (centerline
head code number. at 90 deg to Mach. XXX.4

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For example: table
NOTE: When a machine 301.1 or 303.2. traverse)
tool has additional linear
axis moving parallel to Rotary table(s) with centerline Rotary table Pos. XXX.5

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the primary axis, the of rotation(s) at 90 deg or (centerline Mach. XXX.6
axis designation of the parallel to X-axis travel can parallel to
secondary axis, as be specified by adding a table
indicated by its specified suffix(s) to an appropriate traverse)
code number, will change table code number.
in compliance with For example: Pos. = rotary positioning
ISO 841 (1994). 402.3 or 408.2.4. Mach. = rotary machining

Table 4.1 Key to Unit Code

ASME B5.54-2005
ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

+Y
+Z +Z
+X +Z +X +X
+Y +Y

01 02 03
Horizontal Vertical Tilt

+Z

+Y +X

1
2
3

Multispindle
(02.3)

Fig. 4.6 Code Numbers for Spindle Types

38
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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NUMERICALLY CONTROLLED MACHINING CENTERS
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

11 12 13
Single Fixed Bridge Moving Bridge

Fig. 4.7 Code Numbers for Column Types

+Y +Y +Z +Y +Z
+Z
+X +Z +X +Y +X +Z +X +Y +X +Z +X +Y

21 22 23

+Y +Z +Y +Z +Z
+X +Z +X +Y +X +Z +X +Y +Y +X

24 25 26

Fig. 4.8 Code Numbers for Column Traverse

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NUMERICALLY CONTROLLED MACHINING CENTERS

+Y +Y +Z +Z
+X +X +Z +X +Y +X +Y
+Z

301 302 303

+Y +Y +Y
+X +Z +X +X
+Z +Z

304 305 306

+Y +Y
+Y
+X
+X +X +Z
+Z +Z

307 308 309

+Z +Z
+X +X
+Y +Y
B or C

A
A
310 Tilt Head XXX.1 Gimbal Head XXX.2

Fig. 4.9 Code Numbers for Spindle Head Traverse

40
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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NUMERICALLY CONTROLLED MACHINING CENTERS

+Y +Z +Y +Y +Z
+Z
+X +X +Y +X +X +Y +X +Z +X +Y
+Z +Z

401 402 403

+Y +Y +Z +Y +Z
+Z
+X +X +Y +X +Z +X +Y +X +Z +X +Y
+Z

404 405 406

+Z +Y +Y +Z
+Z
+X +Y +X +X +Y +X +Z +X +Y
+Z

407 408 409

+Y +Z +Y +Y
+Z
+X +Z +X +Y +X +X +Y +X +Z
+Z
"C" Rotary table

XXX.3 or XXX.4
rotary table

Indexing XXX.1 Indexing XXX.3 Combination Indexing XXX.5

Trunnion Table Rotary Table Contouring XXX.4 Contouring XXX.6
Contouring XXX.2 Rotary Tables

Fig. 4.10 Code Numbers for Table Traverse

41 --```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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+Y +Y +Y

+X +X +Z +X +Z
+Z

02-11-21-302-406 01-11-23-301-402 01-11-21-309-405

+Y +Z +Z
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

+X +X +Y +X +Y
+Z

W
1
2
3

01-11-21-304-406.3 02-13-26-310-401 02-3-12-21-310-402

+Y +Y +Y

+X +X +Z +X +Z
+Z

+B
C +A

01-11-21-302-406.4.6 03-11-21-302.1-406.4 01-11-22-301-404.2.4

Fig. 4.11 Examples of Machining Centers Classified by Code Numbers

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ASME B5.54-2005

Chapter 5
Environmental Specifications

5.1 GENERAL supplied, the tests of environmental sensitivity (see

Chapter 6) may lead to an increase in the acceptable
It shall be the responsibility of the User to provide an
specification zone for a given performance test. In this
acceptable environment for performance testing of the
second case, the degradation in performance shall be
machine tool at the installation site. Environmental
solely the responsibility of the User.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
parameters recommended in this Standard are given in
para. 1.2. The environment shall be considered accept- 5.2.2.1 Time Variations. Particular attention should
able if the requirements of this Chapter and Chapter 6 be given to time variations of temperature, although this
are met. The User shall be responsible for conducting all Standard does not offer specific guidelines in this area.
environmental tests at the installation site. The Supplier Machine tools are composed of numerous elements, each
shall have a right to witness all tests. The Supplier shall, with different thermal behavior. For example, the ram
on request, supply test equipment as specified in Chap- of a machine may have a short thermal time constant,
ter 11, and support for equipment and tests, at a price and the bed of the machine may have a very long thermal
to be negotiated between Supplier and User. time constant. Therefore, when the machine is in an
environment with time variations of the temperature,
5.2 TEMPERATURE the resulting response in terms of spindle motion with
respect to the table can be quite complex. Furthermore,
5.2.1 General when a part is being machined there are other time
constants like that of the part and the part fixture, which
Temperature has a significant influence on the accu-
also serve to complicate this problem. Efforts should be
racy of machine tools and measuring instruments, and
made to keep the time variations of temperature either
its effects are often misunderstood. The provisions of
ASME B89.6.2 form a part of this Standard, but interpre- much faster than the fastest time constant in the system
tation is needed for application to machine tools. ASME or to reduce them to acceptable levels.
B89.6.2 defines two alternative conditions under which 5.2.2.2 Thermal Radiant Energy. The machine shall
a test environment is thermally acceptable. The first, not be exposed to direct sunlight or other powerful radi-
that all pertinent components of the measuring system ant energy sources. Other direct radiant energy sources
are at exactly 20°C (68°F), is generally unobtainable. This (e.g., fluorescent lighting, radiant heaters, high-intensity
Standard is primarily concerned with the second: that lamps, etc.) shall be as far from the machine as possible,
the expanded thermal uncertainty (see para. 6.2.3.2) be to reduce their effects on the machine’s thermal behavior.
a reasonable percentage of the specification zone. Where this distance requirement is impractical, indirect
Acceptability of a thermal environment is specified in
lighting designed for diffuse reflection and increased
terms of its effects on the machine.
path length shall be used. Users and Suppliers should
5.2.2 Thermal Environment Guidelines be aware that lights in the machine enclosure might
sometimes have unwanted thermal influence.
The Supplier shall offer guidelines regarding what
thermal environment should be acceptable for the
machine. Such general guidelines could contain, for 5.3 SEISMIC VIBRATION
example, a specification on mean room temperature,
maximum amplitude and frequency range of deviations 5.3.1 General
from this mean temperature, environmental thermal
gradients, air flow rate, and air speed surrounding the The support surface (floor, foundation, isolation pad,
machine, as listed in para. 1.2. The User shall be etc.) upon which the machine will be mounted can have
informed that the conformance to such guidelines does motion induced as a result of external forces in the sur-
not guarantee an acceptable machine thermal environ- rounding area (due to other machines, lift trucks, com-
ment, but does constitute due care on the User’s part pressors, etc.). This motion can be continuous vibration,
and thus shifts responsibility for performance degrada- interrupted shock, or both. Such motion, if transmitted
tion due to environmental sensitivity from User to Sup- to the machine, has a degrading effect on the overall
plier. If the User chooses not to conform to the guidelines accuracy and repeatability of a machine tool by causing

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relative motions among the tool, the machine axes posi- 5.4 ELECTRICAL
tion measuring transducers, and the workpiece. Improp-
erly installed or designed isolators can also cause 5.4.1 General
excessive motions. In addition, certain excessive motion The electrical power supplied to a machine can have
amplitudes can cause damage to the machine. Several an effect on the machine’s ability to perform accurate
major American corporations have developed extensive and repeatable machining operations. This is especially
standards for vibration analysis on machine tools. These true with today’s modern machines, which typically
standards have primarily diagnostic purposes. This incorporate electronic and electrical components that
Standard in no way supersedes these other standards. can be sensitive to voltage variations. For this reason,
it is necessary to characterize the machine in the range
5.3.2 Responsibilities of the electrical environment in which it will operate. It
The User shall be responsible for site selection, envi- is also necessary to know the operating range in which
ronmental shock and vibration analysis, and additional the machine was designed to operate.
special isolators required to ensure compliance with the
5.4.2 Responsibilities
maximum permissible vibration levels specified by the
Supplier. All questions of compliance shall be deter- It shall be the responsibility of the User to provide
mined at the interface between the support system pro- electrical power meeting typical requirements as speci-
vided by the User and the machine system provided by fied by current standards. The Supplier shall be responsi-
the Supplier. Functional tests for measuring the relative ble for providing a specification for which the equipment
vibration are described in para. 6.3. will operate properly.

5.4.3 Electrical Parameters

5.3.3 Seismic Vibrational Parameters The Supplier shall provide, as part of the machine
The Supplier shall provide, as part of the machine specification, a statement of the steady state require-
specification, a statement of the acceptable vibration ments including voltage(s), frequency, and amperage for
spectra at the User–Supplier interface. (This interface the machine, allowable short and long term RMS voltage
may be very different, depending upon details of the variations, and allowable transient voltages expressed
contractual arrangement between Supplier and User. For in percent of nominal voltage.1 These parameters are
example, if the machine is supplied with isolators, the listed in para. 1.2.
interface will be between the foundation and those isola-
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

tors. However, if the User provides an isolation system 5.5 UTILITY AIR
from another source, the interface shall be at the connec-
tion between those isolators and the machine. In any 5.5.1 General
event, it is a requirement of this Standard that the appro- Air supplies to machines can affect their accuracy and
priate interface be defined as part of the machine specifi- useful working life. Temperature variations in the utility
cation.) This statement can contain a complete air can generate thermal gradients in the machine, and
description of the allowable vibration displacement particulates, oils, and water can degrade bearing per-
amplitude as a function of frequency for each vector formance, increase friction, and accelerate wear.
component of the vibration spectrum, or can be simply
a limit on the total vibrational displacement amplitude 5.5.2 Responsibilities
over a specified frequency range. In lieu of vibration
For all machines requiring utility air, it shall be the
displacements, accelerations or velocities will also be
responsibility of the User to supply utility air meeting
acceptable. The sample performance form in para 1.2
requirements specified by the Supplier.
allows for the displacement options. Users desiring to
specify a machine in terms of accelerations or velocities 5.5.3 Specifications
shall create forms and test procedures in equivalent
For utility air, the Supplier shall provide specification
detail. The statement of acceptable vibration spectra
for all air parameters required for the proper operation
applies with the machine in place. It is recognized that
and maintenance of the machine to be supplied. For air
in some atypical cases it is physically possible that the
bearing machines these should include mean tempera-
vibration spectrum of the foundation or floor may be
ture, permissible temperature variation, pressure, and
significantly altered by the installation of the machine,
pressure variations. Further, on some machines, the
particularly for large or very heavy machines. In such
acceptable dew point and the particulate content shall
cases, the party (User or Supplier) contracted to supply
the vibration isolation system shall be responsible for 1
Percentage of nominal voltage is the percentage of the remaining
achieving an acceptable vibration environment for the voltage. For example, a reduction in voltage of 15% would be
machine. expressed as 85% of nominal voltage.

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NUMERICALLY CONTROLLED MACHINING CENTERS

be specified. These parameters are listed in the environ- foundation at the Supplier or User facility does not com-
mental specification form in para. 1.2. Air quality param- ply with the foundation specification, which was gener-
eters, such as particulate, oil, and water content, are the ated as part of the machine design. In new installations it
sole responsibility of the User, although the Supplier is particularly important to pay attention to the inherent
shall offer guidelines. instability and cure time of hydraulic concrete, as this
material can lead to unstable machine structures if
5.6 OTHER improperly installed. For further discussions related to
5.6.1 General foundations, see Appendix F.
Just as air supplies can affect the accuracy and useful
working life of a machine, so can hydraulic supplies, 5.6.2 Responsibilities
coolant supplies, foundations, and the like. For example,
temperature variations caused by pumping can generate For all machines requiring hydraulics or other ser-
large thermal gradients in the machine and, of course, vices, it shall be the responsibility of the Supplier to
particulates, oil, and water can degrade machine per- provide for proper filtering and temperature control,
formance and accelerate wear. Large machine tools also such that these services do not degrade machine per-
often rely on a User-supplied foundation for their stiff- formance. If, for some reason, hydraulics, coolants, or
ness, and improperly installed foundations can signifi- other services are to be supplied by the User, then the
cantly increase a machine’s compliance. User shall be responsible for meeting all requirements
Both the Supplier and the User recognize the impor- as specified by the Supplier. In the case of foundations,
tance of foundations when the machine design utilizes the responsibility for foundation design and installation
the foundation as an integral part of the structure. It shall be negotiated as part of the original contract, but
should be anticipated that test data collected at the Sup- foundation specifications, including construction draw-
plier or User facility will likely be affected if static stiff- ings (where applicable), shall be supplied by the Sup-
ness tests or horsepower cuts are attempted and the plier.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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ASME B5.54-2005

Chapter 6
Environmental Tests

6.1 GENERAL the location of the test artifact with respect to the spindle
The environmental tests are intended to verify that and the position of each axis.
the environment is suitable for the performance tests to (b) The default location of the test artifact shall be on
follow. The Supplier may choose to defer these tests. the spindle centerline, 150 mm from the spindle face.
This might be reasonable when test specification zones (c) The default position of the linear axes shall be
are large, when the environment provided by the User approximately at the center of the axis travel.
is known to be adequate, or when the machine tool 6.2.2.4 Measurement Procedure. See Fig. 6.1.
system is designed to be environmentally robust. If the
(a) Place the test artifact in the machine spindle.
machine performs within the test specification zones,
(b) Fix the gage holder and indicators to the work-
the deferred tests and computations of this Chapter may
piece table aligned to the axes.
be eliminated. If the performance fails, the environmen-
(c) Place the air temperature sensor near the center
tal tests may be performed as part of the diagnostic
of the machine work volume.
process.
(d) Place the surface temperature sensor on the spin-
dle nose.
6.2 ENVIRONMENTAL TEMPERATURE VARIATION
(e) Adjust the machine axes and indicators so that all
ERROR (ETVE)
indicators are near the centers of their ranges.
6.2.1 General (f) Check for setup hysteresis in each direction as
The ETVE test estimates the expected positioning discussed in para. 7.1.4.2.
error due to changes in machine ambient temperature. (g) Ensure that electronic test equipment, computers,
It does not address changes in the above-mentioned etc., do not touch the machine. These shall be located
errors due to the effects of internal heat sources of the as far as possible from the machine tool for the duration
machine tool. Therefore, these effects should be mini- of the test.
mized by a machine stabilization procedure described (h) Place the machine in the “feed-hold” condition
in para. 6.2.2. and zero indicators electronically (if applicable).
(i) Ensure the setup has thermally stabilized from the
6.2.2 Test Procedure effects of handling before recording data.
6.2.2.1 Equipment. Also see para. 6.2.4. (j) Record data from the five displacement indicators
(a) test artifact and two temperature sensors at intervals of 60 sec or
(b) five displacement indicators less. The test period should be at least 4 hr. However,
(c) gage holding fixture the minimum recommended test time is 24 hr.
(d) data recording system/software (as required) (k) Normal activities surrounding the machine shall
(e) air temperature sensor continue during the test.
(f) metal surface temperature sensor
6.2.3 Data Analysis
6.2.2.2 Machine Warm-Up
(a) The machine shall be stabilized to “cold machine” 6.2.3.1 Computation of ETVE
condition. All systems that normally operate while the
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

(a) The thermal drift in the X direction, ETVEX, shall

machine is idle (including systems to control effects of be taken as the maximum range of readings from either
environmental temperature) shall be operating. displacement indicator in this direction for any 4-hr
(b) To detect the effects of spatial temperature gradi- period over the duration of the test.
ents across the machine work volume, the location of (b) The thermal drift in the Y direction, ETVEY, shall
the machine axes during warm-up shall be as far as be taken as the maximum range of readings from either
possible from the position selected by the machine Sup- displacement indicator in this direction for any 4-hr
plier for the ETVE test. period over the duration of the test.
6.2.2.3 Test Location (c) The thermal drift in the Z direction, ETVEZ, shall
(a) The location for the ETVE test may be specified be taken as the maximum range of displacement read-
by the machine Supplier. The description shall include ings recorded with the single displacement indicator in

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NUMERICALLY CONTROLLED MACHINING CENTERS

1
3

Y2
P2
X2
+Z I 4

A +Y +B +A +X

P1 X1
Y1
5
h

Detail A

Fig. 6.1 Typical Setup for Environmental Temperature Variation Error (ETVE) Measurement on a Vertical
Machining Center

this direction for any 4-hr period over the duration of changes in the wavelength of the laser interferometer.
the test. These computations are described in the paragraphs on
(d) Tilt about the X direction (relative to the starting the specific tests.
position) shall be calculated and recorded for each mea- The User shall also compute the expanded thermal
surement interval. It is obtained by taking the difference uncertainty and the angular expanded thermal uncer-
between the two Y direction indicators and dividing by tainty. These shall be used to verify that the environmen-
the distance between them. tal temperature is suitable for the appropriate
(e) The thermal drift of tilt about the X direction, performance tests or to modify the appropriate test spec-
ETVE XX , shall be taken as the maximum range of ification zones.
recorded tilts for any 4-hr period over the duration of The expanded thermal uncertainty UT(L) shall be cal-
the test. culated for each performance test from the following
(f) Tilt about the Y direction (relative to the starting equation:
position) shall be calculated and recorded for each mea-
±UT(L) p kucT(L) p ±2ucT(L) (6-1)
surement interval. It is obtained by taking the difference
between the two X direction indicators and dividing by where
the distance between them. k p coverage factor (which, for this computa-
(g) The thermal drift of tilt about the Y direction, tion, will be assumed to be 2)
ETVE YY , shall be taken as the maximum range of ucT(L) p combined standard thermal uncertainty
recorded tilts for any 4-hr period over the duration of (para. 6.2.3.3)
the test.
(h) Values of thermal drift for each direction and Values in the equation are absolute values and should
angular thermal drift about the X direction and Y direc- be taken as positive.
tion may be taken directly from a graph of the results The angular expanded thermal uncertainty shall be
such as that shown in Fig. 6.2. calculated for each performance test from the following
equation:
6.2.3.2 Thermal Computations. For all tests that mea-
sure machine accuracy, corrections shall be applied for ±UT(A) p kucT(A) p ±2ucT(A) (6-2)
the nominal differential expansion of machine scales,
mechanical masters (standards), and, if applicable, where

47
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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NUMERICALLY CONTROLLED MACHINING CENTERS

42.0 30

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Z
20
Y
10
37.0
X

Displacement, ␮m
0
Temperature, ⬚C

⫺10
32.0
⫺20
4h
⫺30
32 ␮m
27.0
⫺40
Spindle temperature

Ambient temperature ⫺50

22.0 ⫺60
0 4 8 12 16 20 24
Time, h

42.0 15.0

Tilt 10.0
around X

Angular Displacement, sec

37.0
5.0
Temperature, ⬚C

Tilt
around Y
32.0 4h 7.5 sec 0.0

⫺5.0
27.0
Spindle temperature
⫺10.0
Ambient temperature

22.0 ⫺15.0
0 4 8 12 16 20 24
Time, h

GENERAL NOTE: Values for thermal drift in the Z direction, ETVEZ, and thermal drift of tilt about the Y direction, ETVEYY, are
shown graphically. In practice, values for the other directions are found similarly.

Fig. 6.2 Temperature, Displacement, and Tilt Motion Results From a Typical ETVE Test

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ucT(A) p combined angular standard thermal uncer- error is calculated for each test based on the axis direc-
tainty, which is given by tion of the test result and the duration of the test. It is
given by

冪
ETVE2A
ucT(A) p (6-3)
冪
12 ETVE2
uETVE p (6-6)
12
When k is 2,
where ETVE for the particular test is found as follows:
±UT(A) p ±0.577 ETVEA (6-4) (a) The maximum range of indicated values for any
4-hr period over the duration of the test is determined
where ETVEA for the particular test is found as follows: from the recorded data in the relevant direction. That
(a) The maximum range of indicated values for any is, ETVEX, ETVEY , and ETVEZ as defined above.
4-hr period over the duration of the test is determined (b) The ratio of the time for the particular test (in
from the recorded data in the relevant direction. That hours) divided by 4 is calculated. (For example, a test
is, ETVEXX or ETVEYY as defined above. time of 6 hr results in a ratio of 1.5.)
(b) The ratio of the time for the particular test (in (c) The ETVE value to be used in calculation of uETVE
hours) divided by 4 is calculated. (For example, a test for the particular test is the value determined in para.
time of 1 hr results in a ratio of 0.25.) 6.2.3.3.1(a) times the ratio calculated in para. 6.2.3.3.1(b).
(c) The ETVEA value to be used in calculation of ucT(A)
for the particular test is the value determined in para. 6.2.3.3.2 Standard Uncertainty Due to Uncertainty
6.2.3.2(a) times the ratio calculated in para. 6.2.3.2(b). in the Nominal Thermal Expansion Coefficient. The uncer-
tainty in the nominal thermal expansion coefficient of a
6.2.3.3 Combined Standard Thermal Uncertainty, body shall be denoted u(␣) for the part and u(␣s) for the
ucT(L). The combined standard thermal uncertainty is standard. This value, like that of ␣ itself, must be an
defined in the glossary for the general case of a length estimate. Various methods can be used to make this
measurement. The general form is given by estimate. Examples follow:
(a) Option (a). The estimate may be based on the distri-

冪
u2ETVE + L2s (Ts − 20)2u2(␣s) + L2(T − 20)2u2(␣) (6-5) bution found among results of actual experiments con-
ucT(L) p ducted on a number of like objects.
+ L2s ␣2s u2(Ts) + L ␣ u (T)
2 2 2
(b) Option (b). The estimate may be based on the distri-
where bution found among published data.
L p length being measured (usually in machine (c) Option (c). In the absence of other information, for
tool applications, this is nominally the same the purposes of this Standard, it is recommended that
as the length of the standard) the uncertainty in the nominal coefficient of expansion
Ls p length of the standard (calibrated gage or be represented by a rectangular distribution with
laser displacement) bounds of ±0.1␣. The standard uncertainty is then
T p temperature of machine scales, °C
1
Ts p temperature of standard, °C u(␣) p 0.1 ␣ (6-7)
uETVE p standard uncertainty due to the environ- 冪3
mental temperature variation error
for the machine scale and
u(T) p uncertainty in the measurement of the tem-

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
perature of the machine scale 1
u(␣s) p 0.1 ␣s (6-8)
u(Ts ) p uncertainty in the measurement of the tem- 冪3
perature of the standard (air temperature in
the case of the laser) for the standard.
u(␣) p uncertainty of the nominal coefficient of Of the three possibilities given above, Option (a) is
expansion of the machine scale the recommended procedure.
u(␣s ) p uncertainty of the nominal coefficient of When a laser is used as the standard, a thermal expan-
expansion of the master [u(␣s) p 0 for laser sion coefficient and an uncertainty in thermal expansion
interferometers] coefficient are required. The coefficient used to correct
␣ p thermal expansion coefficient of the laser readings for changes in air temperature
machine scale (0.93 ⴛ 10−6/°C) shall be used for the thermal expansion
␣s p thermal expansion coefficient of the stan- coefficient. Because this number is well known, the
dard (␣s p 0.93 ⴛ 10−6/°C for lasers) uncertainty in thermal expansion coefficient can be
assumed 0 for a laser.
6.2.3.3.1 Standard Uncertainty Due to the Environ-
mental Temperature Variation Error. The standard uncer- 6.2.3.3.3 Standard Uncertainty Due to Uncertainty
tainty due to the environmental temperature variation in Temperature Measurement. When a temperature is

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measured, there is uncertainty associated with this mea- 6.2.3.5 Derating Procedure Using Angular Expanded
surement. This uncertainty may come from the calibra- Thermal Uncertainty. If the angular expanded thermal
tion of the thermometer, thermometer mounting uncertainty exceeds 25% of the specification zone for a
procedures, and electronic variations. This uncertainty particular test in Table 6.3, the machine environment
can be estimated by various methods. Examples follow: does not conform to the Supplier’s guidelines, and the
(a) Option (a). The estimate may be based on the distri- User chooses not to upgrade the environment, permissi-
bution found among results of actual measurements con- ble specification zone limits for those tests shall be
ducted on a number of like objects, using the same increased. The increase shall be equal to the amount by
thermometers and the same procedures. which the angular expanded thermal uncertainty
(b) Option (b). The estimate may be based on the distri- exceeds 25% of the specification zone. The following
bution found in published data regarding the use of formula shall apply:
such thermometers and specific procedures.
Permissible
(c) Option (c). The estimate may be made from prior
specification zone p specification zone (6-11)
judgment regarding the range of possible error. For the + [UT(A) − 0.25 specification zone]
purposes of this Standard, in the absence of other infor-
mation, it is recommended to estimate the temperature If the angular expanded thermal uncertainty exceeds
measurement uncertainty as being represented by a rect- 25% but the environment conforms to the Supplier’s
angular distribution with bounds of ±1°C when using guidelines, no derating of the specification zones for the
thermocouples and ±0.5°C when using thermistors or tests given in Table 6.3 is allowed. Methods for testing
platinum resistance thermometers (RTDs). compliance of the thermal environment to the Supplier’s
For Option (c), where the error is estimated by a rect- guidelines are given in Appendix B.
angular (uniform) distribution, the standard uncertainty
in temperature measurement is given by 6.2.4 Discussion Note: Displacement Sensors for

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
ETVE Test

冪
(a+ − a−)2
u(T) p (6-9) The choice of probe for the ETVE test strongly
12
depends upon the machine thermal environment. For
where a+ and a− are the upper and lower ranges of the example, some machines use oil showers. In this case,
rectangular distribution, respectively. inductance probes or LVDTs, meeting the requirements
of Chapter 11, are preferred because capacitance gages
NOTE: When using a laser as the standard, the uncertainty in can give erratic results in the presence of oil. It is also
temperature measurement of the standard applies to the measure-
possible, using such gages, to conduct this test with the
ment of air temperature.
machine cutting fluid on. Although the test with cutting
6.2.3.4 Derating Procedure Using Expanded Thermal fluid on is not a requirement of this Standard, it can
Uncertainty. If the expanded thermal uncertainty provide significant information regarding its effects on
exceeds 25% of the specification zone for a particular the machine performance.
test in Table 6.1, the machine environment does not
conform to the Supplier ’s guidelines, and the User 6.2.5 Discussion Note: Effects of Machine Tool
chooses not to upgrade the environment, permissible Systems
specification zone limits for those tests shall be Although the machine is in the feed-hold condition
increased. The increase shall be equal to the amount by for the ETVE test, there may be effects that can be misin-
which the expanded thermal uncertainty exceeds 25% terpreted as thermal drift due to air temperature. Varia-
of the specification zone. The following formula shall tion in supplied air and hydraulic pressures can cause
apply: changes in machine squareness and positional drift.
Also, inadequate temperature regulation of circulating
Permissible
fluids may cause angular or linear motions that are not
specification zone p specification zone (6-10)
+ [UT(L) − 0.25 specification zone] related to the environmental temperatures. Care should
be taken to interpret results and correctly diagnose the
If the expanded thermal uncertainty exceeds 25% but source of any problem.
the environment conforms to the Supplier’s guidelines,
no derating of the permissible specification zones for the 6.2.6 Discussion Note: Effects of Mean Air
tests given in Table 6.1 is allowed. Methods for testing Temperature
compliance of the thermal environment to the Supplier’s It is possible for errors caused by differential expan-
guidelines are given in Appendix B. sion to be induced in machines when they are operated
Table 6.2 gives example derating results based on the at mean temperatures significantly different from the
ETVE results of Fig. 6.2 and with the noted parameters temperature at which they were aligned and calibrated.
and assumptions. It is not within the current state of the art to develop

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Table 6.1 Specification Zones Derated Due to an Excessive Expanded Thermal Uncertainty
ETVE Used for Lengths Used for
Parameter Uncertainty Calculation Uncertainty Calculation Paragraph

Linear Positioning (per Axis) ... ... 7.3

Bidirectional systematic deviation of positioning Per axis L p Ls p axis length 7.3.4
Bidirectional accuracy of positioning Per axis L p Ls p axis length 7.3.4
Unidirectional systematic deviations of positioning Per axis L p Ls p axis length 7.3.4
Unidirectional accuracies of positioning Per axis L p Ls p axis length 7.3.4

Thermal Tests ... ... 7.6

Spindle thermal stability test Per axis L p Ls p 0 7.6.2
Thermal distortion caused by moving linear axes Per axis L p Ls p axis length 7.6.3
Composite thermal error Per axis L p Ls p axis length 7.6.4

Circular Tests ... ... 7.11

Radial deviations Zero (0) Ball bar length or 7.11.3
circular contour radius
Diagonal Displacement Accuracy RSS of per axis ETVE L p LD p diagonal length 7.7.2
values [Note (1)]
Linear Measurement Accuracy Per axis L p Ls p axis length 7.9.3

NOTE:
(1) Square root of the sum of the squares, sometimes known as root sum squares (RSS).
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

simple tests for these effects. If a machine is to be initial setup, the machine shall be turned off. However,
accepted at a mean temperature which is significantly any vibration isolation features of the machine shall be
different from that used during alignment and calibra- on unless otherwise agreed.
tion, the linear displacement accuracy and circular tests
described in paras. 7.3.2.1 and 7.11 shall be repeated for 6.3.2.3 Test Location. In the absence of other guid-
each temperature. It is the requirement of this Standard ance, the position used for the relative vibration test
that the Supplier specify quantitatively the magnitude shall be the same position used for the ETVE test.
of temperature change that is significant, the significant
mean temperature change (SMTC), for a given machine 6.3.2.4 Measurement Procedure
of given working tolerance. Furthermore, the Supplier (a) Attach the test ball or other artifact to the machine
shall specify a safe operating temperature range (SOTR) spindle.
within which the machine should be kept to prevent (b) Attach indicator(s) to the work-holding machine
physical damage to the machine. table.
(c) Align displacement indicator(s) with one (the)
nominal machine axis direction(s).
6.3 RELATIVE VIBRATION TESTS
(d) Sample the displacement indicators at a minimum
6.3.1 General rate of 1 kHz for a period of between 1 sec and 5 sec.
(e) Record the displacement amplitude as a range of
The relative vibration tests are used to assess the
values.
effects of environmental vibration on the performance
tests and machine performance. In all cases, the vibra- (f) Repeat the sampling and recording at least 10
tion of interest is between the workpiece-holding part times over a period of 10 min.
of the machine and the tool-holding part of the machine. (g) Repeat for all nominal axis directions as required.

6.3.2 Test Procedure 6.3.3 Data Analysis

6.3.2.1 Suggested Equipment
(a) The maximum range of the displacement indica-
(a) high-resolution, high-bandwidth displacement
tor(s) reading over any of the 5 sec test periods along
indicator
each machine axis direction shall be reported as the
(b) test ball or test artifact
relative vibration for that axis direction.
(c) gage holding fixture
(b) The test environment shall be considered accept-
(d) data recording system/software (as required)
able if the relative vibration amplitude is less than 25%
6.3.2.2 Machine Warm-Up. No specific machine stabi- of the machine specification zone for bidirectional
lization is required for the relative vibration tests. After repeatability for the appropriate axis.

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ASME B5.54-2005

Table 6.2 Example Calculations for Derating of Specification Zones

Due to Thermal Uncertainty

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Parameters Used for Uncertainty and Derating Calculations
u ␣s u Permissible
Test Specification ␣ Used, (␣), Used, (␣s), Specification Amount
Time, Zone, ETVE, Length, ␮m, ␮m, ␮m, ␮m, u(T), u(Ts), ucT(L), ±UT(L), Zone, Derated,
Parameter hr ␮m ␮m mm m°C m°C m°C m°C °C °C ␮m ␮m ␮m ␮m

Linear Positioning (Z-Axis)

Bidirectional systematic deviation of positioning 1 60 8 300 11.7 0.68 0.93 0 0.58 0.58 3.1 12 60 0
Bidirectional accuracy of positioning 1 60 8 300 11.7 0.68 0.93 0 0.58 0.58 3.1 12 60 0
Unidirectional systematic deviations of positioning 1 40 8 300 11.7 0.68 0.93 0 0.58 0.58 3.1 12 42 2
Unidirectional accuracies of positioning 1 40 8 300 11.7 0.68 0.93 0 0.58 0.58 3.1 12 42 2

Thermal Tests (Z Direction Only)

Spindle thermal stability test 2 40 16 0 N/A 0 N/A 0 0.58 0.58 4.6 18 48 8
Thermal distortion caused by moving linear axes 2.5 40 20 300 11.7 0.68 0.93 0 0.58 0.58 6.1 25 55 15

52
Composite thermal error 3.5 40 28 300 11.7 0.68 0.93 0 0.58 0.58 8.3 33 63 23

Circular Tests
Radial deviations 0.5 30 0 150 11.7 0.68 11.7 0.68 0.58 0.58 1.1 6 30 0

Linear Measurement Accuracy (Z-Axis) 0.5 60 4 300 11.7 0.68 0.93 0 0.58 0.58 2.4 9 60 0

Diagonal Displacement Accuracy 4 60 35 1 591 11.7 0.68 0.93 0 0.58 0.58 14.9 60 105 45

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GENERAL NOTES:
(a) Vertical machine center work volume 1 000 ⴛ 1 200 ⴛ 300 mm (X, Y, Z).
(b) Ball bar length 150 mm for radial deviations test; ball bar material: steel.
(c) From graph of Fig. 6.2, ETVEX p 8 ␮m, ETVEY p 10 ␮m, ETVEZ p 32 ␮m.

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(d) Mean temperature for machine and standards is 22°C during all tests.
(e) Temperatures of machine scale, atmosphere, and ball bar measured with thermocouples with accuracy of ±1°C.
(f) Coverage factor of 2 used for expanded thermal uncertainty in all cases of this example table.
(g) Calculations for other directions can be done in similar fashion.
NUMERICALLY CONTROLLED MACHINING CENTERS
METHODS FOR PERFORMANCE EVALUATION OF COMPUTER

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
METHODS FOR PERFORMANCE EVALUATION OF COMPUTER ASME B5.54-2005
NUMERICALLY CONTROLLED MACHINING CENTERS

Table 6.3 Specification Zones Derated Due to an such tests should run for a complete daily cycle. For
Excessive Angular Expanded Thermal Uncertainty practicality, however, only a minimum duration is rec-
Parameter Paragraph
ommended. The minimum duration is 10 min. These
tests do not constitute a well-defined measurement of
Angular error 7.4.2.3 the forced vibration amplitude, but rather some compli-
Squareness between linear axes 7.4.4.1 cated function that only relates in a very general way
Parallelism 7.4.4.2
to that amplitude. If the machine does not pass the
Alignment between a linear and a rotary axis 7.4.4.3
functional test, Appendix C provides recommended pro-
cedures for accurate measurement of the vibration spec-
tra at the User–Supplier interface for determining
conformance to the Supplier’s specifications. The vibra-
Table 6.4 Performance Parameters Derated Due
tion tests described above do not assess the classical
to Excessive Environmental Vibration
dynamic performance of the machine tool when sub-
Parameter Paragraph jected to cutting conditions, which lead to regenerative
Positioning Accuracy and Repeatability 7.3
chatter.
Unidirectional accuracies of positioning 7.3.4
Bidirectional accuracy of positioning 7.3.4
Bidirectional repeatability 7.3.4 6.4 ELECTRICAL TESTS
Unidirectional repeatabilities 7.3.4
Well-defined procedures and highly developed instru-
Spindle Axis of Rotation (per Spindle) 7.5 ments exist to characterize the electrical power supplied
Radial error motion 7.5.3.1 to a machine. It is, however, the position of this Standard
Axial error motion 7.5.3.3
that such tests are, in the general case, not required and
Circular Test 7.7.3 should be undertaken only if the machine does not meet
Diagonal displacement 7.7.2 performance specifications and there is reason to suspect
Subsystems repeatability 7.8 the electrical power. Failures due to electrical power
Tool change repeatability 7.8.2 usually become apparent as intermittent control or read-
Pallet change repeatability 7.8.3 out failures, which are difficult to link to mechanical
Tool-setting repeatability 7.8.4
causes. In the case that the power is suspect, this Stan-
Machine Performance as a Measuring Tool 7.9
dard provides Appendix D, which describes the recom-
Feature location repeatability 7.9.2 mended procedure for determining the conformance of
Probe lobing 7.9.2.4 the electrical environment to the Supplier’s guidelines.
Workpiece location 7.9.5 It should be noted that particular attention must be
given to the proper grounding of the machine in accor-
dance with the Supplier ’s guidelines, provided that
these guidelines do not contradict local and national
Permissible specification zone limits for specific tests codes such as the latest edition of the National Electric
in this Standard, given in Table 6.4, shall be automati- Code (NEC). An example of this contradiction would
cally increased to 4 times the measured vibration ampli- be to install an isolated ground rod (not physically con-
tude if nected to the power system ground system) at the
(1) the relative vibration amplitude, measured with machine. Improper grounding of electrical equipment
the machine off, exceeds 25% of the specification zone is one of the most common causes of improper electrical
of the machine for a particular test performance.
(2) the machine vibration environment does not
conform to the Supplier’s guidelines
(3) the User chooses not to upgrade the envi- 6.5 UTILITY AIR AND OTHER TESTS
ronment
The vibration will then be 25% of the new specifica- As with electrical power tests, there also exist many
tion zone. complicated procedures for determining the quality of
the utility air, hydraulics, or other services to the
NOTE: This test does not measure vibrations caused by machine
electronics, hydraulics, axis drives, etc. Further tests given in this machine when such services are required. It is the posi-
Standard will provide this information (see para. 7.5.2). tion of this Standard that exhaustive tests should not
be required for checking conformance to specification
6.3.4 Discussion unless a problem traced to the air or other supply is
The relative vibration tests should be conducted to evident. As stated previously, variations in the mean
include both the steady-state vibrations and any tran- value of the supplied air pressure can, on certain
sients that might occur during normal use. In principle, machines, cause changes in machine squareness and

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positional drifts, so that if such changes occur air pres- for determining conformance of User-supplied air or
sure is a possible suspect. It shall therefore be the respon- other services to the Supplier’s specification. If, however,
sibility of the Supplier to examine, using the gages the Supplier judges such fluctuations to be insignificant,
supplied with the machine, the mean pressure and pres- then the utility air and/or other services shall be judged
sure variations of air or other services at the input to as conforming to specification, without further testing.
the machine. If, in the Supplier’s judgment, such fluctua-
tions are excessive, then further tests shall be performed
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ASME B5.54-2005

Chapter 7
Machine Performance

7.1 GENERAL Supplier-specified functional checks shall be completed

before starting performance testing. A minimal set of
The Supplier shall be responsible for providing a
functional checks is given in Appendix E. All perform-
machine that meets all performance specifications
agreed upon between the Supplier and User when the ance tests in Chapter 7 of this Standard shall be carried
machine is installed according to the Supplier’s recom- out with the machine in an unloaded condition (i.e.,
mendations in any environment meeting the require- without a workpiece, unless specified otherwise; e.g.,
ments of Chapter 5. If required, derating of the para. 7.9.5).
acceptable specification zones is applied as described in Users should be aware that changing machine param-
Chapter 6. Note that the specification zone for any given eters or adjustments of any kind may affect the results
test is the value given in para. 1.1. If a machine meets the of various performance tests. When using this Standard
performance specifications and other conditions agreed for machine acceptance, these parameter changes and
upon between the Supplier and the User, then the User adjustments should be made prior to the commencement
should accept the machine. of acceptance testing.

7.1.1 Test Conditions 7.1.1.4 Compensation Systems. Some machines are

equipped with computer-controlled compensation sys-
7.1.1.1 Environment. Where the temperature of the
tems for geometric and/or thermal errors. If the machine
environment can be controlled, it shall be set to 20°C.
is so equipped, tests should be run with the compensa-
Otherwise, the measuring instrument output and the
tion system ON. Users desiring to see uncompensated
machine nominal readings shall be adjusted to yield
errors may request, as part of the original specification,
results corrected to 20°C, where applicable. This means
that these tests also be performed with the compensation
that for material standards, a nominal differential expan-
system OFF.
sion (NDE) correction shall be applied (see para. 4.1)
and other instruments, such as laser interferometers, 7.1.1.5 Machine Warm-Up. The tests shall be pre-
shall be compensated for environmental conditions. ceded by an appropriate warm-up procedure. If the pro-
Those tests where environmental compensation and cedure is not specified in this Standard for a particular
NDE correction shall be used are listed in Table 6.1 (see test, it may be specified by the Supplier of the machine
para. 6.2). and/or agreed between the Supplier and the User. If
The machine and, if relevant, the measuring instru- no conditions are specified, the preliminary machine
ment or artifact standard shall have been in the test
movements shall be restricted to only those necessary
environment long enough (preferably overnight) to have
to set up the measurement instrument.
reached a thermally stable condition before testing. They
shall be protected from drafts and external radiation
7.1.2 Foundation Checks and Machine Alignment
such as sunlight, overhead heaters, machine lights, etc.
All tests should be run under the lighting conditions Before performing any measurements, it is advisable
that will be used during normal machine operation; that to align the machine following the Supplier’s recom-
is, if the machine is to be run with its internal lights on, mended procedures. If the machine has more than three
it should be tested with the lights on. (For a thorough supports, particular attention should be paid to checking
discussion of thermal effects, see ASME B89.6.2.) that the foundation is properly cured and meets the
7.1.1.2 Sign Conventions. In addition to magnitude, Supplier’s specifications.
the signs of machine performance parameters can be
important when communicating and analyzing mea- 7.1.3 Tool Holders
surement results and when making compensations and Several of the performance tests described in this Stan-
adjustments. Recommendations are given in Appen- dard require the use of a tool holder to attach instrumen-
dix N. tation to the machine. Unless otherwise agreed upon
7.1.1.3 Machine to Be Tested. The machine shall be between Supplier and User, the tool holder to be used
completely assembled and fully operational. All the nec- for these tests shall be the one supplied with the machine
essary leveling operations, geometric alignments, and and used during the normal machine operation.

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7.1.4 Test Setup and Instrumentation (j) The arithmetic sum of the hysteresis values for the
datum fixture and indicator fixture is the total test setup
7.1.4.1 General. Most measurements prescribed in
hysteresis.
this Standard are carried out to measure motion between
The sensitivity of the result to the magnitude of the
the table of the machine that holds the workpiece and
force is, in general, insignificant. If significant hysteresis3
the spindle that holds the cutting tool. All test setups
is measured, and if this hysteresis cannot be reduced by
normally involve two fixtures: one that establishes the
increasing the stiffness of the test setup, it may be caused
reference point or surface and one that holds some type
by the machine itself. In such cases, further testing shall
of indicator to read against this reference point or sur-
be discontinued until this condition is corrected.
face.1 The specific setups and instrumentation are pro-
vided for suggestions only. Other instrumentation and 7.1.4.3 Setup Stability Tests. Machine tools are sub-
setups providing comparable results can be used as well. ject to a wide variety of vibrations from both internal
However, before starting any of the measurements, the and external sources. These vibrations vary in both fre-
User of this Standard has to make sure that the particular quency and amplitude, depending on time and location
setup and instrumentation function properly within the within the machine and machine axis positions. The
machine tool environment. Two main tests are recom- stiffness and damping characteristics of machines may
mended for such checks: setup hysteresis and stability. exclude these vibrations from having an effect on the
actual performance of the machine. However, improper
7.1.4.2 Setup Hysteresis Test. The goal of this test is
mounting of test equipment may also make the instru-
to discover any hysteresis effects, which may be caused
ment/test sensitive to these vibrations. The setup stabil-
by loose bolts in test setups, insufficient structural
ity test is designed to ensure that the mounting of
strength in the brackets, etc. Any hysteresis is normally
instruments does not significantly affect the uncertainty
revealed as a lack of repeatability in machine perform-
of measurements.
ance testing.
The procedure is as follows:
Setup hysteresis is measured by applying a suitable
force,2 in the direction of the intended measurement, (a) Mount the measuring instrument in the manner
between these two fixtures and observing the resulting used for the performance test.
deflection. (b) Position the machine in the middle of travel for
The procedure is as follows: the performance test.
(a) Set up and zero an indicator between the two (c) Set the instrument to zero and sample the output
fixtures in the direction and location of the intended at a rate and time equal to those used in the test,4 without
axis performance test. moving the machine.
(b) Apply the force, by hand, to the fixture holding The mounting of instruments can be altered to reduce
the datum reference. the range of sampled data. Mountings preferably should
(c) After the force is applied, gradually decrease this be stiffened; however, softening of mounts can also
force to zero and read the indicator. reduce the sensitivity to certain vibrations. If changes
to the mounting do not reduce the range, the machine
(d) Apply a force by hand in the opposite direction,
itself may be responsible. Check seismic vibration and
gradually decrease the force to zero, and read the indi-
continue testing.
cator.
(e) The difference in readings is the datum hysteresis.
(f) Apply the force to the fixture holding the indicator. 7.2 MACHINE COMPLIANCE AND HYSTERESIS
(g) Gradually decrease this force to zero and read the
indicator. 7.2.1 General
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(h) Apply a force by hand in the opposite direction,
This test is designed to estimate machine compliance
gradually decrease the force to zero, and read the indi-
and hysteresis when a static load is applied between
cator.
the tool and the workpiece. It provides a simplified indi-
(i) The difference in readings is the indicator fixture cation of what more rigorous compliance testing would
hysteresis. measure. Compliance values vary as functions of the
position of the machine tool axes. The linear compliance
1
The reference point can be the ball (ETVE test) or the retroreflec- is measured near the center of the work zone at a point
tor (linear displacement accuracy test). The indicator can be a
capacitance gage, an eddy current probe, a laser interferometer,
defined by the Supplier and is measured for each linear
or a dial indicator. positioning axis. In general, the Supplier shall specify
2
The range of forces can be between 22 N (5 lb) and 220 N
(50 lb), depending upon the test setup and the resolution of the 3
indicator. The forces applied should not threaten damage to the Conventional practice is that the setup hysteresis be less than
machine or the metrology setups. Forces of less than 44 N (10 lb) one-tenth of the desired measurement repeatability.
4
are recommended to avoid causing machine hysteresis. No attempt The range of the data sampled should not exceed 10% of the
is made to measure the forces. specification zone for the performance test.

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Table 7.1 Suggested Maximum Loads for the Spindle

Machine Compliance and Hysteresis Test
(Not for Spindles With More Than 10,000 rpm)
Spindle Torque Force
N-m lb-ft N lb
Load cell
20 15 1,100 250
50 40 2,200 500
100 75 4,500 1,000
150 110 6,650 1,500 Indicator
200 150 8,900 2,000
250 [Note (1)] 185 [Note (1)] 8,900 2,000

NOTE:
le
(1) Includes torque greater than this number at 600 rpm. Tab

the maximum load and provide appropriate fixturing.5

If a load is not specified, suggested values are given in
Table 7.1. Fig. 7.1 Setup for Measuring the Compliance and
Angular compliance for machines with rotary axes is Machine Hysteresis of a Linear Axis
measured similarly, but at positions as defined in the
text below and at loads to be specified by the machine
Supplier.
Two test procedures are included in this section for
measurement of compliance and machine hysteresis. Spindle
The first method (para. 7.2.2) is the preferred method.
The situations in which the alternate method may be
appropriate are described in the scope of that section
(para. 7.2.3). It must be emphasized that the alternate

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method should only be considered for machines with
Indicator
scale feedback.
WARNING: The suggested loads given in Table 7.1 do not apply
to spindles with a maximum speed of more than 10,000 rpm. In
the case where such spindles are supplied, the User shall negoti-
ate appropriate compliance and machine hysteresis tests with
the Supplier.

7.2.2 Machine Compliance and Hysteresis Test: le Load cell

Linear Axes Tab

7.2.2.1 Test Setup. Typical setups for horizontal and

vertical axes are shown in Fig. 7.1 and Fig. 7.2, respec-
tively. A displacement sensor such as an electronic indi-
cator, dial gage, or laser interferometer is set to read the Fig. 7.2 Setup for Measuring the Compliance and
relative motion between the tool holder and the table Machine Hysteresis of a Linear Axis in a Vertical
along the linear axis. A load cell is aligned with the Direction
machine axis to be tested and rigidly fixtured between
the machine table and the spindle. It is recommended
that the setup should be such that the load cell will
function under tension and compression. If the machine 7.2.2.2.1 Equipment
has backlash compensation, this test is conducted with (a) displacement indicator
the backlash compensation on. (b) force gage (load cell)
7.2.2.2 Test Procedure 7.2.2.2.2 Machine Warm-Up. No warm-up condi-
tion is required.
5
Since the loads applied are large, appropriately tested and
Supplier-approved fixturing is essential for the safety of personnel 7.2.2.2.3 Test Location. The machine axes shall be
and the machine. positioned in the center of their respective ranges.

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150

125

100
⫹ Preload
75

50
250 ␮m
25 deflection
Deflection, ␮m

⫺25
Hysteresis
⫺50

⫺75 ⫺ Preload

⫺100

⫺125
⫺150
⫺5,000 ⫺Fmax ⫺2,500 0 2,500 Fmax 5,000
Force, N

Fig. 7.3 Typical Plot Showing Results of a Compliance and Axis Hysteresis Test

7.2.2.2.4 Measurement Procedure 6 deflections divided by the total range of force (expressed
(a) Zero the indicator at the beginning of each test. as mm/N or in./lb). The machine hysteresis for the
(b) Move the machine axis under test in small incre- axis is computed as the range of deflection between the
ments until the maximum force specified or a maximum positive preload and negative preload points (expressed
deflection7 of 250 ␮m (approximately 0.01 in.) has been as millimeters or inches). The values to be used for these
reached. Call this the positive direction. computations are indicated in Fig. 7.3.
(c) Record the command position, actual position,
and force. 7.2.3 Alternate Machine Compliance and Hysteresis
(d) Jog the axis in the opposite (negative) direction Test: Linear Axes
until the force drops to 1% of the maximum force (posi- 7.2.3.1 Scope. The alternate compliance and machine
tive preload). hysteresis test procedure may produce different results
(e) Record the command position, actual position, compared to those obtained following the primary pro-
and force. cedure. For machine axes with rotary encoder feedback,
(f) Continue jogging in the same (negative) direction the compliance and hysteresis values computed will
until the force (or deflection) reaches its maximum value. probably be less. Thus, the machine performance will
(g) Record the command position, actual position, be overestimated using the alternate method.
and force. For machine axes with scale feedback, the alternate
(h) Jog the axis back in the plus direction until the test procedure will likely produce similar results com-
force drops to 1% of the maximum force (negative pared with the primary method for both compliance
preload). and hysteresis. In this case, the alternate method may
(i) Record the command position, actual position, be preferred as it generally requires less range on the
and force. displacement indicator. Therefore, it allows the use of a
higher resolution displacement indicator. In addition,
7.2.2.3 Data Analysis. To evaluate machine compli-
the resolution of the machine display does not affect the
ance and hysteresis, the deflection (actual position
resolution of the measurement.
minus command position) at each of the four measure-
ment points is computed. The compliance in the direc- 7.2.3.2 Test Procedure
tion of the axis is computed as the total range of the
7.2.3.2.1 Equipment
6
(a) displacement indicator
Performing the test in this fashion removes any effects due to
clearance in the test fixtures or deflections of the load cell. (b) force gage (load cell)
7
The deflection is defined as the difference between the actual (c) linear actuator (e.g., differential screw, hydraulic
position and the command position. jack)

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Spindle
Clamp
Spindle

Load cell R Indicator

Offset bracket
Load cell
Bracket R
Indicator
Tilt table
Table
h

Rotary table
xis
X-a
Fig. 7.5 Setup for Angular Compliance
Measurement on a Tilt Table

(m) Repeat the measurement procedure for each axis

Fig. 7.4 Setup for Angular Compliance
direction.
Measurement on a Rotary Positioning Axis
7.2.3.3 Data Analysis. The compliance for each axis
is reported as the total range of recorded displacements
7.2.3.2.2 Machine Warm-Up. No warm-up condi- divided by the total range of recorded forces.
tion is required. The machine hysteresis for each axis is computed as
the range of measured displacements between the posi-
7.2.3.2.3 Test Location. The machine axes shall be tive preload and negative preload points (expressed as
positioned in the center of their respective ranges for micrometers or microinches).
this test.
7.2.4 Machine Compliance and Hysteresis Test:
7.2.3.2.4 Measurement Procedure
Rotary Machining Axes
(a) Connect linear actuator and force gage in series
between spindle and worktable. 7.2.4.1 Test Setup. Two typical setups for measuring
(b) Set up displacement indicator to record relative the compliance and hysteresis of the rotary axis are
displacement between spindle and worktable. shown in Figs. 7.4 and 7.5. A load cell is aligned parallel
with one of the linear axes of the machine that has
CAUTION: Place the displacement indicator as near as possible
been previously tested and rigidly fixtured between the
to the point of force to minimize the effects of tilt errors.
machine table and the spindle at a distance, R, from the
(c) Create a zero-force condition with the linear center of rotation of the rotary axis. The distance, R, and
actuator. the maximum force shall be specified by the Supplier. An
(d) Set zero on the displacement indicator. indicator is set to read the relative linear displacement
(e) Operate the actuator to achieve the maximum test between the bracket on the rotary table and the spindle.
load (or maximum deflection of 250 ␮m). Call this the If the machine has compensation for backlash, this test
positive direction. is conducted with the compensation on.
(f) Record the force and displacement. 7.2.4.2 Test Procedure
(g) Operate the actuator in the opposite direction until
the force drops to 1% of the maximum force (positive 7.2.4.2.1 Equipment
preload). (a) displacement indicator
(h) Record the force and displacement. (b) force gage (load cell)
(i) Continue operating the actuator in the same (nega- 7.2.4.2.2 Machine Warm-Up. No warm-up condi-
tive) direction until the force (or deflection) reaches its tion is required.
maximum value.
(j) Record the force and displacement. 7.2.4.2.3 Test Location. The machine axes shall be
positioned in the center of their respective ranges for
(k) Operate the actuator in the opposite (positive)
this test.
direction until the force drops to 1% of the maximum
force (negative preload). 7.2.4.2.4 Measurement Procedure
(l) Record the force and displacement. (a) Zero the indicator at the beginning of each test.

59
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(b) Move the rotary axis in small increments until the For rotary machining axes with clamping capability
maximum force specified has been reached. that will also be used as rotary positioning axes, this
(c) Record the angular command position, actual test shall also be performed.
position (indicator reading), and force.
(d) Jog the axis in the opposite (negative) direction 7.2.6 Alternate Machine Compliance and Hysteresis
until the force drops to 1% of the maximum force (posi- Test: Rotary Axes (Machining or Positioning)
tive preload). 7.2.6.1 General. The alternate compliance and
(e) Record the angular command position, actual machine hysteresis test procedure may produce different
position, and force. results compared to those obtained following the pri-
(f) Continue jogging in the same (negative) direction mary procedure. For machines with indirect rotary posi-
until the force (or deflection) reaches its maximum value. tion feedback, the computed compliance and hysteresis
(g) Record the angular command position, actual values will probably be less. Thus, the machine perform-
position, and force. ance will be overestimated using the alternate method.
(h) Jog the axis back in the plus direction until the For machines with feedback that directly measures
force drops to 1% of the maximum force (negative the position of the rotary axis, the alternate test proce-
preload). dure will likely produce similar results. In this case,
(i) Record the angular command position, actual posi- the alternate method may be preferred, as it generally
tion, and force. requires less range on the displacement indicator. There-
7.2.4.3 Data Analysis. To evaluate compliance8 and fore, it allows the use of a higher-resolution displace-
machine hysteresis, the deflection (actual position minus ment indicator. In addition, the resolution of the machine
command position) at each of the four measurement display does not affect the resolution of the mea-
points is computed. The command position is obtained surement.
from the angular command position using the following 7.2.6.2 Test Procedure
formula:
7.2.6.2.1 Equipment
CM p 0.01746 ⴛ A ⴛ R (7-1) (a) displacement indicator
(b) force gage (load cell)
(c) linear actuator (e.g., differential screw, hydraulic
where jack)
A p angle command (decimal degrees)
CM p command position 7.2.6.2.2 Machine Warm-Up. No warm-up condi-
R p distance of the point of load application from tion is required.
the center of rotation
7.2.6.2.3 Test Location. The machine axes shall be
The hysteresis for the axis is similarly computed as positioned in the center of their respective ranges for
the range of deflection between the positive preload and this test.
negative preload points (expressed as micrometers or 7.2.6.2.4 Measurement Procedure
microinches). (a) Connect linear actuator and force gage in series
NOTE: The compliance for each axis is reported as the total range between spindle and worktable as described in para.
of recorded displacements divided by the total range of 7.2.4.1.
recorded force. (b) Set up displacement indicator to record relative
displacement between spindle and worktable.
7.2.5 Machine Compliance and Hysteresis Test:
Rotary Positioning Axes CAUTION: Place the displacement indicator as near as possible
to the point of force to minimize the effects of tilt errors.
The procedure and analysis described in para. 7.2.4
should be applied for this test, except for the following (c) Create zero-force condition with the linear
differences in the test procedure: actuator.
(a) Before commencing the test, the rotary axis should (d) Set zero on the displacement indicator.
be positioned and any clamping or braking mechanism (e) Operate the actuator to achieve the maximum test
used when machining should be applied to this axis. load (or maximum deflection of 250 ␮m). Call this the
(b) The motion necessary to produce a load in the positive direction.
rotary direction shall be applied by the appropriate lin- (f) Record the force and displacement.
ear axis rather than the rotary axis. (g) Operate the actuator in the opposite direction until
the force drops to 1% of the maximum force (positive
8
The composite of the compliance of the rotary axis and the preload).
other machine elements in the structural loop. (h) Record the force and displacement.

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(i) Continue operating the actuator in the same (nega- Linear

interferometer
tive) direction until the force (or deflection) reaches its
maximum value. Linear
Optics reflectors
(j) Record the force and displacement. Direction of
mounting kit
(k) Operate the actuator in the opposite (positive) movement
direction until the force drops to 1% of the maximum
force (negative preload).
(l) Record the force and displacement.
Laser
(m) Repeat the measurement procedure for each axis
direction.
Material
7.2.6.3 Data Analysis. The compliance for each axis temperature
is reported as the total range of recorded displacements sensors
divided by the total range of recorded forces calculated
Air temperature
as shown in para. 7.2.4.3. sensors
Tripod
7.3 POSITIONING ACCURACY AND REPEATABILITY
This paragraph of the Standard specifies the tests to
evaluate the accuracy and repeatability of positioning
of numerically controlled machine tool axes. The tests
address deviations in the direction of motion of an axis
at stationary target positions. The methods described
apply to linear and rotary axes, including servoed spin-
dle axes and indexing axes. Paragraph 7.3.5 describes a Fig. 7.6 Application of a Laser Interferometer to
test that focuses on the periodic term of the deviations. Test the Positioning Accuracy of a Linear Axis

7.3.1 Mode of Operation of the ball screw, are adequately sampled. Paragraph
The machine shall be programmed to move the axis 7.3.5 describes a test for periodic error.
under test and to position it at a series of target positions.
7.3.2 Test Procedure
At a target position, the machine will remain at rest long
enough for the actual position reached to be measured The measurement setup is designed to measure the
and recorded. relative displacements between the component that
For linear axes, target positions are required over the holds the tool and the component that holds the work-
full travel range. The measuring intervals shall be no piece in the direction of motion of the axis under test.
larger than 25 mm for axes of 250 mm or less. For longer 7.3.2.1 Linear Axes. The displacement shall be mea-
axes, the intervals shall be no more than 1⁄10 of the axis sured along a line through the center of the workspace,
length. When the measurement reference of the machine parallel to the axis under test. Alignment of the measur-
axis consists of several segments, additional target posi- ing instrument to the axis motion should be such that

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tions may be selected to ensure that each segment has the cosine error is less than 1% of the specification zone
at least one target position. For rotary axes, a minimum of the axis under test. A laser interferometer is the pre-
set of nine target positions is required over the full travel ferred measuring instrument. A typical setup for a mov-
range. For axes exceeding 360 deg, the total measure- ing table machine is shown in Fig. 7.6. If possible, the
ment travel of the axis up to 1,800 deg (five revolutions) retroreflector should always be the moving element, par-
shall be tested at intervals not exceeding 180 deg. Over ticularly on very accurate machines. The optics associ-
an angle of 360 deg in the normal working area, addi- ated with the tool should be mounted in the spindle.
tional target positions may have to be added such that However, on machines where the spindle cannot be
within this angle the intervals do not exceed 45 deg. For locked, a bracket should be made to position the optics
indexing axes, the number of target positions may equal near the point where a tool would be, with the bracket
the number of indexing positions. attached to the spindle housing.
It is recommended that the target points should not This Standard requires that the nominal differential
be the points used by the Supplier to acquire data used expansion (NDE) correction be performed for linear dis-
for error compensation. Furthermore, it is desirable to placement measurements. In addition, an interferometer
either choose a nonuniform spacing of the target points must be compensated for air pressure and air humidity.
or to select an interval that is not an even fraction of The environmental compensation unit supplied with the
the pitch of the axis measurement system. This ensures laser interferometer must be used for all these correc-
that periodic errors, such as errors caused by the pitch tions. The part temperature sensor must be placed in a

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Angular Reflector
Angular retroreflector Electronic indicator
reflector mount
Angular Calibrated
interferometer auxiliary Anti-rotation
rotary device
Laser table

Calibrated auxiliary
rotary table
0
Rotary axis
Clamping 0
being
Tripod plate
calibrated Rotary table

Fig. 7.8 Setup for Adjusting the Alignment of an

Indexing Table and a Laser Angle Interferometer
Fig. 7.7 Setup for Measuring the Positioning
Accuracy of a Rotary Table With a Laser Angle
Interferometer and a Calibrated Indexing Table used that exceed the measuring range of the instruments.
Most angular indicators can have large errors if not
properly aligned and need to be corrected for nonlinear-
position where the temperature corresponds, as closely ity if the measurement angle exceeds a few degrees. In
as possible, to the temperature of the machine scale or such cases, the indicator supplier’s recommendations
its equivalent. The position of the temperature sensor(s) should be followed. In the case of an angular interferom-
on the machine components and the type of compensa- eter, the centerline of the double retroreflector must be
tion routine shall be stated on the test sheet. The correct square with the axis of rotation. Figure 7.8 illustrates a
effective coefficient of expansion for the machine axes test for verifying this alignment. An indicator is brack-
shall be used (see para. 1.1). If the laser system does not eted to the machine slide and adjusted so that the stylus
provide for environmental correction, both laser read- contacts the outer edge of the double retroreflector. The
ings and machine readings shall be corrected manually indicator is zeroed at this point. The linear axes of the
(see Appendix H). machine are moved so that the indicator is clear of the
7.3.2.2 Rotary Axes corner cube. The auxiliary rotary table is lifted, and the
rotary axis is rotated 180 deg with the anti-rotation bar
7.3.2.2.1 Setup With an Auxiliary Rotary Table. This in place on the auxiliary table. The table is then re-
method uses an auxiliary calibrated rotary table to clamped and the machine slides are returned to their
extend the range of a small-angle indicator. Suitable original position. The procedure is repeated for a 90-
indicators are a laser interferometer with angular optics, deg and a 270-deg rotation. For each pair of rotations,

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
an autocollimator, and electronic levels. Electronic levels the reading of the indicator should be within 50 ␮m
can only be applied to test horizontal axes. A diagram (0.002 in.) to ensure an error less than 1 part in 1,000 of
for a typical setup using a laser interferometer is given the measured angle. Such a procedure assumes that the
in Fig. 7.7. An auxiliary calibrated rotary table is side faces of the angular retroreflector assembly are par-
attached to the face of the rotary axis to be measured. allel to the plane defined by the centerline of the two
The axis of rotation of the auxiliary table must be aligned reflectors to within 5 ␮m (0.0002 in.).
to the rotary axis being measured. The angular interfer-
ometer is attached to the spindle with the double retrore- 7.3.2.2.2 Setup With a Polygon. This test is per-
flector mounted on the center of the auxiliary rotary formed using a calibrated optical polygon with a mini-
table. The machine axis is commanded to move in steps mum of nine faces. For an indexing axis, the faces may
smaller than the measuring range of the interferometer. correspond to the positions of the axis. A setup is shown
After each step, the auxiliary table is moved in the oppo- in Fig. 7.9. The polygon is fixtured to the face of the
site direction to maintain a condition of approximate rotary axis to be measured. Special attention should
parallelism between the retroreflectors and the interfer- be given to the attachment of the polygon in order to
ometer. The actual angular displacement of the machine minimize any fixture-induced stresses that might distort
axis equals the observed indicator reading minus the the polygon. An autocollimator should then be placed
sum of the auxiliary table displacements. For both the so that an image is obtained from one of the polygon
autocollimator and the electronic levels, steps can be faces. The setup allows readings on the angular position

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Optical Autocollimator 7.3.3 Measurement Procedure

Rotary polygon
axis (a) Before commencing measurements, the machine
shall be run through an exercise sequence of two back-
and-forth movements between the first and last target
points.
(b) The next five sets of bidirectional measurements

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Table are made at all the target positions using the cycle
depicted in Fig. 7.11. The default traverse speed shall
be the machine’s maximum programmable feed rate.
Fig. 7.9 Setup for the Positioning Accuracy of a Other feed rates may be negotiated between User and
Rotary Axis Showing the Polygon, Autocollimator, Supplier.
and Rotary Table
(c) At each target position, the machine motion is
halted for a short duration, 1 to 5 sec, after which a
measurement is taken. On some large machines, longer
“Wobble” adjustment
Small four-jaw chuck

Encoder

Spindle
C-axis

Anti-rotation
fixture

Table

Fig. 7.10 Setup for Measuring the Positioning Accuracy of a Rotary Axis With a Calibrated Rotary
Encoder

of the machine table corresponding to each of the poly- settling times may be required. In this case, the settling
gon faces.9 time should be negotiated between the User and Sup-
plier. It is recommended that the instrument readings
7.3.2.2.3 Setup With a Rotary Encoder. This method
employs a calibrated rotary encoder to measure the be averaged for about 0.25 sec and at least 120 readings
angular displacement. A typical setup is shown in be taken to compute this average. The data shall be
Fig. 7.10. acquired without rezeroing the measurement instru-
ment. A set of measurements shall consist of the target
9
Particular attention must be paid to obtain the correct sign (±) positions and the corresponding instrument readings.
for the autocollimator reading when performing this test.

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NUMERICALLY CONTROLLED MACHINING CENTERS

Position i (m ⫽ 8)
1 2 3 4 5 6 7 8

3 Cycle j (n ⫽ 5)

= target points

Fig. 7.11 Standard Test Cycle

(d) For each target point there will be ten measure- (2) The mean unidirectional positional deviation at
ments, five in each direction. a position, xi↑ or xi↓, is the mean of the positional devia-
tions for a series of n unidirectional approaches to a
7.3.4 Data Analysis target position. It is calculated as
(a) For each measurement, the respective deviation
n
of position is calculated as the measured actual position 1
minus the target position. For each axis, the calculated
xi ↑ p 兺 xij↑
n jp1
(7-2)

deviations shall be plotted as shown in Fig. 7.12. For

clarity, the forward data are shown separately in Fig. and
7.13. On both figures the data averages are shown as
dark lines. From these data, the following parameters 1
n

shall be computed for each axis and compared to the xi ↓ p 兺 xij↓

n jp1
(7-3)
appropriate specification zones:
(1) the unidirectional systematic deviations of posi-
(3) The estimator of the unidirectional standard
tioning, E↑ and E↓
uncertainty of positioning at a position, si↑ or si↓, is the
(2) the bidirectional systematic deviation of posi-
standard deviation of the positional deviations obtained
tioning, E
by the series of n unidirectional approaches at a target
(3) the unidirectional repeatabilities, R↑ and R↓
position. It is calculated for each position as:
(4) the bidirectional repeatability, R
(b) The computations for these and other parameters n

冪
1
are summarized in Table 7.2 and consist of the follow- si↑p 兺 (xij↑ − xi↑)2
n−1 jp1
(7-4)
ing steps:
(1) The positional deviation, xij↑ or xij↓, equals the
actual position reached by the moving part minus the and
target position. It is calculated for each approach j to
target position i. The symbols ↑ and ↓ are used to indi- n

冪
1
cate a positive and negative approach direction.
si↑p 兺 (xij↓ − xi↑)2
n−1 jp1
(7-5)

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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R1 B1
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Deviation, µm

0
E
A

–2 R

X
–4
X

X 2si or X 2 si
–6

0 500 1000 1500 2000

Position, mm

Fig. 7.12 Full Data Set for the Positioning Deviations of an Axis, Bidirectional

(4) The unidirectional repeatability at a position, (7) The mean bidirectional positional deviation at
Ri↑ or Ri↓, is the range derived from the expanded uncer- a position, xi, is the mean of the mean unidirectional
tainty of unidirectional positional deviations at a posi- positional deviations, xi↑ and xi↓, obtained from the two
tion using a coverage factor of two. It is calculated for approach directions at a target position. That is,
each position as
xi↑ + xi↓
xi p (7-10)
R i↑ p 4s i↑ (7-6) 2

and (8) The reversal deviation of an axis, B, is the maxi-

mum of the absolute mean reversal deviations, 冨Bi冨, at
R i↓ p 4s i↓ (7-7) all target positions,

(5) The reversal deviation at a position, Bi, is the B p max. [冨Bi冨] (7-11)
difference between the mean unidirectional positional
deviations, and xi↑ and xi↓, obtained from the two direc- (9) The mean reversal value of an axis, B, is the
tions of approach at a target position. It is calculated as mean of the reversal deviations, Bi, at all m target posi-
tions,
Bi p xi ↑ − xi↓ (7-8)
m
1
(6) The bidirectional repeatability at a position, Ri, Bp 兺 Bi
m ip1
(7-12)
is the range derived from an estimate for the expanded
uncertainty of bidirectional positional deviations at a (10) The unidirectional systematic deviation of
position. It is calculated for each position as positioning of an axis, E↑ or E↓, is the difference between
the maximum and minimum of the mean unidirectional
Ri p max. 关2si↑ + 2si↓ + 冨Bi冨; Ri↑; Ri↓兴 (7-9) positional deviations for an approach direction, xi↑ or

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NUMERICALLY CONTROLLED MACHINING CENTERS

–1
2s1
R1

2s1
Deviation, µm

–2

E
A
–3

–4
X

X 2si

–5

–6
0 500 1000 1500 2000

Position, mm

Fig. 7.13 Positioning Deviations of an Axis, Forward Direction Only

xi↓, at any position along or around an axis. It is the (that is, the range of the average values as shown in Fig.
range of the average plot in the forward or reverse direc- 7.12). The equation is
tion and is calculated as
E p max. [ xi↑; xi↓ ] − min. [ xi↑; xi↓ ] (7-15)
E↑ p max. [ xi↑] − min. [ xi↑] (7-13)
(12) The unidirectional repeatability of an axis, R↑
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

and or R↓, is the maximum value of the repeatability at any

position. That is,
E↓ p max. [ xi↓] − min.[ xi↓] (7-14)
R↑ p max. [Ri↑ ] (7-16)
(11) The bidirectional systematic deviation of posi-
tioning of an axis,10 E, is the difference between the and
maximum and minimum of the mean unidirectional
R↓ p max. [Ri↓ ] (7-17)
positional deviations for both approach directions, i.e.,
xi↑ and xi↓, at any position along or around the axis (13) The bidirectional repeatability of an axis, R, is
the maximum value of the bidirectional repeatability at
10
The bidirectional systematic review of positioning of an axis any position. That is,
is the preferred method for measuring positioning capability. It is
the same as the linear displacement accuracy in ASME B5.54-1992. R p max. [Ri] (7-18)

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Table 7.2 Typical Test Results for the Positioning and Repeatability of a Linear Axis
(Measured in ␮m)
Target Position, i

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1 2 3 4 5 6 7 8 9 10 11
Parameter ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑

Positional deviations, j p 1 2.3 −1.2 3.6 −0.50 3.5 0.20 3.0 −0.60 1.7 −1.9 0.40 −3.0 −0.40 −3.7 −0.20 −3.7 0.20 −3.5 0.30 −3.2 −0.10 −3.6
Positional deviations, j p 2 2.1 −1.7 3.5 −0.90 3.3 −0.60 2.7 −1.2 1.5 −2.3 0.20 −3.5 −0.70 −4.3 −0.60 −4.4 −0.20 −4.3 −0.10 −3.8 −0.60 −4.0
Positional deviations, j p 3 1.9 −1.9 3.1 −1.1 3.0 −0.70 2.4 −1.3 1.0 −2.9 −0.20 −3.7 −1.0 −4.6 −1.0 −5.1 −1.0 −5.0 −0.90 −4.7 −1.2 −4.5

Positional deviations, j p 4 2.8 −1.3 3.7 −0.20 3.8 0.10 3.6 −0.70 1.9 −1.4 0.90 −2.8 0.00 −3.6 −0.20 −3.6 0.50 −3.2 0.50 −2.8 0.40 −3.2
NUMERICALLY CONTROLLED MACHINING CENTERS

Positional deviations, j p 5 2.2 −1.9 3.2 −0.80 3.5 −0.70 2.6 −1.3 1.1 −2.3 −0.10 −3.7 −0.90 −4.5 −1.1 −4.6 −0.50 −4.5 −0.40 −4.1 −0.90 −4.5
Mean unidirectional positional 2.3 −1.6 3.4 −0.70 3.4 −0.30 2.9 −1.0 1.4 −2.2 0.20 −3.3 −0.60 −4.1 −0.60 −4.3 −0.20 −4.1 −0.10 −3.7 −0.50 −4.0
deviation, xi ↑; xi ↓
METHODS FOR PERFORMANCE EVALUATION OF COMPUTER

“Estimator of standard 0.34 0.33 0.26 0.35 0.30 0.45 0.47 0.34 0.39 0.56 0.44 0.42 0.41 0.46 0.43 0.63 0.59 0.74 0.56 0.75 0.64 0.57
uncertainty,” si ↑; si ↓
2si ↑; 2si ↓ 0.68 0.66 0.52 0.70 0.60 0.90 0.94 0.68 0.78 1.1 0.88 0.84 0.82 0.92 0.86 1.3 1.2 1.5 1.1 1.5 1.3 1.1
xi ↑ − 2si ↑; xi ↓ − 2si ↓ 1.6 −2.3 2.9 −1.4 2.8 −1.2 2.0 −1.7 0.62 −3.3 −0.68 −4.1 −1.4 −5.0 −1.5 −5.6 −1.4 −5.6 −1.2 −5.2 −1.8 −5.1

67
xi ↑ + 2si ↑; xi ↓ + 2si ↓ 3.0 −0.94 3.9 0.00 4.0 0.60 3.8 −0.32 2.2 −1.1 1.1 −2.5 0.22 −3.2 0.26 −3.0 0.98 −2.6 1.0 −2.2 0.78 −2.9
Unidirectional repeatability at 1.4 1.3 1.0 1.4 1.2 1.8 1.9 1.4 1.6 2.2 1.8 1.7 1.6 1.8 1.7 2.5 2.4 3.0 2.2 3.0 2.6 2.3
a position, Ri ↑ p 4si ↑;
Ri ↓ p 4si ↓

Reversal deviation at a position −3.9 −4.1 −3.7 −3.9 −3.6 −3.5 −3.5 −3.7 −3.9 −3.6 −3.5
Bidirectional repeatability at a 5.2 5.3 5.2 5.5 5.5 5.2 5.2 5.8 6.6 6.2 5.9

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position, Ri
Axis Deviation Unidirectional, ↓ Unidirectional, ↑ Bidirectional

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Reversal deviation, B Not applicable Not applicable 4.1 (at i p 2)
Mean reversal value, B Not applicable Not applicable −3.7
Systematic deviation of positioning, E ↓, E ↑, E 4.0 [from 3.4 − (−0.60)] 4.0 [from (−0.30) − (−4.3)] 7.7 [from 3.4 − (−4.3)]
Repeatability of positioning, R ↓, R ↑, R 2.6 (at i p 11) 3.0 (at i p 10) 6.6 (at i p 9)
Accuracy of positioning, A ↓, A ↑, A 5.8 [from 4.0 − (−1.8)] 6.2 [from 0.60 − (−5.6)] 9.6 [from 4.0 − (−5.6)]

GENERAL NOTES:
(a) The down arrows (↓) and up arrows (↑) represent approach direction.
(b) Boldface numbers in main body of table are used in last three rows of four-column portion of table.
ASME B5.54-2005
ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

(14) The unidirectional accuracy of positioning of Large thimble micrometer

(0.2 ␮m resolution)
an axis, A↑ or A↓, is a range derived from the combina-
tion of the unidirectional systematic deviation and the
estimator of the standard uncertainty of unidirectional
positioning using a coverage factor of 2. It is the range
of the uncertainty envelope shown in Fig. 7.13 and is MR
calculated as

A↑ p max. [ xi↑ + 2si↑] − min. [ xi↑ + 2si↑] (7-19)

and

A↓ p max. [ xi↓ + 2si↓ ] − min. [ xi↓ + 2si↓ ] (7-20)

(15) The bidirectional accuracy of positioning, A,

is a range derived from the combination of the bidirec- Rotary axis
tional systematic deviation and the estimator of the stan-
dard uncertainty of bidirectional positioning using a Electronic or mechanical
coverage factor of 2. It is the total range of the uncertainty indicator mounted in
tool position
envelopes shown in Fig. 7.12 and is calculated as: (0.2 ␮m resolution)
A p max. [ xi↑ + 2si↑; xi↓ + 2si↓ ]
− min. [ xi↑ − 2si↑; xi↓ − 2si↓ ] (7-21) Fig. 7.14 Setup for the Measurement of the
Periodic Angular Error With a Displacement
7.3.5 Periodic Error Indicator
This paragraph addresses the periodic term of the
positioning error by selecting a set of closely spaced 7.3.5.3 Measurement Procedure. Before commencing
target points on a small range of the axis motion. The measurements, the machine shall be run through an
test does not apply to positioning axes. exercise sequence of two back-and-forth movements
7.3.5.1 Target Points. A set of at least 20 evenly between the first and last target points. The next five
spaced target points is selected over two periods of the sets of unidirectional measurements are made at all the
expected periodic error. For a machine with a leadscrew target positions using the same procedure as for the
this would be the screw pitch, for a linear scale or angu- positioning accuracy test over the full axis range (para.
lar encoder it is the line spacing, and for laser interferom- 7.3.3).
eter scales it is the wavelength of light or a fraction 7.3.5.4 Data Analysis and Reported Parameters. The
thereof. On rotary tables whose angular position is mea- calculated deviations shall be plotted as shown in Fig.
sured by the position of a worm gear drive, the interval 7.15. The periodic error, P, is the total range of the average
shall at least correspond to two rotations of the worm. of the deviations as shown in the figure. It is computed
7.3.5.2 Setup and Instrumentation. The setup and precisely the same as the unidirectional systematic devi-
instrumentation can be identical to that used for the ation of positioning, E↑, as described in para. 7.3.4;
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

positioning accuracy test over the full axis range (para. that is,
7.3.2). Because of the small range of motion, the auxiliary
P p max. [xj↑ ] − min. [xj↑ ] (7-22)
rotary table or polygon is often not needed when testing
a rotary axis. Periodic angular positioning can also be
measured using a displacement indicator. A setup using 7.4 GEOMETRIC ACCURACY TESTS
a micrometer and an appropriate electronic or mechani-
cal indicator with a spherical stylus is shown in Fig. 7.4.1 General
7.14. At each target point the indicator is re-zeroed using All machine tools are composed of moving carriages,
the micrometer. A laser displacement-measuring inter- tables, or other elements whose purpose is to change
ferometer, or other long-range displacement indicator, the position of the workpiece with respect to the cutting
can also be substituted for the micrometer and indicator tool. It is customary to design each element to behave
shown. The angular motion, ␪ (in radians), is approxi- as a rigid body with five of its six degrees of freedom
mately the ratio of the measured displacement divided virtually eliminated, and drive that element in the
by the radius, MR, as shown in the figure. This approxi- remaining direction while measuring its motion in that
mation is only valid for small angles, and corrections direction as accurately as possible. Traditionally, the
shall be applied if the measured angle exceeds a few motion desired is the pure linear or rotary motion lead-
degrees. ing to linear and rotary machine axes. The measurement

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2.5

1.5
Error, ␮m
1
P
0.5
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

–0.5

–1
0 1 2 3 4 5
Axis position, mm

Run 1 Run 2 Run 3

Run 4 Run 5 Average

Fig. 7.15 Periodic Error, P, of a Linear Axis

of how well the individual machine elements conform When machines with more than three axes are consid-
to their ideal geometric behavior is the purpose of this ered, other geometric interrelationships between multi-
section. A typical linear carriage moving in the X direc- ple axes, such as parallelism and coaxiality of rotary
tion is shown in Fig. 7.16. One can measure six error axes, become important to machine function. Such spe-
terms associated with its motion. These measurements cial cases will not be considered here. Some machine
are the linear displacement error (positioning accuracy tool test codes also require measurement of such param-
and repeatability) along the intended direction of travel eters as table flatness, alignment of T-slots, etc. Since the
(X); two straightness errors, in this case the Y effects of such errors can be eliminated by the machine
straightness of X and the Z straightness of X; and three operator following proper procedures, these geometric
angular errors, rotations about the X-, Y-, and Z-axes, measurements are not included in this Standard.
called roll, pitch and yaw, respectively.11 Therefore, for
a three-axis machine, there are six error terms per axis 7.4.2 Individual Linear Axes
to measure plus three error terms to define the square- For each individual axis of the machine, six error terms
ness of the axes with respect to each other, yielding 21 should be measured. For each of the linear error terms,
different error terms. measurements shall be made at at least the same number
All measurements must be made with respect to the of points specified for the positioning accuracy and
same reference system to measure the relative displace- repeatability test defined in para. 7.3.1.
ments between the component that holds the tool and the
component that holds the workpiece in the appropriate 7.4.2.1 Linear Displacement Error. See para. 7.3.
direction with respect to error term of interest. There 7.4.2.2 Straightness Error. Straightness of a linear
are many acceptable ways to perform these measure- axis is measured by positioning a straightedge in the
ments. It is important that the chosen method be consist- workpiece position, aligned to the motion axis, and mea-
ent with the above-mentioned principle. suring the lateral motion in the two directions orthogo-
nal to the traverse direction, using an indicator in the
11
Although the definition of these errors appears straightforward, tool position. The best positions for performing the
there are some ambiguities. First, the value obtained for the posi- straightness measurement in the machine work zone are
tioning accuracy and for the straightness errors depends upon the those that most commonly reflect the normal position
location of the measurement, due to the effects of angular errors
of the workpiece in the work zone.
and nonrigid body behavior. Furthermore, there are two equally
valid definitions and methods for measuring straightness (see para. 7.4.2.2.1 Test Procedure. Common methods of
4.1), and the choice of which to measure depends on how the data
are to be used. Finally, the terms pitch and yaw are ambiguous straightness measurement use mechanical straight-
when dealing with axes that are not in the horizontal direction. edges, “optical” straightedges, taut wires, geometry

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Z
⑀Z
Straightedge
Y
⑀Y Straightedge
support points (3),
both sides
⑀X X n
otio
b lem
Ta

Fig. 7.17 Setup for Measuring Straightness

Using an Electronic Indicator and a Mechanical
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Fig. 7.16 Typical Linear Carriage Designed for Straightedge

Motion in the X Direction
(b) Taut Wire. Taut wires are often used for measuring
lasers, and laser straightness interferometers. the horizontal straightness on large machines. The wire
(a) Mechanical Straightedges. The straightedge is fix- is stretched along the axis direction and measurements
tured in the position where a part would be placed of wire position are made with a sensor (proximity sen-
during machining and is aligned approximately parallel sor or microscope) mounted in the machine spindle. (See
to an axis motion.12 The straightness error is measured Fig. 7.18.)
with a mechanical or electronic indicator or a plane (c) Geometry Laser. A laser head is mounted in the
mirror interferometer (if the straightedge has an optical position where a part would normally be fixtured and
quality reflective surface) mounted in the machine’s tool the laser beam aligned along the axis of motion as shown
position. This situation is depicted in Fig. 7.17. in Fig. 7.19. A sensor13 (either a lateral effect photodiode
or a quadrant photodiode) capable of measuring the
WARNING: The calibration chart of the straightedge should be lateral motion of the spindle from the laser beam is
used to determine if its accuracy is adequate enough compared
attached in the nominal tool position.
to the straightness specification of the slide under test (see Chap-
ter 11). If the straightedge is not accurate enough, the calibration WARNING: When using this method, care must be taken due
chart or a technique called straightedge reversal should be used to “wandering” of the laser beam and to intensity variations over
to eliminate the effects of straightedge errors from the measure- the beam cross-section as a function of distance, which are caused
ments (see Appendix L). However, the straightedge reversal tech- by interference, diffraction, and thermal effects. For best results,
nique does not work when measuring the vertical straightness averaging should be performed at every point, the air in the laser
of a horizontal axis when the sag of the straightedge due to path should be vigorously mixed using fans, and an adequate
gravity is important. number of repetitions should be performed.

When an interferometer is used as the measurement (d) Laser Straightness Interferometers. The most com-
sensor, the air gap between the interferometer and the monly used laser straightness interferometers consist
straightedge should be kept as small as possible to avoid of a Wollaston prism and a straightness reflector. The
effects of air turbulence. Since the measurement is differ- straightness reflector should be mounted in the position
ential and the air gap is small, it is usually not necessary where the part will be fixtured and the Wollaston prism
to make corrections for errors in laser wavelength due should be mounted in the tool position14 (see Fig. 7.20).
to atmospheric conditions such as temperature and pres- WARNING: The centerline of the straightness reflector can be
sure. For the highest measurement accuracy, however, thought of analogously to the mechanical straightedge. Thus,
these corrections should be made as described in para. extreme care must be taken in the fixturing of this reflector,
5.5.2.3.
13
Interference filters are often used at the sensor to reduce the
12
For large machines, either a very long straightedge is required effects of changes in ambient illumination.
14
or the straightedge must be staged. To improve relative alignment If, due to the difficulty of setup, the positions of the Wollaston
between stages, larger overlap of gage positions is required, but and the straightness reflector are reversed, then the measured
this increases the number of gage positions. It is thus difficult and parameter is called “lateral deviation.” This value can be converted
time-consuming to make accurate straightness measurements on into straightness as defined in this Standard by mathematically
a large machine using a short straightedge (cases exist where combining the effects of the angular motions of the slide at the
mechanical straightedges have been used successfully for distances measurement line to this measured value. Users not familiar with
up to 2 m). these calculations should avoid such setups.

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METHODS FOR PERFORMANCE EVALUATION OF COMPUTER ASME B5.54-2005
NUMERICALLY CONTROLLED MACHINING CENTERS

Spindle
Spindle

Quadrant
Microscope
photodiode

Taut wire Alignment

n
laser

io
ct
re
le

di
Tab

n
io
ot
M
Table

Weight Fig. 7.19 Straightness Setup Showing an

Alignment Laser
Fig. 7.18 Test Setup for Measuring Straightness
Using Taut Wire
speed shall be the machine’s maximum programmable
feed rate. Other feed rates may be negotiated between
User and Supplier. A set of measurements shall consist
particularly in situations where table bending is suspect. Any
of the target positions and the corresponding instrument
local bending will cause the centerline of the reflector to change
its position (see Fig. 7.20), and the result obtained will not reflect
readings.
the straightness one would obtain on a part fixtured at multiple 7.4.2.2.2 Data Analysis. For each set of bidirec-
points over the table surface. This situation can be partially
tional measurements, the best-fit line corresponding to
rectified by mounting the reflector to a secondary surface which
is kinematically supported over the table. the data is drawn or determined by software using the
least-squares method. For the purposes of this Standard,
Laser straightness interferometers, like alignment and the minimum distance between the two lines parallel
geometry lasers, are sensitive to changes in the proper- to this least-squares best-fit line that are enveloping the
ties of the air. Mixing and averaging should be used to straightness data will be considered the straightness
minimize the effects of these changes. value for that measurement. The average and the stan-
Flatness errors of the mirrors of the straightness reflec- dard uncertainty of the five straightness values calcu-
tor are also sources of measurement errors. Reversing lated as such are reported as the straightness error of
the straightness reflector, as shown in Fig. 7.20, and the axis. Straightness errors should also be plotted.
averaging the results from the two positions is conceptu-
ally similar to straightedge reversal and can cancel 7.4.2.3 Angular Error. For each linear axis, three angu-
this error. lar errors about the X-, Y-, and Z-axes, commonly called
(e) Measurement Procedure roll, pitch, and yaw, should be measured.
(1) Before commencing measurements, the 7.4.2.3.1 Test Procedure. The common methods of
machine shall be run through an exercise sequence of angular error measurement use (1) laser angular interfer-
two back-and-forth movements between the first and ometers or autocollimators to measure pitch and yaw
last target points. of an axis (rotations about axes orthogonal to the direc-
(2) The machine shall be programmed to move the tion of axis motion), and (2) differential levels to measure
axis under test, and to position it at a series of target the roll (rotation about the axis of linear motion) of
positions. horizontal axes. Differential straightness measurements
(3) At a target position, the data can be recorded are used to assess the roll of vertical axes. Differential
with the machine stationary or during continuous levels may also be used for measuring the pitch of hori-
motion. The target positions are required over the full zontal axes and the yaw and pitch of vertical axes. Geom-
travel range of the axis. The measuring intervals shall etry lasers are also capable of measuring angular errors.
be no larger than 25 mm for axes of 250 mm or less. For (a) Laser Angle Interferometer. The laser angle interfer-
longer axes, the interval shall be no more than 1⁄10 of the ometer is used for measuring rotations about the axes
axis length. perpendicular to the axis of motion (i.e., pitch and yaw).
(4) Five sets of bidirectional measurements are A typical setup using the laser angle interferometer
made at all the target positions. The default traverse is shown in Fig. 7.21, where the pitch of a horizontal
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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NUMERICALLY CONTROLLED MACHINING CENTERS

Spindle Motion directions

Straightness
Straightness optic reflector Spindle
Interferometer and
Laser bending mirror

From Retroreflectors
Table laser

To laser
Rotate reflector 180 deg
about this axis for reversal
Table

Fig. 7.20 Typical Straightness Interferometer of

the Most Common Type Fig. 7.21 An Angular Interferometer Setup to
Measure Pitch on a Machine Where the Spindle
Moves Relative to the Table
axis is being measured. In this figure the spindle is being
moved relative to a fixed table. The position of the retro-
reflector pair and the interferometer 15 should be between tool and workpiece so must be removed from
reversed if the table is the moving element. the measurement results.
WARNING: The angular interferometer, like a straightness WARNING: When using differential levels on machines that
interferometer, is extremely sensitive to local bending of the have large tilts with respect to gravity, care must be taken that
table. If the table is bent as a function of spindle motion, then both levels are properly calibrated16 (see Chapter 11) and that
the measured pitch will be greatly different than the average their weight does not affect the measurement result.
pitch of the spindle with respect to the table. Therefore, when
bending is suspected, care should be taken in mounting the (d) Differential Straightness Measurements. This mea-
interferometer in order to obtain average results. surement is performed by carrying out two parallel sets
of straightness measurements. The principle is illus-
For yaw measurements, the retroreflector and interfer- trated in Fig. 7.23, which shows the setup for measuring
ometer should be rotated 90 deg about the beam axis. the roll of a vertical axis using a mechanical square and
On machines where the spindle cannot be locked, one or two electronic indicators. Different straightness-
external brackets should be used to fixture either the measuring instruments may be substituted.
retroreflector or the interferometer in the spindle to pre- The instrumentation is set to measure straightness
vent instability. perpendicular to the line of motion of the carriage. The
(b) Autocollimator. Angular error measurement setup carriage is moved along its axis normal to the direction
with an autocollimator is conceptually identical to that of the straightness measurement and straightness data
with a laser interferometer. The interferometer is are recorded. The indicator is next mounted on an exten-
replaced by the autocollimator and the retroreflector by sion and the straightness is remeasured, being careful
an accurate, flat mirror of appropriate size. to follow the same measurement line along the straight-
WARNING: Autocollimators are sensitive to refraction in the edge. The roll in any particular vertical position is the
air and thus fans and averaging are the accepted method for difference between the two measured straightness val-
reducing these effects. ues at that position divided by the distance between the
(c) Differential Levels. Differential levels can be used two spindle positions.
for measuring roll and pitch of horizontal axes and yaw
and pitch of vertical axes, as shown in Fig. 7.22. One 16
The level calibration is particularly important on machines
level is placed in the part position and a second measur- that have large tilts with respect to gravity, where errors in the
ing level in a fixture attached to the machine spindle. calibration of the individual levels may be significant compared
with the differential angular error being measured. In all cases
The readout device is set to display the difference they should be checked by placing the levels side by side and
between the two readings of the levels. inducing a controlled tilt to assure that there is no difference. In
Differential levels are required, since most machines highest accuracy calibrations, the levels should be reversed and
two runs made, with the levels interchanged between runs and the
exhibit some tilt with respect to gravity as their axes are results averaged. Like straightedges, levels also can be compared to
moved, and this tilt has no effect on the relative position themselves by a 180-deg rotation. For the most accurate calibration,
both reversals should be performed; that is, reversal of the level
position and 180-deg reversal of each level at each position, which
15
If the interferometer and bending mirror are assembled by the would yield four complete sets of data for each measurement run
User, a great deal of care must be taken to assure that the beams on each axis. Averaging of these results will reduce many of these
are parallel. Nonparallelism can lead to large errors. effects.

72
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NUMERICALLY CONTROLLED MACHINING CENTERS

Traverse direction Spindle

Spindle position 2
(locked)
Spindle
position 1

Counter-
weighted
Electronic
offset
cs indicator
ni bracket
tro
ec
el
To
Level 2
n
c tio Square (or straightedge
dire mounted approximately
n square)
io
ot
Level 1 M
Table

To electronics
Roll Fig. 7.23 Differential Straightness Measurement
Used to Measure the Roll of a Vertical Axis
Fig. 7.22 Typical Setup Showing Differential
Levels to Measure the Roll of a Horizontal Axis
The measurement of angular displacement accuracy
and repeatability is described in para. 7.3. The measure-
ment of axial and radial errors and the tilt errors are
WARNING: Because one carriage has to be moved to accommo- covered in para. 7.5.
date the extension fixture (either table or spindle) in a direction Each of these errors should be measured using the
other than the vertical during this measurement procedure, the procedure (the number of points with the number of
roll measurement of the vertical axis must be corrected for the repetitions and directions of approach) specified for the
change in angular orientation of the table or spindle caused by displacement accuracy (see para. 7.3.1).
this motion. The effect of this angular orientation is illustrated
in Fig. 7.24. 7.4.4 Interrelationships Between Axes
(e) Measurement Procedure. This is similar to the proce- Depending upon the machine configuration, the mea-
dure for straightness errors; see para. 7.4.2.2.1. surement of alignment between machine axes can be
quite complex. This Standard provides only general
7.4.2.3.2 Data Analysis. The data shall be analyzed comments for the most commonly encountered cases.
and reported as given in para. 7.3.4, except that the Users requiring different measurement procedures shall
names of the parameters shall be as follows: make such procedures a part of the machine specifi-
(a) bidirectional systematic angular error, Eae cation.
(b) bidirectional total angular error, Aae
7.4.4.1 Squareness Between Linear Axes. Squareness
(c) unidirectional systematic angular error, Eae↑ and
is measured with a variety of instruments as described
Eae↓
below. The procedure is similar in all these cases. Two
(d) unidirectional total angular error, Aae↑ and Aae↓
nominally square reference lines are established in the
(e) bidirectional repeatability of angular error, Rae middle of the work zone where possible, each nominally
(f) unidirectional repeatabilities of angular error, Rae↑ parallel to one of the axes whose squareness to each other
and Rae↓ is to be measured. For each axis in turn, the machine is
(g) reversal deviation of angular error, Bae traversed along its motion axis and the lateral motion
between the nominal tool point and the reference surface
7.4.3 Individual Rotary Axes is measured in a direction orthogonal to the traverse
The six error terms to be measured for each rotary direction using an indicator in the tool position.
axis are the 7.4.4.1.1 Test Procedure
(a) angular displacement accuracy and repeatability (a) Mechanical Square. The square is placed in such a
(b) axial and radial motion in two orthogonal direc- way that its reference surfaces are nominally aligned
tions with the two axes whose squareness is to be measured.
(c) two tilt motions A mechanical indicator is used to trace the reference

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

Z Y

Straightness
reflector
First line of X
measurement Second line of
measurement

Tilt angle of Z-axis

caused by roll
Straightness optic
or cross slide

Line 1 Laser
X
Y

Line 2 Optical square

Fig. 7.24 Diagram Showing the Effect of Cross-
Axial Roll on the Measurement of Roll of a Vertical
Axis Using Differential Straightness Fig. 7.26 Setup for Measuring Squareness With
an Optical Square and a Straightness
Interferometer: Line 2
Y

to the straightness reflector through the optical square.

Next the straightness optics are moved and the
straightness of line 2 is measured (see Fig. 7.26) without
X
moving the optical square, straightness reflector, or laser.
Straightness
In the second method, the straightness of the first axis
reflector
is measured, as previously. The optical square is then
Straightness optic removed, and the laser is realigned with the straightness
reflector by moving the laser only. The straightness
reflector must not be moved during this procedure.
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Line 1 Laser 7.4.4.1.2 Data Analysis. The measurements

obtained are first plotted as shown in Fig. 7.27. Lines
through the measured data are obtained by a least-
Optical square squares fit.
Line 2
The slopes of these lines are calculated. These slopes
are the angular deviations between the traverse line and
Fig. 7.25 Setup for Measuring Squareness With the reference line for each axis.
an Optical Square and a Straightness Depending upon the sign convention chosen for the
Interferometer: Line 1 measurement, these two angles should be either sub-
tracted or added to determine the initial out-of-square-
ness. For the purposes of this Standard, positive
surfaces of the square along the axes of travel.
squareness will indicate greater than 90 deg, and the
(b) Straightedge and an Indexing Table.17 The straight-
negative squareness will indicate less than 90 deg.
edge is mounted to an indexing table, which is rigidly
Next the correction for the out-of-squareness of the
attached to the table of the machine. The straightedge
reference square should be applied. This must be deter-
is aligned initially along one machine axis and this refer-
mined from the calibration certificate of a mechanical
ence surface is measured as in para. 7.4.2.2. The table is
square18 or the indexing table.
then indexed 90 deg and the measurement repeated for
The locations of reference lines within the work zone
the second axis. Either a mechanical or optical straight-
must be reported along with the calculated squareness
edge may be used.
value.
(c) Optical Square and Straightness Interferometer. The
measurements may be performed in at least two ways. WARNING: Since there is no established convention for the sign
of the out-of-squareness of a reference square, careful attention
In the first method, the straightness of the first axis should be given in applying this correction.
(labeled 1 in Fig. 7.25) is measured by aligning the laser
18
A form of reversal technique can be used to calibrate a mechani-
17
The indexing table should meet the accuracy requirements cal square in situ and optical squares can also be calibrated by
specified in Chapter 11. reversal.

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NUMERICALLY CONTROLLED MACHINING CENTERS

Y Y⬘ 7.4.4.2 Parallelism Between Linear Axes. It is often

necessary to measure parallelism between linear axes
where there are more than the traditional three linear
␪Y axes. For example, parallelism may be checked between
the Z- and W-axes on a machining center, where the W
is an extending spindle.
7.4.4.2.1 Test Procedure. This test is performed by
using any straightness measurement device.
Straightness of each axis is measured using the proce-
dure described in para. 7.4.2.2.1.
7.4.4.2.2 Data Analysis. The parallelism between
two linear axes shall be calculated and reported for two
orthogonal planes. For each plane, the least-squares best-
fit lines of their respective straightness data should be
X compared to a common reference line (e.g., laser beam,
plane, etc.). The slope of the best-fit line is the angular
␪X deviation between the traverse line and the reference
line for each axis. The basic analysis is to compare the
angular deviation of the slope of the best-fit data line
X⬘ for the Z-axis from the Z reference to the angular devia-
tion of the best-fit slope line of the W-axis from the
same Z reference. The deviation can be expressed in
Fig. 7.27 Conceptual Diagram Showing the millimeters per meter or arcseconds. This is depicted in
Angles Obtained in a Squareness Measurement Fig. 7.28. More specifically, the analysis is as follows:
The parallelism of the Z-axis to the W-axis,
ParallelismZW , is defined by

ParallelismZW p ␪Z − ␪W (7-23)

La
se
r ref
ere
nc
e

W
’b
es
t-fi
ts
lop
e [␪
W ⫽
⫹0
.00
57
] (sl
WR op
Ou es
t-o to
f-p rig
ara h t)
lle
l [p
Z’ ara
be llel
st- ism
fit ⫽
Be slo ⫺0
st- pe .1
fit [␪ 97
lin Z ⫽ ] (di
e ⫺0 ve
.14 rg
] (s ing
lop )
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

es
t ol
eft
ZR )

Fig. 7.28 Analysis of Parallelism Between Two Linear Axes (Parallelism Is Calculated From the
Differences in Best-Fit Slopes of Each Profile)

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␤ ␤
X-axis X-axis

C-axis CL

␻ ␻

␸F ␸R

(a) Forward, ␪ ⴝ 0 deg (b) Reverse, ␪ ⴝ 180 deg

Fig. 7.29 Measurement of Rotary Axis Squareness Using a Mechanical or Optical Straightedge
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

where the gaging surface of the straightedge and an appro-

W′ p least-squares best-fit line to the straightness priate machine axis, called X in the figure, is measured
data for the W-axis either optically or mechanically. A least-squares fit to
Z′ p least-squares best-fit line to the straightness the data yields a line whose slope is equal to the angle
data for the Z-axis between the X-axis and the straightedge gaging surface.
ZR p reference line for the Z-axis Next the rotary axis is rotated 180 deg and a similar
␪W p angular deviation of W′ from ZR, expressed in measurement performed. In the figure we depict an arbi-
millimeters per meter or seconds trary “forward direction” with the rotary axis at zero
␪Z p angular deviation of Z′ from ZR, expressed in angle, and the “reverse direction” with the rotary axis
millimeters per meter or seconds rotated 180 deg.
The angle, ␤, in the figure is the squareness error
7.4.4.3 Alignment Between a Linear Axis and the Axis
between the straightedge and the rotary table axis
of Rotation of a Rotary Axis or a Machine Spindle. The
resulting from supporting fixtures, while the angle, ␻,
relationship between the axis of rotation of a rotary axis
is the desired squareness error. We denote the measured
or machine spindle and a linear axis is conceptually
angles and the respective orientations by ␸F and ␸R.
determined by first establishing a reference line corres-
Examination of the figure yields the relationship ␻ p
ponding to the axis of rotation. Then the motion of the 1
⁄2(␸F + ␸R).
linear axis is measured against this reference line. The
axis of rotation reference line in the plane of measure- By performing these measurements again, beginning
ment (plane containing both the axis of rotation and with the first measurement at 90 deg with respect to the
the linear axis) is determined by averaging straightness first measurement in the initial step, squareness with an
measurements at two positions of the rotary axis that orthogonal linear axis can be determined.
are 180 deg apart over the 180-deg rotation of the axis. 7.4.4.3.2 Measurement of Parallelism Using a
To indirectly represent the axis of rotation reference, Straightness Interferometer. The setup for such a mea-
sometimes a reference line perpendicular to the axis surement is shown in Fig. 7.30. The measurement is
of rotation can be established. Mechanical artifacts or conceptually similar to the squareness measurement dis-
optical methods can be used to generate these axis of cussed above.
rotation reference lines. The following equipment-
A straightness reflector is mounted to the table and
specific test setups are for examples only; any other
aligned so that its measurement axis is close to the table’s
instrument providing comparable results can be used
axis of rotation. Straightness measurement is made with
instead.
the straightness reflector in one position and then
7.4.4.3.1 Measurement of Squareness Using a rotated 180 deg in the other direction. The actual angle
Mechanical Straightedge. A typical setup for such a mea- deviation is one-half the algebraic sum of the slopes
surement is shown in Fig. 7.29. measured in the two orientations. Again, by changing
The straightedge is mounted so as to straddle the the phase of this measurement 90 deg the parallelism
rotary axis center, and the change in separation between in the other plane may also be obtained. This procedure

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NUMERICALLY CONTROLLED MACHINING CENTERS

Straightness Straightness
reflector interferometer
Spindle

Laser

Rotary
Table
table

Rotary table

Fig. 7.30 Measurement of Rotary Axis

Squareness (or Parallelism) Using a Straightness
Interferometer

can also be performed with a mechanical straightedge. Indicator

7.4.4.3.3 Measurement of Parallelism Using

(a) First Position
Mechanical Artifacts. The parallelism between a rotary
axis and a linear axis may also be measured with a simple
mechanical setup using an indicator and a precision
test ball as shown in Fig. 7.31 for a vertically oriented
rotary axis.
The precision test ball is mounted on the linear axis
and the indicator mounted to the table. The position of
the ball is moved using the machine’s controls, while
the table with the indicator reading against the ball is
rotated in order to center the ball along the table axis
of rotation close to the table surface. This position is
recorded.
Next the ball is moved to a height, h, above the table
and the indicator re-bracketed to read against the test
ball. The procedure of centering the test ball is repeated.
Test ball
The angles of the rotary axis with respect to the linear
axis are computed by dividing the differences between
the coordinates obtained by centering the ball in the
first and the second positions by the height difference
between the two setups. Two angles can be obtained
simultaneously.
The parallelism of the axis of rotation of a machine
spindle to a linear axis can be measured by inserting a
precision test mandrel into the machine spindle taper
or collet. A mechanical or electronic indicator is mounted
to the linear axis to contact the side of the test mandrel.
Indicator readings are recorded while traversing the
linear axis along the length of the mandrel.
By rotating the machine spindle with mandrel 180
(b) Second Position
deg and recording a second set of readings, the misalign-
ment of the test mandrel to the machine spindle can
be eliminated by calculation similar to the straightedge Fig. 7.31 Measurement of Parallelism of the
method described in para. 7.4.4.3.1. Z-Axis With a Rotary Table
By performing these measurements again with the
indicator contacting the test mandrel at 90 deg with
respect to the first set of measurements, the spindle
parallelism in the orthogonal direction can be deter-
mined.

77
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ASME B5.54-2005 METHODS FOR PERFORMANCE EVALUATION OF COMPUTER
NUMERICALLY CONTROLLED MACHINING CENTERS

7.4.4.3.4 Data Analysis. The squareness data shall

Spindle
be analyzed and reported according to para. 7.4.4.1.2.
The parallelism data shall be analyzed and reported
according to para. 7.4.4.2.2. X

Y
7.5 SPINDLE AXIS OF ROTATION Precision
ball
7.5.1 General ⌬X
The general problem of the specifying and testing of
axes of rotation is thoroughly treated in ASME B89.3.4M.
This Standard defines a minimum set of tests necessary ⌬Y
for ensuring spindle performance. Only the case of rotat-
ing sensitive direction will be treated (see para. 4.1). Capacitance probes
For axes of rotation, the general term, error motion,
will be used herein to refer to the relative displacement
in the sensitive direction between the tool (or gage head) Fig. 7.32 Schematic of the Test Setup for Radial
and the workpiece. Error motions in the sensitive direc- Error Motion With a Rotating Sensitive Direction
tion cause one-for-one form errors to be cut into the
workpiece and thus are most significant for machine-
tool performance characterization. Error motions per- on (i.e, with the machine in the feed-hold mode).
pendicular to the sensitive direction are considered to 7.5.2.3 Data Analysis. If the structural motion in
be in the nonsensitive direction and are not evaluated. either condition exceeds 25% of the specification zone
The measurements required by this Standard include for unidirectional repeatability (see para. 7.3.4) and the
(a) structural motion with the spindle off
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

User has met the Supplier’s guidelines regarding vibra-

(b) average and asynchronous error motions for rotat- tion and environment (para. 5.3), the Supplier shall be
ing sensitive direction responsible for rectifying the situation.
(c) average and asynchronous tilt error motions for
rotating sensitive direction 7.5.3 Spindle Tests, Rotating Sensitive Direction
(d) total axial error motion 7.5.3.1 Radial Error Motion
Optional measurements include static error motion
(see Appendix O). 7.5.3.1.1 General. The radial error motion shall be
measured by computing and displaying the error motion
7.5.2 Structural Motion, Spindle Off polar plot according to the following formula:
7.5.2.1 General. Before commencing spindle error
r(␪) p r0 + ⌬X(␪) cos ␪ + ⌬Y(␪) sin ␪ (7-24)
testing, assessing structural motions of the machine with
the spindle off is required. These tests are designed to where
point out relative motion between the spindle and the r0 p value of the offset of the center of the test
workpiece, which is caused by the machine itself, and ball relative to the center of rotation
the environment. The structural motion value is the ⌬X(␪) p output of the gage oriented with the X-axis
peak-to-valley displacement observed over a relatively ⌬Y(␪) p output of the gage oriented with the Y-axis
short time period (such as 1 sec). ␪ p angle of rotation of the spindle
7.5.2.2 Test Procedure 7.5.3.1.2 Test Procedure. Figure 7.32 schematically
7.5.2.2.1 Equipment represents a test setup for the measurement of the spin-
(a) spindle analyzer or oscilloscope dle error motions for the case of rotating sensitive direc-
(b) artifact tion. In this setup, a precision test ball or other suitable
(c) displacement sensors (2, 3, or 5) artifact such as a cylinder is mounted in the machine
spindle. Indicators are mounted to the table of the
7.5.2.2.2 Measurement Procedure. The test setup is machine in orthogonal orientations. The ball may be
the same as for the ETVE test described in para. 6.2.2. centered on the axis of rotation to minimize eccentricity,
(a) First, measure structural motion with the in which case a signal proportional to the spindle rota-
machine’s power and auxiliary systems, such as hydrau- tion angle is required. The ball may be mounted slightly
lics, turned on, but with the machine drives off (i.e., the eccentrically, and this eccentricity is used to generate
emergency stop position). the signals necessary for a polar plot. The setup for this
(b) Second, measure the structural motion with the latter case is shown in Fig. 7.33, and both cases are
machine’s power, auxiliary systems, and machine drives described in detail in ASME B89.3.4M.

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Wobble plate

Vertical gage head

Master ball C
Y X
offset in direction
of tool

Horizontal
gage head

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Fig. 7.33 Test Method for Radial Motion With a Rotating Sensitive Direction and the Ball Mounted
Eccentric to the Spindle

7.5.3.1.2.1 Equipment. The equipment includes 7.5.3.1.3 Data Analysis. At each speed a polar plot
a spindle analyzer, or oscilloscope with indicators of the of the spindle error motion shall be made for a minimum
noncontacting type, such as capacitance, with a band- of 20 revolutions. A typical plot for a single spindle
width sufficient to cover the revolutions per minute speed is shown in Fig. 7.34. For the purposes of this
range specified. The bandwidth required depends upon Standard, only two error-motion values will be com-
the number of undulations per revolution that one puted from the error motion plot. The asynchronous
desires to resolve and the revolutions per minute range error motion value shall be the maximum scaled width
of the spindle. For most machining centers, a bandwidth of the total error motion polar plot (before averaging),
of 10 kHz is acceptable for rotational speeds of up to measured along a radial line through the polar chart
6,000 rpm and scaling of this value can be used for other center, as shown in Fig. 7.34. Next, the average error
spindle speeds. The displacement indicator and test arti- motion polar plot shall be computed by averaging the
fact should meet the specifications outlined in Chapter total error motion polar plot results for the total number
11. For more detailed descriptions and background, see of revolutions. A typical average error motion polar plot
ASME B89.3.4M. is shown as the dark line in the figure. The average
radial error motion value is the scaled difference in radii
7.5.3.1.2.2 Machine Warm-Up. Radial error
of two concentric circles, centered at the LSC center, just
motion measurements shall be carried out at three spin-
sufficient to contain the average error motion polar plot.
dle speeds after the spindle has been allowed to warm
up at half of the maximum speed for a minimum of 10 7.5.3.2 Tilt Error Motion
min or after performing the short-term thermal stabil-
ity test. 7.5.3.2.1 General. Measurement of the tilt error
motion requires simultaneous measurement of the radial
7.5.3.1.2.3 Measurement Procedure error motion at two spatially separated points, as shown
(a) Rotate spindle at 10% of maximum speed and in Fig. 7.35, using radial displacement indicators 1 and
record measured average radial error motion and asyn- 4, and also 2 and 5 (test method 2). A commercial spindle
chronous radial error motion. error analyzer can be used for this purpose, or a test
(b) Rotate spindle at 50% of maximum speed and fixture with two balls with their centers spaced some
record measured average radial error motion and asyn- distance apart (50 mm is adequate; or a precision test
chronous radial error motion. mandrel or other artifact) may be attached to the spindle
(c) Rotate spindle at 100% of maximum speed and nose and aligned with high precision to the axis of spin-
record measured average radial error motion and asyn- dle rotation, in order to minimize eccentricity. As stated
chronous radial error motion. previously, the balls (or mandrel, or any master in the

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Asynchronous
error motion Spindle
value

Test mandrel
PC
1 2
LSC
Sensors (5)
5
4

Fixture

Average Average
error motion error motion 3
value

ble
Fig. 7.34 Typical Total Error Motion Polar Plot Ta
Showing Asynchronous Error Motion and Average
Error Motion Value as Utilized in This Standard

commercial system) shall have a roundness such that Fig. 7.35 Five-Sensor Test System for Tilt Error
any error in their form is less than the value of error Motion Test on a Machining Center
expected in the machine (see Chapter 11). Otherwise,
procedures taken from ASME B89.3.4M should be used
7.5.3.2.3 Data Analysis Method 1. For each spindle
to extract artifact out-of-roundness of the artifact from
speed, the average tilt error motion polar plot is con-
the measurement.
structed as the difference between the average error
Two methods are discussed for measuring tilt error
motion polar plots obtained at different tool offsets,
motion. Method 1 describes the use of two indicators
divided by the distance between the two measurements
and method 2 describes using four indicators for mea-
(nominally 50 mm). The average tilt error motion value,
suring tilt. Both procedures are acceptable methods of
calculated in radians,19 is the scaled difference in radii
measuring average tilt error motion.
of two concentric circles centered at the LSC center just
7.5.3.2.2 Test Procedure Method 1 sufficient to contain the average tilt error motion polar
(a) First a test ball or other artifact and displacement plot. This method is not reliable to assess the asynchro-
indicators are fixtured as shown in Fig. 7.32, and the nous tilt motion error.
average radial error motion and the asynchronous radial
7.5.3.2.4 Test Procedure Method 2
error motion are measured.
(a) First a test ball or other artifact and displacement
(b) Rotate the spindle at 10% of maximum speed and
indicators are fixtured as shown in Fig. 7.35, and the
measure the average radial error motion and the asyn-
average radial error motion and the asynchronous radial
chronous radial error motion.
error motion are measured.
(c) Rotate the spindle at 50% of maximum speed and
(b) Rotate the spindle at 10% of maximum speed and
measure the average radial error motion and the asyn-
calculate the average and asynchronous tilt error
chronous radial error motion.
motions as described below.
(d) Rotate the spindle at 100% of maximum speed
(c) Rotate the spindle at 50% of maximum speed and
and measure the average radial error motion and the
calculate the average and asynchronous tilt error
asynchronous radial error motion.
motions as described below.
(e) Next, refixture the ball or other artifact a distance
(d) Rotate the spindle at 100% of maximum speed
of at least 50 mm (approximately 2 in.) from the previous
and calculate the average and asynchronous tilt error
position and a second set of measurements is taken at
motions as described below.
10%, 50%, and 100% of maximum speed. Note that both
sets of measurements before and after refixture of the 19
Note that in performance forms (para. 1.2), the spindle tilt
artifact should be performed at the same spindle angles error motion is presented in the unit of seconds. One second is
(phase lock using marker or spindle encoder). approximately equal to 5 ⴛ 10−6 radians.

80
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(b) Rotate the spindle at 10%, 50%, and 100% of maxi-

Spindle
mum speed and record the total axial motion.
7.5.3.3.3 Data Analysis. At each speed, the maxi-
mum range of the displacement over approximately 20
revolutions of the spindle shall be used as a measure-
ment of total axial error motion.
Test ball
7.6 MACHINE THERMAL TESTS
Capacitance gage
7.6.1 General
For the thermal tests described in this paragraph, the
Table
machine shall be powered up with auxiliary services
operating and axis in the “feed-hold” position, with no
spindle rotation, for a period sufficient to stabilize the
effects of internal sources. The machine and measuring
instrument shall be protected from drafts and external
Fig. 7.36 Setup for Axial Error Motion
radiation such as that from overhead heaters or sunlight.
Measurement for Rotating Sensitive Direction
If the machine is equipped with an enclosure and the
machine will be operated with this enclosure closed,
then these thermal tests shall be done in this configu-
7.5.3.2.5 Data Analysis Method 2. The differences ration.
between the outputs of sensors 1 and 4 and sensors 2 All tests shall be carried out with the machine in
and 5 are used as the ⌬X and ⌬Y in the equation and the unloaded condition. In all cases, the tests shall be
r0 is set equal to zero (note that sensor number 3 is between a nominal workpiece location and a nominal
not required). The average tilt motion, in radians,19 is tool location. If any compensation capability or facilities
obtained by dividing the average error by the distance for minimizing thermal effects, such as air or oil showers,
between the sensors in the test setup. A polar plot is are available on the machine tool, they shall be used
constructed and analyzed as in para. 7.5.3.1.3. The asyn- during the tests and their existence recorded.
chronous error motion, in radians, is obtained by divid- All measuring instruments described in this para-
ing the asynchronous error by the distance between the graph must conform to instrumentation and test equip-
sensors in the test setup. ment requirements given in Chapter 11 and also be “cap”
7.5.3.3 Axial Error Motion tested according to the procedures outlined in Appendix
I. The results of the cap test on the instrument should be
7.5.3.3.1 General. To measure axial error, synchro- no greater than 10% of the expected range of deviations
nization to the spindle angular position and sophisti- during the test. Otherwise, the instrument should be
cated data analysis are not required. The measurement modified or replaced.
can be done with an oscilloscope. This test is optional,
since for many applications, such as boring, axial motion 7.6.2 Spindle Thermal Stability Test
is in the nonsensitive direction. For certain other applica- This test is carried out to identify the effects of the
tions, such as contour milling, fly cutting, and die sink- internal heat generated by rotation of the spindle and
ing, however, it can contribute significantly to machining the resultant temperature gradients on the distortion of
error and degradation of surface finish. For these appli- the machine structure observed between the workpiece
cations it is strongly recommended that these tests be and the cutting tool. This test should be performed for
performed. all spindles.
NOTE: Fundamental, residual, average, and asynchronous axial Before proceeding with this test, the machine should
error motions are described in ASME B89.3.4M. be in a quiescent state as described in para. 7.6.1, after
a soak-out period of at least 12 hr.
7.5.3.3.2 Test Procedure
7.6.2.1 Spindle Warm-Up Test. A test fixture, such as
7.5.3.3.2.1 Equipment that used for the spindle error analysis tests (Fig. 7.35),
(a) spindle analyzer or oscilloscope is used.20 This fixture, in which the displacement sensors
(b) artifact are mounted, shall be securely fixed to the nonrotating
(c) displacement probe
20
7.5.3.3.2.2 Measurement Procedure If desired, the fixturing for the gage nest and for the test
ball may be made of low-expansion material. The concept here is,
(a) Position capacitance gage as indicated in the axial insofar as possible, to check the thermal stability of the spindle
position as shown in Fig. 7.36. and not the thermal stability of the test fixture(s).

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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NUMERICALLY CONTROLLED MACHINING CENTERS

workholding zone of the machine to measure the fol- where

lowing: DXZ p tilt in the XZ plane
(a) the relative displacements between the component DYZ p tilt in the YZ plane
that holds the cutting tool and the component that holds D1 p reading of gage 1
the workpiece along the three orthogonal axes parallel D2 p reading of gage 2
to the linear axes of travel of the machine D4 p reading of gage 4
(b) tilt or rotation around the X- and Y-axes of the D5 p reading of gage 5
machine tool Ld p distance between gages 2 and 5 or 1 and 4
The sensors should be of similar sensitivity to those
used in the ETVE and spindle error tests and be of the (Note that the tilt angles are in radians,22 defined
noncontacting type (see Chapter 11). A test mandrel with respect to the gages and not to the machine’s axes.
shall be mounted on the spindle and adjusted to mini- Positive tilts indicate tilting towards the lower gage pair
mize radial runout. The sensors shall be set to read 4 and 5 used in the computation.) Based on these calcula-
positive for deflections of the mandrel toward them. tions, tilt drifts of the axis average line are plotted as
This test should be performed in a configuration sug- shown in Fig. 7.38.
gested by the Supplier; that is, if the machine has active To facilitate comparison between machines, this Stan-
spindle thermal control, as in a liquid shower machine, dard requires reporting the thermal drift of the spindle
it should be on during this test. The test may also be axis average line as close to the face of the spindle as
performed with both coolant on and coolant off.21 possible. The displacements of the axis average line at
the face of the spindle are calculated by
7.6.2.1.1 Procedure
(a) The spindle is turned on to 75% of its maximum DX p D2 − L1,2 ⴛ DXZ (7-27)
rpm.
(b) Data from the five sensors are taken at intervals DY p D1 − L1,2 ⴛ DYZ (7-28)
of a maximum of 5 min (shorter intervals than 5 min
are acceptable). DZ p D3 (7-29)
(c) The data at each interval should be averaged for
at least 5 sec to remove dynamic effects. If a digital where
measurement system is used, a minimum of four sam- DX p displacement of the axis average line at the
ples per revolution for 20 revolutions, at any time during face of the spindle in the X-direction
the 5-min period, is sufficient. DY p displacement of the axis average line at the
face of the spindle in the Y-direction
(d) During the first 30 min of the test, the range of
DZ p displacement of the axis average line at the
the data at all sensor locations shall be noted.
face of the spindle in the Z-direction
The test shall continue until the maximum change in
D3 p the reading of gage 3
any sensor reading over any 30-min period, at all of the
L1,2 p measured distance between the centerlines of
sensor locations, has reduced to 15% of the maximum
sensors 1 or 2 and the face of the spindle
change of that sensor reading over the first 30 min of
the test. However, if this condition is not achieved, the The displacements are positive in the direction of the
test will stop after 4 hr. corresponding sensors, not necessarily in machine coor-
The data shall be plotted as shown in Fig. 7.37. The dinates. The ranges of average displacements in each
zero for this figure is established by reading the sensors direction shall be reported.
immediately after spindle rotation has commenced.
7.6.2.2 Transient Shutoff Test.23 This test is performed
7.6.2.1.2 Data Analysis. The thermal tilts of the with the same setup used for spindle warm-up tests. At
spindle axis average line (refer to Fig. 7.35 for gage the end of the spindle warm-up test described in para.
designations) in two orthogonal planes are calculated 7.6.2.1, the spindle is turned off and the sensors are read
using the following formulae: for a period equal to that of the spindle warm-up test.
D5 − D 2 The data are taken at maximum intervals of 5 min, with
DXZ p (7-25) each data point being an average of all the readings
Ld

and 22
Note that in performance forms (para. 1.2), the spindle thermal
tilt error motion is presented in the unit of seconds. One second
D4 − D1 is approximately equal to 5 ⴛ 10−6 radians.
DYZ p (7-26) 23
Ld The behavior of a spindle during warm-up is often dramatically
different from its behavior during cool-down. This can lead to
significant problems when using machines in intermittent duty
21
When tests are performed using cutting lubricant, capacitance cycles. It is therefore recommended that a transient shutoff thermal
sensors should not be used. stability be measured.

82
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25 40

Sensor 1
Spindle
housing 35
temperature Sensor 4
20

30

15
Ambient temperature 25
Indicator Reading, ␮m

Temperature, C
Sensor 3

10 20

15

10

Sensor 5
0
50 100 150 200 240
5

Sensor 2

–5 0

Time, min

Fig. 7.37 Sensor Data From a Typical Spindle Thermal Warm-Up Test

obtained for a minimum of 5 sec within the 5-min inter- displacements between a nominal workpiece and a nom-
val. For a more-detailed discussion of the sampling inal tool. The test indicates the amount of drift in the
required, see para. 7.6.2.1. The data are analyzed as machine axis “home” position as well as the amount of
described in para. 7.6.2.1.2. elongation of machine scales or equivalent during the
The transient shutoff thermal stability, as the total warm-up period.
range of the linear (and tilt) readings for a period of 1
hr after spindle shutdown, shall be reported. 7.6.3.1 Test Procedure. A displacement-measuring
instrument, usually a laser interferometer, shall be set
7.6.3 Thermal Distortion Caused by Moving Linear so as to measure the distance traversed by the axis under
Axes test (corresponding to the relative motion between the
This test is carried out to identify the effects of internal nominal tool and the nominal workpiece of the machine)
heat generated by the machine positioning system (lin- between two target positions. Note that the laser inter-
ear axes only) on the machine structure observed as ferometer should have been “cap” tested as specified in

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20 40

Spindle housing
temperature 35
15

30
10 XZ plane

25
Ambient temperature
5

Temperature, C
Tilt, µrad

20

0
50 100 150 200 240
Time, min 15

–5

10

YZ plane

–10
5
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

–15 0

Fig. 7.38 Tilts of the Axis Average Line, Spindle Warm-Up Test

Appendix I. If the measuring instrument incorporates instrumentation shall be located such as to allow for
compensation for environmental factors, such as air tem- minimum opening in the machine enclosure (if sup-
perature and pressure, then these shall be used. If the plied) during the measurements.
measuring instrument incorporates facilities by which Starting from one of the reversal positions, the
the measured data can be modified for the part tempera- machine shall be programmed to move the axis to target
ture, then the part sensor shall not be used. For machines position 1, where it will remain at rest long enough for
using lasers for positioning feedback, environmental the actual position reached to be measured and recorded.
compensation for air temperature, pressure, and humid- The axis shall then move in the same direction to
ity should be used, if available, as part of the normal
target position 2, where the second reading will be taken.
machine configuration as supplied by the Supplier. An
The motion should then continue to reach the second
example of a typical test setup is shown in Fig. 7.6. The
reversal point, where the direction will be reversed. The
two target positions should be selected close to the end
readings at target position 2 and target position 1 shall
points of travel, where applicable. Two additional rever-
sal positions should be selected outside this test range then be measured and recorded during this motion in
to allow for bidirectional measurement. Measuring the reverse direction.

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average position values will then be used to compute

the thermal drift. Note that this test does not fully assess
the machine’s thermal behavior, but rather indicates
thermal problems and can be effective for machine com-
parison.
7.6.3.2 Data Analysis. At the end of the test period,
the error at the two target positions for each direction
shall be calculated at 10-min intervals. This shall be done
by subtracting the first average position reading from
all subsequent readings. The data sets shall be plotted
in the form of position error versus time graphs, an
example of which is shown in Fig. 7.40. With reference
to this figure, error e(X1↑) is the total range of thermal
drift of target position 1 in the X direction for the forward
direction, and error e(X2↑) is the total range of thermal
drift of target position 2 in the X direction for the forward
Target position 1 Target position 2 direction. The drifts in the reverse direction will be noted
similarly, using the down arrow (↓).
⫽ measurements taken The dwell (settling) times, traverse rates, setup posi-
tions, position of the air temperature sensor, type of test
equipment, and target positions shall be recorded with
Fig. 7.39 Path for Measuring Thermal Distortion the test results.
Caused by Moving Linear Axes
7.6.4 Composite Thermal Error
This test is carried out to identify the combined effects
A diagram showing this procedure is given in Fig. of the internal heat generated by the main spindle(s)
7.39. The programmed traverse rate shall be 0.5 times and the positioning systems on the relative position
the rapid traverse rate and the dwell time shall be the between the workpiece and the tool. It should be noted
settling time used for the positioning accuracy and that the results of this test cannot be derived from the
repeatability tests (para. 7.3). Different dwell times and results of the two types of tests described in paras. 7.6.2
traverse rates produce different heat inputs; therefore, and 7.6.3 of this Standard.
they cause different axis drifts. If other dwell times and
traverse rates are to be specified, they shall be the subject 7.6.4.1 Test Procedure. Figure 7.35 shows a typical
of prior agreement between User and Supplier. measurement setup for a machining center. Five dis-
The test sequence described above shall then be placement indicators shall be rigidly mounted to the
repeated, recording data bidirectionally at the two target worktable, so as to be able to measure changes in posi-
positions. During the first 30 min of the test, the range tion and tilt between the structure that holds the tool
of the data for each axis shall be reported at each target and the structure that holds the workpiece.
position for both directions of motion. The test shall Wherever possible, all the other axes and spindles
proceed until the maximum change in any axis reading should be exercised during the test.
over any 30-min period at both end points has reduced The temperature of the machine structure, as close as
to 15% of the maximum of either end point change over possible to the front spindle bearing housing, along with
the first 30 min of the test, with a maximum test period the ambient temperature, shall be continuously moni-
of 4 hr, whichever is smaller. tored. Although these temperatures do not exactly corre-
Before commencing the test on another axis, sufficient late to the measured displacements, they are indications
time should be allocated to allow for the machine to cool of the thermal changes of the machine structure.
down. The ambient temperature shall be continuously The recommended test position is at the center of the
monitored during these tests.24 Note that on a machine work zone. After reading the displacement indicators,
of normal size, a very large number of data will be all machine axes are exercised over their full travel at
produced by this test which may last as long as 4 hr. It half the maximum rapid traverse rate while taking care
is recommended that the average value over 10-min to avoid collisions with the test setup. Next the test
intervals be retained, rather than the full data set. The mandrel is returned to the test position and a new read-
ing is taken after a dwell equal to the settling time as
24
specified in the positioning accuracy and repeatability
It is useful to measure the drift during the cool-down period. test (para. 7.3). The final 5-mm approach to the test
To do this, at the end of the test period, the machine should be at
the target position which indicated the largest drift and the drift position should be carried out at a low feed rate, and the
at this position is periodically recorded as the machine cools down. direction of approach should not be changed throughout

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Target 2,
18
e (X2 )

Target 2,
16

14

12
Positioning Error, ␮m

10

Target 1,
2 e (X1 )
Target 1,

0
10 50 100 150 200 250

Time, min

Fig. 7.40 Position Error Versus Time for a Typical Test for Thermal Distortion Caused by a Moving Linear
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Axis

the test. It is recommended to run the spindle continu- Note that, as in the preceding test, a large number of
ously at half the maximum speed throughout the test. data points may be generated by this test. Again it is
Other test conditions, including variable spindle speed recommended that only the average value over a reason-
spectra, may be specified by prior agreement between able period of time, say 5 to 10 min, be retained for the
User and Supplier. The dwell time, spindle speed spec- purposes of analysis.
trum, traverse rate, sequence of axis movements, and
travel ranges change heat input and therefore can cause
7.6.4.2 Data Analysis. The effect of warming up the
different drift rates.
machine structure on the ability of the machine to main-
The test shall proceed in this manner until the change
tain the position of the tool relative to the workpiece
in the position over any 30-min period, at all the mea-
can be assessed from the deflections versus time graphs.
surement locations, has reduced to less than 15% of the
maximum position change over the first 30 min of the The results are influenced by the positional repeatability
test, with a maximum test time of 4 hr. The results should of the machine axis.
be plotted in graphs of deflection and temperature ver- The range of displacements measured by each indica-
sus time, as shown in the example given in Fig. 7.41. tor shall be reported for the first 30 min and for the

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NUMERICALLY CONTROLLED MACHINING CENTERS

60.0 30.0

Spindle temperature
50.0

40.0 Ambient temperature

25.0
Displacement, ␮m

Temperature, ⬚C
Z data
30.0 c (Z, t)

Y2 data c (Y2, t)
c (Z,30)
20.0
c (Y2,30) Y1 data c (Y1, t)
c (Y1,30)
c (X1, t) 20.0
10.0 X1 data

c (X2, t)
c (X1, 30); c (X2, 30) X2 data
0.0
0.0
10.0
19.0
28.0
37.0
46.0
55.0
64.0
73.0
82.0
91.0
100.0
109.0
118.0
127.0
136.0
145.0
154.0
163.0
172.0
181.0
190.0
199.0
208.0
217.0
226.0
235.0
244.0
⫺10.0 15.0
Time, min
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Fig. 7.41 Typical Results From a Composite Thermal Error Test

duration of the test (see para. 1.1). Furthermore, deflec- the machine at the center of the work zone or any suit-
tion versus time graphs shall be provided. The test pro- able location. The measurements shall be carried out
cedure, traverse rate, dwell time, sequence of axes along the four body diagonals of the working volume
movements, location of target positions, location of the of the machine. To adequately characterize the working
measurement setup, including the locations of the tem- volume, the measured diagonals shall be of a maximized
perature sensors, and spindle speed should also be length with recorded start and end points.
reported with the results of the tests.
NOTE: On machines with large aspect ratios, the diagonal dis-
placement measurement test can be insensitive to certain errors.
7.7 DIAGONAL DISPLACEMENT TEST One should take particular care when interpreting results in the
case of large aspect ratio machines. For these large aspect ratio
7.7.1 General machines, additional measurement of face diagonals can be useful.

These tests are used to determine displacement accu- 7.7.2.2 Test Procedure
racy of the machine along body or face diagonals. To
obtain an estimate of the volumetric positioning capabil- 7.7.2.2.1 Equipment
ity of the machine, one has to combine the results of (a) laser interferometer
these tests with those of linear displacement tests. The (b) optics for diagonal displacement measurements
linear displacement tests are preferably executed at dif- (optics for linear displacement measurements and optics
ferent Abbe offsets to assess effects of yaw and pitch for beam alignment)
errors. A more complete estimate can be obtained using (c) environmental compensation measurement
the tests in para. 7.4, which may be required for certain sensors
applications and machine configurations. (d) machine temperature sensors
7.7.2 Volumetric Performance Using Diagonal 7.7.2.2.2 Measurement Procedure
Displacement Measurements
(a) Measurements shall be made at all the target posi-
7.7.2.1 General. The procedure is similar to that tions according to the standard test cycle described in
described in the section for linear displacement accuracy, the positioning accuracy and repeatability test (paras.
except that displacement measurements are done along 7.3.1 and 7.3.3) for measuring intervals and feed rates.
the work volume’s four body diagonals. For performing If, for practical reasons, the feed rate must be reduced
these measurements, the average scale temperature shall to perform this test, the percentage reduction shall be
be assumed to be the mean temperature of the table of reported as part of the test results.

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NUMERICALLY CONTROLLED MACHINING CENTERS

(b) The measuring instrument is set up approximately

along a diagonal of the work volume. The start and end
points are aligned when a measuring signal is obtained
after jogging the machine tool axes.
7.7.2.3 Data Analysis. The data obtained for each of
the diagonals shall be analyzed in a similar manner to
that used for the positioning accuracy and repeatability,
with the exception that only the bidirectional systematic
250 mm
deviation, E, and the reversal deviation, B, are evaluated
Gage line
and reported.

7.8 SUBSYSTEMS REPEATABILITY

7.8.1 General
Machining centers are complex systems and contain
many subsystems, which also contribute to the accuracy
and performance of the machine. Three important sub-
systems that affect accuracy are the tool changer, pallet
changer, and the tool setting system.
In the computation of the tool change repeatability
Fig. 7.42 Tool Holders Used for Tool Change
and the pallet change repeatability, the standard uncer-
Repeatability
tainty of measurement for the combined effect of the
machine’s linear axis repeatability and the test instru-
ment repeatability should be determined first. Next, the Indicator
Sensor nest
standard uncertainty of measurement for the combined
effect of the machine’s linear axis repeatability, test
instrument repeatability, and subsystem repeatability
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

should be determined. Finally, the subsystem repeatabil-

ity is computed from the difference between the two
squared standard uncertainties. Tests for the three sub-
systems are addressed in the following paragraphs.

7.8.2 Tool Change Repeatability

7.8.2.1 General. Tool change repeatability is checked Sphere
using two tool holders selected from a Supplier’s speci-
fied tooling package. Precision test spheres are to be Pallet
mounted in these tool holders in a manner similar to
that shown in Fig. 7.42. One of the test spheres is at
the minimum possible distance from the tool holder or
spindle gage line, and the second test sphere is mounted Fig. 7.43 Three-Sensor Nest Setup for Tool
on a rigid column at a distance of 250 mm (approxi- Change Repeatability
mately 10 in.) from the first sphere. These tool lengths25
are default options, and the User is free to select other
lengths appropriate to his or her application, if required. spindle and the machine jogged into position such that
the three displacement indicators are nulled. This posi-
7.8.2.2 Test Procedure. The tool holders with their
tion is recorded. This procedure is repeated on the sec-
test spheres are to be inserted in User-selectable posi-
ond sphere.
tions in the tool magazine, and a displacement indicator
An automatic cycle is established to place sphere 1
nest, such as the three-sensor nest26 shown in Fig. 7.43,
into the spindle and position it to its established null in
is to be rigidly attached to the machine table or pallet
the displacement indicator nest, withdraw it safely from
in the nominal position of the part. The test then pro-
the nest, and move the spindle to the tool change posi-
ceeds as follows. The first sphere is loaded into the
tion at the tool change feed rate. Note that the tool
25 holder is not to be removed from the spindle. This cycle
Result for long and short tool length provides a basis for
estimating the tilt motions of the tool. is repeated ten times in rapid succession and the X, Y,
26
This test can, if required, be performed on an axis-by-axis basis and Z indicator readings for each trial are recorded. The
using a single sensor. estimate of standard uncertainty for the combined effect

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NUMERICALLY CONTROLLED MACHINING CENTERS

of the machine’s linear axis repeatability and the test corner of the bracket is located as close as possible to
instrument repeatability is now calculated for each the center of the pallet as shown in Fig. 7.44. The size
axis as of the angle bracket should be slightly less than half the
shortest length of the pallet. Six measurement points
n

冪n − 1 兺 (x
1 are required on the angle bracket and these points are
utx p txj − xtx )2 (7-30)
jp1 numbered 1 through 6. In addition to pallet-change posi-
tioning repeatability along the X-, Y-, and Z-axes, the
where
three tilt motions about the three axes are also deter-
n p 10 is the default value for this test
mined. For ease of measurement, the use of a spindle
utx p standard uncertainty for combined effect of
probe is recommended.
machine linear axis repeatability and test
instrument repeatability 7.8.3.2 Test Procedure. The pallet carrying the angle
xtx p average of the ten readings in the X direction bracket is loaded onto the machine table pallet receiver.
xtxj p jth reading in the X direction The face of the angle bracket is aligned to the X-axis
travel of the machine. An automatic cycle is established
Another automatic cycle is established to place sphere to probe the six measurement points. The cycle is

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
1 into the spindle and position it to its established null repeated ten times in rapid succession, and the X, Y,
in the displacement sensor nest, withdraw it safely from and Z probe readings are recorded. Note that the pallet
the nest, interchange it with sphere 2, position sphere carrying the angle bracket is not removed from the table
2 to its null position in the nest, and then withdraw and pallet receiver. This preliminary step establishes the
return sphere 2 safely to the tool magazine. This program standard uncertainty that includes the combined effect
is executed ten times in rapid succession at the tool of the machine’s linear axis repeatability and the probe
change feed rate, and the X, Y, and Z indicator readings system repeatability for both linear and tilt motion mea-
of each sphere are recorded for each trial. surements. For example,
The estimate of standard uncertainty for the combined
n

冪n − 1 兺 (x
effect of the machine’s linear axis repeatability, test 1
upx2 p p2j − xp2)2 (7-33)
instrument repeatability, and tool change repeatability jp1
is now calculated for each axis as
where
n

冪
1 n p 10 is the default value for this test
n − 1 j兺
utcx p (xtcxj − xtcx ) 2 (7-31)
p1 upx2 p standard uncertainty for the pallet linear posi-
tioning error along the X-axis that includes
where the combined effect of machine’s linear axis
n p 10 is the default value for this test repeatability and probe system repeatability
utcx p standard uncertainty for combined effect of xp2 p average of the ten readings for measurement
machine linear axis repeatability, test instru- point 2 in the X direction
ment repeatability, and tool change repeat- xp2j p jth reading in the X direction for measurement
ability point 2
xtcx p average of the ten readings in the X direction
xtcxj p jth reading in the X direction Similar calculations are performed for measurement
points 1 and 3. Next, the standard uncertainty of the tilt
7.8.2.3 Data Analysis. Tool change repeatabilities in
motion measurement in the XY plane is computed.
the X, Y, and Z directions are reported for each tool
length. For example, the tool change repeatability for (xp6j − xp2j)
the short tool length in the X direction is reported as ␤pxyj p (7-34)
Ld

Rxts p 4冪(u2tcx − u2tx) n

冪
(7-32) 1
up␤xy p 兺 (␤pxyj − ␤pxy)2
n − 1 jp1
(7-35)
where
Rxts p tool change repeatability for the short tool where
length in the X direction Ld p nominal distance between measurement
points 2 and 6
Note that these results include any thermal errors n p 10 is the default value for this test
induced by traversing the machine spindle to and from up␤xy p standard uncertainty of the tilt motion mea-
the tool change location. surement that includes the combined effect of
machine’s linear axis repeatability and probe
7.8.3 Pallet Change Repeatability
system repeatability
7.8.3.1 General. A suitably sized precision angle xp2j p jth reading in the X direction for measure-
bracket is securely bolted to the pallet such that the ment point 2

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NUMERICALLY CONTROLLED MACHINING CENTERS

Y
Pallet surface
tilt in XZ plane
Repeatability
(1 4)
3

Probe touch points

(1 through 6)
5 6
X
Z

4 d
1 2

Pallet surface Pallet surface

tilt in XY plane tilt in ZY plane
(2 6) (1 5)

Fig. 7.44 Test Setup for Pallet Change Repeatability

xp6j p jth reading in the X direction for measure-

ment point 6
␤pxy p average tilt motion of the pallet in the XY
plane
␤pxyj p jth reading of the tilt motion of the pallet in
the XY plane
Similar calculations are performed for measurement
points 1 and 4, and for points 1 and 5.
Another automatic cycle is now established to place
the pallet carrying the angle bracket onto the machine
table pallet receiver, probe and record the readings at
measurement points 1 through 6, shuttle the pallet from
the machine table receiver to the pallet stand, and return
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

the same pallet to the machine table pallet receiver. This

cycle is repeated ten times in rapid succession. The esti-
mates of the standard uncertainties that include the com-
bined effect of the machine’s linear axis repeatability,
probe system repeatability, and pallet change repeatabil-
ity for linear and tilt motion errors are evaluated as
shown before.
7.8.3.4 Data Analysis. Six pallet change repeatabili-
ties are reported; they are the three linear errors in pallet
change positioning along the X-, Y-, and Z-axes, and
three tilt motion errors in pallet-change positioning
about the X-, Y-, and Z-axes. For example, the linear
Fig. 7.45 Tool Length Measurement With No error in pallet change positioning in the X direction is
Spindle Rotation given by

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NUMERICALLY CONTROLLED MACHINING CENTERS
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Fig. 7.47 Tool Diameter Measurement

Fig. 7.46 Tool Length Measurement With
Rotating Spindle

up␤xy p standard uncertainty for the pallet tilt

motion error in the XY plane that includes
Rpcx p 4 冪u2pcx2 − u2px2 (7-36) the combined effect of machine’s linear axis
repeatability and probe system repeatability
where
Rpcx p pallet change repeatability along the X-axis Similarly, R pcxz is determined using readings from
upcx2 p standard uncertainty for the pallet linear measurement points 1 and 4, and Rpcyz is determined
positioning error along the X-axis that using readings from measurement points 1 and 5. Note
includes the combined effect of machine’s lin- that the tilt motion errors are in radians, and may be
ear axis repeatability, probe system repeat- converted into seconds using the relation 4.85 ␮rad p
ability, and pallet change repeatability 1 sec.
upx2 p standard uncertainty for the pallet linear
positioning error along the X-axis that 7.8.4 Tool Setting Repeatability
includes the combined effect of machine’s lin- 7.8.4.1 General. Some machining centers are
ear axis repeatability and probe system equipped with a sensor/probe system designed to set,
repeatability under machine control, the length and/or diameter of
a variety of tools. The performance of these sensors can
Similarly, Rpcy and Rpcz are determined using readings
vary considerably depending on their design and func-
from measurement points 3 and 1, respectively. Next,
tionality (e.g., single axis measurement, 3D probe, and
the tilt error motion of the pallet change positioning in
noncontact optical systems).
the three planes is computed. For example, the pallet
surface tilt motion in the XY plane is given by: 7.8.4.2 Scope. Some sensors can only measure tool
length without the spindle rotating. Others are capable
Rpcxy p 4 冪u2pc␤xy − u2p␤xy (7-37) of measuring length and diameter with the spindle rotat-
ing. This test will evaluate the performance of these
where systems in three modes of operation with a single tool
Rpcxy p pallet surface tilt motion repeatability in the type and will make use of the software control routines
XY plane provided by the manufacturer and/or the machine
upc␤xy p standard uncertainty for the pallet tilt OEM.
motion error in the XY plane that includes The tool will be a 50-mm diameter two flute end mill
the combined effect of machine’s linear axis of 150-mm length. If the machine is incapable of using
repeatability, probe system repeatability, a tool of this size, then a similar tool type of half the
and pallet change repeatability diameter and length should be used.

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7.8.4.3 No Spindle Rotation (Length Measurement systems, etc. To reduce the time required for testing, this
Only). Position the spindle center over the sensor/probe, Standard also incorporates into the repeatability test the
without the spindle rotating. Using the cycle provided measurement of a simple artifact.
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

by the equipment Supplier, measure the end mill length Two tests are specified. The test chosen for a particular
ten times. The repeatability is reported as 4 times the machine shall be the test for the principal mode of opera-
standard uncertainty of the measured length. See Fig. tion and probe type specified for that machine. The
7.45. artifact chosen for the test depends on this principal
mode of operation. A precision 25-mm (approximately
7.8.4.4 Spindle Rotation (Length Measurement Only).
1-in.) diameter ring gage is used for machines whose
On systems that allow length measurement with the
software allows only planar measurement. A precision
spindle rotating, select the recommended speed. Posi-
25-mm (approximately 1-in.) diameter reference sphere
tion the spindle center offset from the sensor center
is used for machines whose software allows 3D measure-
by 25 mm. Using the cycle provided by the equipment
ment. Regardless of which artifact is chosen, it must
Supplier, measure the slot drill length ten times. The
conform to the requirements of Chapter 11. Its nominal
repeatability is reported as 4 times the standard uncer-
coefficient of thermal expansion is also required for
tainty of the measured length. See Fig. 7.46.
this test.
NOTE: These systems allow for the automated length setting of Unless otherwise specified by the User, the feature
discrete cutting inserts located off the spindle axis. location repeatability and feature measurement accu-
7.8.4.5 Diameter Setting. Using the cycle provided racy tests shall be performed at the center of the work
by the equipment Supplier, measure the diameter of the zone with a default stylus length of 50 mm (approxi-
end mill ten times. The repeatability is reported as 4 mately 2 in.). It should be noted that the size value for
times the standard uncertainty of the diameter recorded. feature location repeatability and feature measurement
See Fig. 7.47. accuracy is position-dependent; therefore, the User may
specify other locations or several locations, if required.
7.9 MACHINE PERFORMANCE AS A MEASURING 7.9.2.2 Common Features. In these tests, the require-
TOOL ment in the definition of repeatability to sense the same
quantity is satisfied by measuring the center coordinates
7.9.1 General of the precision artifact rigidly mounted on the work-
The following procedures have been designed to eval- piece supporting surface near the center of the work
uate the performance of a machine tool, equipped with zone multiple times. Ten determinations of the reference
a suitable probing system, as a measuring machine. The artifact’s center shall be made as rapidly as practical to
tests below are meant to apply to machines equipped determine feature location repeatability. Feature location
to measure in the point-to-point mode. The results of repeatability will be reported on a per-axis basis. To
these tests do not reflect on the performance of the determine the feature measurement accuracy, the same
machine tool in a metal-cutting mode. The following data will be used to determine the size of the artifact
tests address the issue of measuring performance in being measured.
discrete stages that depend on the level of software
7.9.2.3 Standard Tests for Feature Location Repeat-
capability provided by the Supplier and the intended
ability and Feature Measurement Accuracy. The follow-
use of the measuring system. Testing shall be performed
ing tests are designed to assess the ability of the machine
in a manner that most closely represents the way in
to repeat a measurement and to accurately measure fea-
which the machine measurement system will be used
tures that are within the capability of the machine
after acceptance. Prior to commencing these tests, the
software.
machine probe shall be calibrated and qualified
according to the Supplier’s recommendations for normal 7.9.2.3.1 Tests Where Software Allows for Only Pla-
operation of the machine when measuring parts. Qualifi- nar Measurements
cation on the test artifact to be used for this test is (a) A 25-mm (approximately 1-in.) reference ring gage
specifically excluded. It is also assumed that prior to shall be rigidly mounted on a fixture in the part position
performing these tests, the machine performance has such that the axis of the ring is aligned with the spin-
been assessed as described in Chapter 7. dle axis.
(b) A thermometer shall be coupled tightly to the ring
7.9.2 Feature Location Repeatability (FLR) and gage to measure its temperature, and a second thermom-
Feature Measurement Accuracy (FMA) eter shall be placed at the position designated by the
7.9.2.1 General. The concept of feature location Supplier to be representative of the mean scale tempera-
repeatability testing requires that the test must evaluate ture of the machine.
the complete system, which may include effects due to (c) After alignment, the machine shall be set in its
machine characteristics, computer algorithms, control normal automatic cycle to be used for the measurement

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of a bore. (If such a normal program cycle is not available, 5 Probe

then the machine shall be set in an automatic cycle to 4
make ten sets of up to ten readings on the inner diameter
of the reference ring. Contact points for each automatic Test ball
cycle shall be spaced as widely as possible, but shall be 3 100 deg
90 deg
in the same plane.)
60 deg
(d) For each set of these data, the center coordinates
30 deg
(X, Y) and the diameter of the ring gage shall be com- 2
puted.
1
(e) Feature location repeatability shall be reported as
follows:
(1) Feature Location Repeatability FLRX. Four times
the standard uncertainty of the mean X coordinate.
(2) Feature Location Repeatability FLRY. Four times Probe points
the standard uncertainty of the mean Y coordinate.
The feature measurement accuracy (FMA) for each
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

axis shall be the difference between the average diameter

obtained from the ten sets of measurements, corrected
for temperature, and the calibrated diameter of the gage.
The diameter of the gage, corrected for machine and
gage temperatures, is given as follows:
Table
CD p MD[1 + ␣(T − 20) − ␣s(Ts − 20)] (7-38)

where Fig. 7.48 Illustration of the Probing Pattern Used

CD p corrected diameter for Determining Three-Dimensional Probing
MD p measured diameter Capability
T p average temperature of point selected as rep-
resentative of the mean scale temperature
Ts p average temperature of gage during measure-
ment (degrees Celsius)
␣ p nominal thermal expansion coefficient of the widely spaced as possible and not all on the same plane.
machine scales (d) Coordinates of the center of the ball shall be com-
␣s p thermal expansion coefficient of calibration puted for each set of readings and the feature location
gage repeatability values FLRX, FLRY, and FLRZ computed as
described in para. 7.9.2.3.1.
The Z-axis repeatability shall be determined by taking
(e) The same data shall be used to calculate the diame-
ten measurements of the position of the top face refer-
ter of the precision sphere.
ence surface on the precision ring without moving the
(f) The average diameter of the sphere, corrected for
other two machine axes. Feature location repeatability
temperature, shall be computed.
FLRZ will be reported as 4 times the standard uncertainty
The feature measurement accuracy (FMA) shall be the
of the mean Z-axis coordinate. (For the case of machines
difference between the corrected sphere diameter, as
having only planar measurements, there is no three-
measured, and the calibrated diameter.
dimensional feature measurement accuracy.)
7.9.2.4 Standard Test for Probe Lobing. While the
7.9.2.3.2 Tests Where Software Allows for 3D Mea-
machine is still set up for the repeatability and feature
surements
measurement accuracy test, it is optional that a probe
(a) The precision reference sphere shall be rigidly
lobing test be performed. For the purposes of this Stan-
mounted to a fixture in the part position such that it is
dard, probe lobing is tested in two different ways. The
readily accessible for machine probing.
first way is for machines which only allow probing in
(b) A thermometer conforming to the requirements
a plane. The second, for machines which have three-
of Chapter 10 shall be appropriately thermally contacted
dimensional measurement capability, is identical to
with the test sphere in a position that does not interfere
those tests used for coordinate measuring machines as
with probing and a second thermometer placed in a
specified in ASME B89.4.1.
position designated by the Supplier as being representa-
tive of the mean scale temperature. 7.9.2.4.1 Test for Probe Lobing Where Software
(c) Ten sets of up to 15 readings shall be made on the Allows Only for Planar Measurements. Care should be
reference sphere. Contact points for each set shall be as taken to ensure that the ring gage is aligned to the XY

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NUMERICALLY CONTROLLED MACHINING CENTERS

plane of the machine. Before commencing the test, the performance. Since the bidirectional systematic devia-
approximate center of the ring gage is determined by tion of positioning (E; para. 7.3.4) and the feature mea-
probing at the axis coordinate directions. Next, the ring surement accuracy (para. 7.9.2) have been previously
gage is probed in the radial direction at 36 points uni- measured, the values obtained for these measurements
formly distributed around the circumference. For will be used in the computation of the LMA.
machines that allow only single-axis probing, four points
7.9.3.2 Estimate of Linear Measurement Accuracy.
spaced 90 deg apart shall be sufficient. The measured
The estimate of the LMA will be reported for each linear
X and Y coordinates of each point shall be recorded.
axis. It is the sum of the feature location repeatability
The center of the thus-measured circle is calculated as
(FLR) for an axis (para. 7.9.2.3), the feature measurement
the average of these coordinates. The coordinates of this
accuracy (FMA; para. 7.9.2.3) for the machine, and the
center shall be subtracted from the X, Y coordinates of
bidirectional systematic deviation of positioning (E;
each point and the vector distance, the square root of
para. 7.3.4) for an axis.
the sum of the squares of the coordinate differences,
calculated for each of the 36 touches. The range of the LMAX p FLRX + FMA + EX (7-39)
distances is reported as the specification zone for the
probe lobing. Probe lobing can be further analyzed by
plotting these data on a polar plot. 7.9.4 Volumetric Measuring Performance (VMP)
7.9.2.4.2 Test for Probe Lobing Where Software 7.9.4.1 General. The volumetric measuring perform-
Allows for Three-Dimensional Measurements. A precision ance is determined using principles similar to those out-
reference ball shall be rigidly mounted on the workpiece- lined in para. 7.11. That is, the volumetric measuring
supporting surface in the work zone of the machine performance is obtained from the addition of the volu-
on a fixture that allows access by the machine probing metric positioning performance data, the feature loca-
system. Any position may be chosen for this mounting, tion repeatability data, and the feature measurement
with the default position being the ETVE position. A accuracy.
single probing test shall be performed on this ball using a
50-mm (approximately 2-in.) long, straight stylus probe. 7.9.4.2 Calculation of Volumetric Measuring Perform-
Other lengths may be specified, as long as specification ance. The VMP will be reported as the maximum range

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
is made as a detailed part of the machine procurement. of error over the work zone of the machine. This shall
Before commencing the test, the approximate center be defined as the sum of the largest of the bidirectional
of the sphere is determined by probing at the axis coordi- systematic deviation in positioning of diagonals, Ed
nate directions. Next, 49 points are probed on the test (para. 7.11), the vector repeatability error (VRE), and the
ball (at four different heights and 12 points around the feature measurement accuracy (FMA; para. 7.9.2). The
circumference at each height, in addition to the point at VRE is determined as follows:
the pole of the ball) as shown in Fig 7.48. In all cases,
the manufacturer ’s probe approach distance, probe VRE p (FLR2X + FLR2Y + FLR2Z )1/2 (7-40)
approach rate, and settling time, as shown in perform-
where
ance forms (para. 1.1), shall be used.
FLRX p feature location repeatability for the X-axis
7.9.2.4.2.1 Data Analysis on Machines With FLRY p feature location repeatability for the Y-axis
Three-Dimensional Measuring Capability. From the set FLRZ p feature location repeatability for the Z-axis
of 49 readings, a sphere center is computed using the
manufacturer ’s recommended algorithms. From this The volumetric measuring performance is then
center, a radius is then determined for each measure-
ment point. (The minimum radius is subtracted from VMP p Ed + VRE + FMA (7-41)
the maximum radius to produce the point-to-point probe
lobing.) The range of the magnitudes of these vectors
is reported as the specification zone for 3D-probe lobing. 7.9.5 Workpiece Location Tests

7.9.3 Linear Measurement Accuracy (LMA) 7.9.5.1 General. In many cases, probing on a machine
is used to locate a workpiece in the machine reference
7.9.3.1 General. The procedure described in this sec- system in order to alter machine programs. This test is
tion of the Standard represents a minimum requirement designed to evaluate the ability of the measuring system
to ensure conformance to linear measurement accuracy to locate the position of a workpiece relative to the spin-
specifications. Linear measurement accuracy can be con- dle centerline. Before performing this test, a calibration
sidered a combination of the positioning accuracy of the of the probe system for stylus eccentricity and ball radius
machine, the ability of the measurement system to repeat must be performed according to the Supplier’s recom-
a measurement, and any offsets introduced by probe mendations.

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7.9.5.2 Procedure The workpiece location specification zone for the Z

direction is defined as the maximum deviation from the
7.9.5.2.1 The workpiece location specification
defined datum (zero) point established in the Z-axis, as
zone is defined as the maximum deviation from the
determined by the probing system. Note that during
defined datum (zero) point established in both X and
this test the X and Y coordinates are to be the same each
Y axes.
time the part is probed.
[If desired, the User may defer this test until the
machining tests are performed, as one of the bores on
the precision positioning machining test part (Chapter
8) can be used to perform this analysis.]
(a) A test part of at least 25-mm (approximately 1-in.)
7.10 CNC PERFORMANCE TESTS
thickness is rigidly mounted to the machine table in
preparation for machining. The part material shall be 7.10.1 General
7075-T6 Al, as specified in the section on machining
tests (para. 8.4). The following tests are designed to check the function
(b) A hole at least 25 mm (approximately 1 in.) in of the machine tool controller and the programming
diameter is bored in the part following predrilling of a limitation of the system.
hole 1.25 mm (approximately 0.050 in.) undersized, in
7.10.2 Minimum Block Execution Time
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

order to obtain a high-quality bore with surface finish

better than the specification zone for repeatability of the The minimum block execution time (MBET) is a mea-
probing system. sure of the time it takes for the CNC to translate a
(c) Without moving the machine, the XY position of G-code command, input the translation into the servo
the bore is established as a datum. This ensures that the algorithms, and execute the command in the servo loop.
axis of rotation of the spindle is coincident with the hole Factors that impact MBET are number of axes pro-
centerline. grammed, number of characters per block, and buffer
(d) The precalibrated probe is introduced into the size of the CNC.
measuring position by a procedure which duplicates the 7.10.2.1 Test Procedure
normal method of the machine in the production mode
(that is, either manually or with a tool changer, which- 7.10.2.1.1 Suggested Equipment. Laser interfer-
ever is standard procedure). ometer.
(e) The machined bore is probed using the Supplier’s 7.10.2.1.2 Machine Warm-Up. No warm-up condi-
recommended software for bore measurement, as tion is required.
described in para. 7.9.2.4.1, and the center coordinates
of the hole computed. 7.10.2.1.3 Test Location. No test location is spec-
(f) The deviations of the coordinates of the center of ified.
the hole from the datum are noted. 7.10.2.1.4 Measurement Procedure
(g) The probe is removed from the measuring posi- (a) Prepare a part program to run the machine tool
tion, returned to the tool changer, reintroduced into the in 3D (along the diagonal of the work volume), using
measuring position, and the bore remeasured. Before linear interpolation.
the probe is returned to the spindle, the tool changer (1) The overall travel length shall be at least three
shall be indexed at least one position and returned in times the square of the maximum feed rate divided by
order to check the repeatability of this system. the maximum machine acceleration.28
(h) This procedure is repeated ten times. (2) Set the length of the line segments to 0.2 mm.
7.9.5.2.2 The Z-axis workpiece location specifica- (3) The number of blocks in the part program is
tion zone is assessed in a similar manner as follows: equal to the overall travel length divided by the length
(a) The previously bored part shall be faced with an of the line segments (0.2 mm).
appropriate facing tool, either over its complete surface (4) The size of the program should exceed the buffer
or at a spot.27 size of the CNC.
(b) This faced surface is now probed ten times to (b) Begin the test by running the program at 10% of
determine its Z offset, returning the probe to the tool maximum feed rate. Measure the actual feed rate with
changer after each probing. Before the probe is returned a laser interferometer set in the velocity mode as
to the spindle, the tool changer shall be indexed at least described in para. 7.10.5.
one position and returned in order to check the repeat- (c) If the feed rate is constant over the axis travel,
ability of this system. increase the programmed feed rate. Continue to do this

27 28
If desired, any appropriately flat surface properly fixtured may This condition assures that the overall travel length is long
be used for this test. enough for the programmed feed rate to be reached.

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0.0100

0.0080

0.0060

0.0040
Displacement, mm

0.0020

0.0000

⫺0.0020

⫺0.0040

⫺0.0060

⫺0.0080

⫺0.0100
0.0 15.6 31.2 46.8 62.4 78.0 93.7 109.3 124.9 140.5 156.1
Time, sec
(a)

0.0100

0.0080

0.0060

0.0040
Displacement, mm

0.0020

0.0000

⫺0.0020

⫺0.0040

⫺0.0060
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

⫺0.0080

⫺0.0100
0.0 16.1 32.2 48.3 64.4 80.5 96.6 112.7 128.8 144.9 161.0
Time, sec
(b)

Fig. 7.49 Sample Results From the Small Increment Tests

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Axis direction

Rotary axis
Transducer Transducer

Transducer wire rope Fixture Transducer wire rope

Fixture
Spindle

Stationary Stationary

(a) Linear Axis (b) Rotary Axis

Fig. 7.50 Test Setup

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

until the feed rate begins to vary over the total distance. 7.10.4 Least Increment Tests
The test program should be run from the CNC mem-
7.10.4.1 General. Machine tools are designed to oper-
ory to determine the CNC MBET. Direct numerical con-
ate over a wide range of feed rates and distances. Posi-
trol (DNC) or direct CNC networking (DCN) affects the
tioning accuracy and repeatability can vary greatly
minimum block execution time. Therefore, transfer the
depending on these variables and the machine construc-
test program to the CNC using DNC or DCN in order
tion. The least increment test is used to determine the
to determine the overall system MBET also. effect of these variations. In this test, the smallest incre-
7.10.2.2 Data Analysis. Use the maximum steady ment at which the machine can position in a specified
feed rate measured (less than 5% fluctuation), Vmax, to period of time is determined. This test also quantifies the
compute the block execution time (MBET) with the fol- machine’s ability to make small corrections in position,
lowing equation: which are necessary for thermal, reversal, and taper
compensations. The test procedure described below
MBET p INCR/Vmax (7-42) applies to linear axes. However, a similar procedure can
be applied for rotary machining axes. The setup for such
tests is similar to the periodic angular positioning test
described in para. 7.3.5.2.
7.10.3 Test for Varying Segment Lengths 7.10.4.2 Test Procedure
As in para. 7.10.2, this test moves the three cutting
7.10.4.2.1 Equipment
axes at once. The program is made up of varying line
(a) electronic gage or laser interferometer system
segment lengths. The line segment lengths shall range
(b) optics for linear displacement test
from 50% to 150% of the test line segment length used
(c) temperature, pressure, and humidity sensors
in the test in para. 7.10.2 in a random pattern. The feed
(d) personal computer for data gathering and analysis
rate shall be the maximum steady feed rate observed
in para. 7.10.2 for the machine. 7.10.4.2.2 Measurement Procedure
The feed rate is measured by a laser interferometer (a) Position the electronic gage or laser retroreflector
set in the velocity mode. If the feed rate varies by more along the axis to be measured. The distance from the
than 5% during the total axis travel, the feed rate should spindle gage line should be measured and recorded.
be reduced by 5% increments until it does not vary by Note that the gage or retroreflector are placed on the
more than 5%. This steady feed rate should be recorded spindle centerline to reduce sensitivity to spindle axis
as the varying segment feed rate (VSFR). Realistic line roll, and the spindle should be locked. If the spindle
segments and feed rates shall be negotiated between the cannot be locked, brackets, as described in para. 7.3.2.1,
User and Supplier. should be used.

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(b) The ten positive, ten negative, and ten positive (b) The linear axis must be commanded, using two
increments shall start at the resolution of the machine points only, to execute a simple motion.30 The travel
and shall be increased until the machine positions clearly distance of about half the axis travel or 500 mm, which-
definable steps to the commanded increment. ever is the shortest, should allow the axis to accelerate,
then move at constant feed rate for a distance equal to
7.10.4.3 Data Analysis. The specification zones for at least 10% of its total range, and then decelerate to
the least increment test shall be defined by two parame-
stop.31 The same travel distance should be used for both
ters: least increment step and reversal errors. The least
feed rates. For rotary axis tests, the rotary axis shall be
increment step is the commanded increment at which
programmed to rotate from 0-deg position to 360-deg
the ten negative and the second ten positive steps can
position (one complete revolution).
be counted and overshoot does not exceed the step. The
(c) The test should be carried out in both positive and
least increment reversal error shall be the amplitude of
negative directions.
the first negative step minus the commanded increment.
(d) Data acquisition should be made at approximately
See Fig. 7.49.
0.01 mm intervals (for linear axis tests); alternative sam-
7.10.5 Linear and Rotary Axes Feed Rate and pling rates are to be agreed between User and Supplier.
Acceleration Tests29 No smoothing or averaging techniques should be used.
(e) The tests must be repeated a minimum of three
7.10.5.1 Scope. This test is designed to measure the times.
axis feed rate characteristics of accuracy and variability
NOTE: The above-described test specifies that all linear axis tests
from a target value. This test is also designed to check shall be run using linear move (G01). This addresses the effect
the machine velocity profile, from which the User can of acceleration and deceleration seen during contour machining.
identify However, if acceleration and deceleration rates need to be known
(a) the actual acceleration and deceleration rates of for point-to-point positioning cycle time evaluation, a test using
the machine positioning moves (G00) will need to be added. To see the effect
of acceleration/deceleration, the added test will have to be con-
(b) the stability of the machine when changing feed ducted in a stop-and-go series along each axis separately. The
rates moves will need to be of short duration but long enough to allow
Rotary axis tests are only applicable for machine tools the maximum feed rate to be reached before deceleration starts.
that have rotary machining axes. See Figs. 7.50 and 7.51.
7.10.5.3 Data Analysis
7.10.5.2 Test Procedure (a) Plot the measured velocity versus time for each
test as shown in Fig. 7.51, showing positive and negative
7.10.5.2.1 Equipment
direction separately.
(a) Laser interferometer with suitable dynamic data
(b) For each direction, calculate the mean velocity and
acquisition and analysis software (see Fig. 7.6 for linear
state the range of the variation as a value and percentage
axis tests only). of the target.
(b) Alternative displacement transducers with ade- (c) For each test, determine the time it takes to reach
quate frequency response, such as pullout wire position- 63.2% of the programmed feed rate.
ing and velocity transducer with sampling rate of at (d) Calculate the acceleration for each test by dividing
least 200 Hz (see Fig. 7.50 for linear and rotary axes). the 63.2% of the programmed feed rate by the time in
7.10.5.2.2 Machine Warm-Up and Test Location. para. 7.10.5.3(c).
These tests should be carried in similar conditions to (e) The average acceleration of the machine is the
those for positioning accuracy and repeatability tests average of all accelerations calculated in para.
7.10.5.3(d). --```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
(see para. 7.3). For rotary axis tests, the rotary axis shall
be positioned at 0 deg. (f) Similar analysis should be done for computing
average deceleration.
7.10.5.2.3 Measurement Procedure. For each mov- For acceptance purposes of a new machine, Supplier
ing axis to be evaluated, two different tests shall be and customer must agree beforehand on the specifica-
conducted at 10% and 100% of the maximum program- tions to be met for these tests.
mable feed rate (G01):
(a) Align the measuring equipment with the axis 30
In some instances, the CNC has a feature of automatically
under test as described in para. 7.3.2.1 for linear axes, reducing feed rate and/or acceleration in order to meet the speci-
and as shown in Fig. 7.50, illustration (b), for rotary axes. fied cutting accuracy for complex cutting paths. In this case, the
selection of a straight line defined with two points only (start–
end) should allow the test to be performed without the interference
29
These tests are not intended to measure the time required to of this feature.
31
index a rotary axis. This parameter is measured using a suitable Prior to these tests, two preliminary tests may be done in such
timing device as the average indexing time during ten repeated a way that the distance to be traveled is not enough to allow the
back-and-forth indexing operations. two programmed feed rates (10% and 100%) to be reached.

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7 000

6 000

63.2% of
5 000 programmed 63.2% of programmed
feed rate feed rate
Accel. ⫽
Velocity, mm/min

time to reach 63.2% of

4 000 programmed feed rate

3 000

2 000
Time to reach 63.2% of
programmed feed rate
1 000

0
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20
Time, sec

GENERAL NOTE: Only the feature tolerances shown are to be inspected for machine acceptance.

Fig. 7.51 Sample Acceleration Plot

NOTE: A useful additional analysis would be to evaluate the data During this test, the temperature sensor location shall
in the frequency domain by carrying out a fast fourier transform be agreed upon between the manufacturer and User.
(FFT) and showing if there is any dominant frequency content in
the results.
7.11.2 Test Procedure: All Machining Centers
7.11.2.1 Equipment
7.11 CONTOURING PERFORMANCE USING
CIRCULAR TESTS (a) machine temperature sensors
(b) circular test device (telescoping ball bar, precision
7.11.1 General disk, grid encoder, etc.)
Circular contours provide one of the best checks for 7.11.2.2 Measurement Procedure. An NC program
contouring performance evaluation. When contouring a using circular interpolation (linear interpolation can be
circle, a machine is running with multiple axes along used as an option to the circular interpolation) is now
a circular path and each axis goes through sinusoidal prepared to move the machine in a 360-deg circle in the
acceleration, velocity, and position changes. Circular test plane. Examples of circle test setups are shown in
tests can be performed using telescoping ball bars, grid Fig. 7.52. Although full circle is strongly recommended,
encoders, or precision disks. Each test specified shall be for some machine configurations only partial circles may
run at two speeds. These two speeds are approximately be possible. The acquired circular test data must be
10% and 80% of maximum programmable feed rate. reduced to a polar plot so that the residual eccentricity of
Other feed rates may be used if agreed to by the User the measuring instrument can be eliminated. All circular
and Supplier. On some machines the controller will auto- tests shall be carried out with the machine in the
matically slow the feed rate in order to compensate for unloaded condition (without workpiece).
errors. It is therefore required that the User measure the
time required to perform the circular test and report the 7.11.2.3 Parameters. Parameters of the test are
actual feed rate computed from the circle circumference (a) diameter (or radius) of the nominal path
and time. The radius recommended for this test is (b) contouring feed
slightly less than one-half of the range of travel of the (c) contouring direction (clockwise or counter-
shortest axis under test or 250 mm, whichever is smaller. clockwise)

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Z
Y X

(a) Typical Setup for a 360 deg Circular Test

(b) Example of Setup for Horizontal Spindle Machine

Fig. 7.52 Examples of Circle Test Setups

(d) machine axes moved to produce the actual path (i) position of slides or moving elements on the axes
(e) location of the measuring instrument in the which are being tested
machine working zone (j) programming techniques (G01, G02, G03)
(f) temperature (measuring instrument and machine
temperature32) for the radial deviation measurement 7.11.3 Data Analysis
only
(g) data acquisition method (data capture range if For each circular test, the circular deviations for clock-
different from 360 deg, starting and ending points of wise, G↑, and counterclockwise, G↓, contouring, and
the actual movement, number of measuring points taken the radial deviations, Fmax and Fmin, for clockwise (↑)
for digital data acquisition) and counterclockwise (↓) contouring, shall be reported,
(h) any machine compensation routines used during as well as the measured feed rates in the clockwise and
the test cycle counterclockwise directions (see Fig. 7.53). The circular
deviation is the minimum radial separation of two con-
32
centric circles that will envelop the actual path. Finally,
A better estimate of the machine representative temperature the radial deviations are the maximum deviation from
for this test will be obtained if the temperatures of the relevant
machine scales were measured during this test. Any of the two the true ball bar length, corrected to 20°C using the
scale temperatures can be used for the NDE correction. NDE correction. (See Chapter 4.) For the purpose of this

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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ASME B5.54 (2002)

Example Data
Operator: A. N. Other Machine: Example machine
Date: Mar-20-2002 Time: 13:50 Instrument: Dynamic ball bar
Circular Deviation
Value (CW) 100.0 ␮m
Value (CCW) 106.6 ␮m
Radial Deviation
Min. value (CW) -150.7 ␮m
Max. value (CW) -50.7 ␮m
Min. value (CCW) -159.4 ␮m
Max. value (CCW) -52.8 ␮m
Calculated Feed Rate
Value (CW) 3012.0 mm/min
Value (CCW) 3012.0 mm/min
Test Parameters
Radius 150.0000 mm
Sample rate 18.750 Hz
Feed rate 3000.0 mm/min
Run sequence CCW CW
Plane under test XY
Test position
Start angle 0 deg
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

End angle 360 deg

Overshoot angle 180 deg

Scale: 50.0 ␮m/div.

Fig. 7.53 Typical Results From a 360 deg Circular Test

Standard, the manufacturer of the circular test instru- Supplier of such machines and develop tests suitable
ment shall supply an effective coefficient of the thermal for the particular geometry required. Appendix J shows
expansion for the instrument and recommendations as a set of recommended patterns. These tests shall be spec-
to appropriate calibration procedures, where applicable. ified in detail equivalent to that of the other circular
tests in this Standard, as part of the initial machine
7.11.4 Additional Measurement Procedures: Four- specification.
and Five-Axis Machining Centers
Four- and five-axis machines can be built in a wide 7.11.5 Other
variety of configurations. Because of this high variability, At the time of issuance of this Standard, other circular
a simple test suited for all these machine types has not test instruments were in the process of development and
been developed. It is recommended that circular tests testing. The use of any of these instruments is suitable,
for three-axis machines be used on these machines, exer- as long as the instrument system is able to perform the
cising the rotary as well as the linear axes wherever same task with the required accuracy defined in this
possible. Users are advised to work closely with the Standard.

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ASME B5.54-2005

Chapter 8
Machining Test Parts

8.1 GENERAL utilized for these tests, with these parts placed in more
than one location on the machine. If the size is modified,
Machining test parts has an important role in the
appropriate tooling and process parameters should be
acceptance testing of machining centers. The machining
used to suit the modified test part. Whenever the test
accuracy is checked under a limited set of machining
parts specified in the Standard are modified or new test
conditions, to arrive at standard means of machine com-
part(s) have been agreed upon by the User and the
parison. Since such tests necessarily include factors that
Supplier, procedures and acceptance specifications for
may not have any direct relation to the machine tool,
machining such test parts should be provided in equiva-
such as materials variation, tooling variations, thermal
lent detail.
effects of cutting, and fixturing variations, careful atten-
tion must be paid to the minimization of these effects 8.1.2 Location of Test Parts
for accurate comparison of different machining centers.
The User of this Standard may require testing of the In general, the test part shall be placed as close as
machine on the specific parts (referred to as production- possible to the position where operations will be per-
part runoffs) for which it is initially purchased, as dis- formed on the machine in production. The test parts,
cussed in para. 8.4. The User may also specify other however, shall be machined at different locations based
machining tests, provided specifications are supplied in on the applications of the User, subject to agreement by
equivalent detail. the User and the Supplier. For example, on a long-bed
Test parts may be used simply to provide assurance machine, parts could be placed at each end and at the
that the machine is functioning as expected or can be center of the bed to provide some coverage of the entire
used as a part of the machine specification for establish- work zone, whereas on some machines, the test parts
ing the conditions of machine acceptance. The accept- could be placed only at the center of the work zone.
ance specifications on all of the features in the test part
8.1.3 Material of Test Parts
shall be supplied as part of the initial machine specifica-
tion for each of the test parts to be machined. The material of the test parts is subject to agreement
Using test parts alone to determine machine accuracy between Supplier and User and shall be recorded.
and acceptance is not recommended. The machine per- Depending on the material chosen for test parts, appro-
formance is best tested by the procedures outlined in priate process parameters and tooling shall be selected.
the preceding chapters of this Standard. It is recom-
8.1.4 Tooling and Fixturing
mended that the test parts machining is done as one of
the last acceptance tests, after the machine passes all The tooling used for machining test parts in this Stan-
the other acceptance tests agreed upon between the User dard shall be standard tooling, thoroughly inspected to
and the Supplier. Any change in machine performance ensure tool accuracy. If agreed to by Supplier and User,
would affect the results obtained from machining test inserts can be changed between cuts to minimize the
parts. effects of tool wear. The inspection of the tool shall
include all components of the system, such as tool, tool
8.1.1 Types and Sizes of Test Parts holders, adapters, etc., to ensure that any deviation from
There are five types of test parts in this Standard, as requirements is either noted or corrected before com-
shown in Table 8.1. One or more of these test parts could mencing machining tests. The fixtures should be
be used based on agreement between the User and the designed so that the effect on part accuracy from fixture-
Supplier. induced deflections is insignificant.
The sizes of test parts can be scaled or modified to
suit the applications of the User. The test part(s) shall 8.1.5 Procedure
be selected so that the size is appropriate for the machine Procedures shall be thoroughly defined and agreed
size, with the size of the test part approximating the upon by both Supplier and User. Test part material,
size of parts that will be produced on the machine. If tools, process parameters (feeds, speeds, depths of cut),
the machine is extremely large and if the cost of the test and the part program shall be thoroughly documented
part or the time involved in machining is prohibitive, and tested before commencing any test. The machine
then it is recommended that more than one part be should be warmed up by moving the machine axes for

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Table 8.1 Types and Sizes of Test Parts

Paragraph Test Part Name Referenced Standard Applicable Machining Center Type

8.2 Precision contouring test part ISO 10791-7 [Note (1)] Machining centers with 3 or more axes
8.3 Transverse tilt machining test part NAS 979, Section 4.3.3.6.1 Machining centers with 4 or more axes
8.3 Longitudinal tilt machining test part NAS 979, Section 4.3.3.7.1 Machining centers with 4 or more axes
8.3 Profile cone frustum machining test part NAS 979, Section 4.3.3.8.1 Machining centers with 5 or more axes
8.4 Production parts ... All machining centers

NOTE:
(1) Modifications have been made to the part and inspection procedure.

a minimum of 1 hr before starting this test. The test

A
setup(s) should be constructed and tested before begin-
ning the machining tests. Furthermore, attention should
B be paid to the temperature at which the part is machined
so that the dimensions of the part are correct at 20°C.
This documentation shall be retained as part of the test
record.

8.1.6 Inspection
C E A
Measurement of the temperature of the test part, the
F machine, and the ambient air is recommended, and cor-
D B rections for thermal expansion shall be applied when
differences exist between the inspection temperature
and 20°C.
F Test equipment and instrumentation used to inspect
X4. OJ E all test parts shall comply with the requirements in
OJ
.25 A para. 11.11.
A
120 deg
N G 8.2 PRECISION CONTOURING MACHINING TEST:
M H ALL MACHINING CENTERS
OK .025
This machining test and procedures for inspection are
OL
designed to provide data to determine the following
D characteristics of the machine tool:
C (a) positioning accuracy and repeatability in the X-,
Y-, and Z-axes
Size 1, Size 2, (b) deflection of the machine head under cutting load
160 mm 320 mm (c) squareness of the X- and Y-axes
Dimension Square Square
(d) angular and circular profiling capability in the X-
A 170 330 and Y-axes
B 85 165
The test piece blank (see Fig. 8.1) may be mounted
C 140 280
D 70 140
on a subplate, angle bracket, or tombstone fixture,
depending on the configuration of the machining center
E 104 200 being tested.
F 52 100 Two sizes of test piece are shown in this Standard,
G 55 85 size 1 (160-mm square) and size 2 (320-mm square). See
H 20 42 Figs. 8.2 and 8.3. The choice of the test piece size and
material to be used for machine acceptance should be
J 22 41
K 11 17 determined at the contract stage of purchase and will
L 18 26 depend on the size of the machine and its intended use.
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

M 18 40
N 10 26 8.2.1 Location of Test Pieces
Extreme location positions for the test piece should
Fig. 8.1 Precision Contouring Test Part Test Piece only be adopted by agreement between the Supplier
Blank and the User. Unless otherwise specified, the test piece

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3 deg
K
OC ⫺ x4
2

H A
J
G x4
OD 30 deg
B
90 deg

OD OD G
4x Z 3 deg
-A- H
OD ⫹ 1
OC ⫺ 2
4x
6
6
E
E 6
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Section Z—Z
F [Note (1)] OD ⫹ 1 [Note (1)]
B
A

Size 1, Size 2, Size 1, Size 2,

160 mm 320 mm 160 mm 320 mm
Dimension Square Square Dimension Square Square
A 160 320 F 25 40
B 80 160 G 52 100
C 110 220 H 104 200
D 26 45 J 35 65
E 6 10 K M4 X 0.7 8 deep M12 X 1.75 20 deep

GENERAL NOTE: Only the features dimensioned in the above figure are machined during the test cut. See Fig. 8.3 for geo-
metric control features.
NOTE:
(1) Only on machines where test part is mounted on a rotary or index table.

Fig. 8.2 Precision Contouring Test Part Machining Dimensions

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should be placed approximately at mid-travel of the X- The four bored holes, datums (-D1- through -D4-) shall
axis and in positions along the Y- and Z-axes suitable be approached in the positive X- and Y-axes directions
for the location of the test piece and/or fixture and for to the final boring location. Their counterbore (D+1)
the tool lengths employed. locations shall be approached in the negative X- and Y-
axes directions.
8.2.2 Number of Test Pieces Also, to test the effect of tool change repeatability on
In principle, no more than one test piece should be the size of bored holes, the boring tool producing the
machined for acceptance purposes. In case of special four counterbored holes (D+1) shall be returned to the
requirements, such as statistical assessment of the tool storage after machining each of the four counter-
machine performance, the machining of more test pieces bores.
is to be submitted to the agreement between Supplier
and User.
8.3 MACHINING TESTS FOR FOUR- AND FIVE-
8.2.3 Multiple Usage of Test Piece Blanks AXIS MACHINING CENTERS
The same contouring test piece may be machined sev- To verify the accuracy of four- and five-axis machining
eral times, with the consequent reduction of external centers under cutting loads, for the purposes of this
dimensions and increase of hole diameters. When such Standard, the following tests as given in NAS 979 shall
a test piece is used for acceptance purposes, it is recom- be performed:1
mended that the final test piece should comply with the (a) transverse tilt machining test (NAS 979, para.
dimensions specified in the present Standard, so as to 4.3.3.6.1, Transverse Tilt Test)
represent the cutting accuracy of the machine. (b) longitudinal tilt machining test (NAS 979, para.
If the contouring test piece comes from previous cut- 4.3.3.7.1, Longitudinal Tilt Test)
ting tests and is reused, its characteristic dimensions (c) cone frustum machining test (NAS 979, para.
should remain within ±10% of those indicated in this 4.3.3.8.1, Profile — Cone Frustum)
Standard. When the test pieces are reused, a shallow Other tests may be substituted if they are specified
cut shall be made to clean up all surfaces before new in equivalent detail.
finishing cuts are taken.
It is also recommended that type and serial number
of the machine, date of the test and designations, and 8.4 PRODUCTION PARTS
orientation of the axes be marked on the test piece and Where the machine is to be used in producing a single
that they be delivered with the machine for reference part or a family of parts, the best machining test to
purposes. determine machine capability would be a run of produc-
tion parts or parts that are as close to the production
8.2.4 Temperature Measurement part as possible. This paragraph is included to allow the
Temperature difference has a significant effect when machine User to specify the machine performance on
testing machine tools and must always be considered. selected parts, with the performance criteria on these
parts specified in equivalent detail to the other machin-
8.2.5 Inspection Method and Requirements ing test parts specifications in this Standard. Such tests
Inspection methods for test pieces shall be agreed are not of great value in assessing machine performance
upon between the User and the Supplier. Test equipment over the long term, except for dedicated equipment.
and instrumentation used to inspect the precision con- They do, however, provide the User with more rapid
touring test part shall comply with requirements in start-up and thus are of significant economic value.
para. 11.11. In this case, the machine shall be started and allowed
Figure 8.2, Fig. 8.3, and Form 8.1 specify the machined 1 hr for warm-up. The first part shall be cut and checked
features of the test part to be inspected, and the results and any corrections to the tooling or programming made
are to be used to evaluate the accuracy and acceptability at that time. A minimum of 30 parts is recommended
of the machine tool. These are the only features to be to obtain statistically valid information. This shall be
measured for evaluation purposes. There are no surface subject, however, to agreement between the User and
finish requirements applied to these tests. the Supplier. The machine shall be kept running between
the various test cuts in a dry cycle to increase thermal
8.2.6 Programming and Cutting Techniques stability of the machine without requiring an excessive
Acceptable programming and cutting techniques, amount of material to be run and inspected for test
consistent with the test part material, the cutting tools cutting.
employed, and the machine tool’s design capabilities,
1
shall be used. Tolerances to be agreed between the User and Supplier.

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g l d
j –E– m –C– f –B–

–D 2– –D 3–
g g
j –E– k –F–
2x
d
–
–F e –B–

2x 3 deg
n
C
p –B–
–
–E
H
G
g
-B- 30 deg h –B–

d
G
–D 1– 3 deg
Z

4x H –D 4–
q –C–
a
b -A-
–D–
–C– -A-
4x
r –D–

This section typical of four

places (–D1– through –D 4–)
with counterbores concentric
to their respective datums c –C–

Only on machines where test part is

mounted on a rotary or index table

GENERAL NOTES:
(a) Only the feature tolerances shown are to be inspected for machine acceptance.
(b) See Table 8.2 to record predetermined tolerance and inspection results.

Fig. 8.3 Precision Contouring Test Part Inspection Requirements

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Form 8.1 Precision Contouring Test Part Inspection Results

To Be Agreed Between Supplier and Customer Actual Test Results
Feature Size 1 Size 2 Size 1 Size 2
Inspection Feature Tolerance 160 mm 320 mm 160 mm 320 mm
Cylindricity /⌷/ of bore datum -C- a
Squareness ⊥ of bore datum -C- to surface b
datum -A-
Concentricity 䉺 of C/bore to bore datum -C- c
Straightness — of all (4) sides of square d

Squareness ⊥ of (2) adjacent sides of square e

to datum -B-

Parallelism // of opposite face of square to f

datum -B-
Straightness — of (4) sides of canted square g

Angularity ∠ of 30 deg face, datum -E- h

to datum -B-
Squareness ⊥ of datum -F- to datum -E- j
Parallelism // of opposite faces of k
datums -E- and -F-

Circularity, ⌷, of contoured circle l

Concentricity 䉺 of contoured circle to m
datum -C-
Straightness — of two 3 deg angular faces n

Angularity ∠ of two 3 deg faces to datum -B- p

True position ⊕ of (4) bored holes, q

datums -D1- through -D4- to datum -C-

Concentricity 䉺 of (4) C/bored holes to r

their respective datums -D1- thru -D4-

(4) C/bored holes (D+1) same size diameter s

within given tolerance(s)
(D+1) max. − (D+1) min.

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ASME B5.54-2005

Chapter 9
Cutting Performance Tests

9.1 GENERAL Table 9.1 Metric to English Conversion Used in

This Standard
In the performance of a cutting operation, the follow-
ing types of “errors,” or limitations, may arise: Metric English
(a) The drive cannot deliver the necessary torque, and 25.4 mm 1.00 in. (exact)
it either stalls or the machine breaks. This leads to a test 746 W 1 hp (U.S.)
of the ability to use the rated torque. A preliminary to 750 W 1 hp (metric)
this test is the test of spindle idle run losses. 1 mm/N 0.175 in./lb approximate
(b) Chatter occurs. In roughing cuts this leads to 1 N/mm2 145 lb/in.2 approximate
excessive vibratory forces that may damage the tool and
cause chatter marks on the surface in finishing cuts.
(c) In stable cuts (without chatter), the deflections in
the English approximation immediately following the
the tool/spindle/structure/fixture/workpiece system
metric number will be deviated from here. Instead, Table
cause errors of position and profile of the machined
9.1, which has conversion factors from metric to English
surface.
for all of the units used in this Chapter, has been pro-
(d) Other kinds of problems may arise, such as failures vided.
of the coolant delivery system, leakage of oil from the
spindle lubricating system, clogging of chips in the chip
removal system, etc., that cannot be quantified and con- 9.2 COMPLETE SET OF TESTS
stitute what is distinguished from tests by calling them
A complete set of tests of a machine’s dynamic per-
simple checks. These are not discussed any further in
formance is summarized in Appendix G. These include
this Standard.
measurements of the machine’s structural dynamics as
The limitations in paras. 9.1(a) through (c) must be
well as cutting performance. If the machine tool Supplier
determined in well-organized tests performed under
has investigated the particular model of the machine
carefully selected conditions. For practical reasons, the tool concerned in considerable detail and has established
tests are organized in the following sequence: the complete set of characteristics, then these shall be
Step 1. Spindle Idle Run Loss Test. This test is carried offered to the User upon request. These characteristics
out first to measure the power available for are assumed to be repeatable for all the individual
the cutting tests.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
machines of a particular model. It is further assumed
Step 2. Chatter Limits and Full Torque Test. Measure- that the User will want a limited selection of the com-
ments of these two limitations are combined plete set of tests to be carried out for verification that the
in a series of tests during which one or the machine being supplied possesses characteristics close
other limitation prevails. Both these limita- enough to those being specified. It is these limited verifi-
tions occur decisively in milling (particularly cation tests that are fully defined in this Standard. If the
in end milling), and these limitations do not Supplier cannot provide the data described above and
have to be tested in any other of the various in Appendix G, two options are possible: either the Sup-
cutting operations, such as boring and drilling, plier provides a limited set of data as described below
commonly performed on machining centers. or default values of the required parameters are used.
Step 3. Cutting Force Induced Error Tests. These test the
errors of position and flatness of the machined 9.2.1 Limited Data Set From the Complete Set
surface due to deflections in the system and At the present stage of general practice of machine
their imprint on the surface. Two tests are spec- tool testing, it is not considered possible to require the
ified: the end milling deflection test and the Supplier to provide all the machine characteristics
face milling deflection test. described in Appendix G. However, to obtain some
guidance for the cutting performance tests, the following
9.1.1 Conversion Factors data should be supplied by the machine tool Supplier.
This Chapter is completely in metric. Because of the (If this limited data set is not available, default values
complexity of the tables, our usual practice of including for the test parameters are given; however, this may

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sometimes lead to unsatisfactory results.) 9.4 SPINDLE IDLE RUN LOSS TEST
For each of the tool/tool holder combinations selected
for a cutting performance test (see para. 9.5), a limited This test is performed first. It measures the economy
set of structural dynamic parameters should be supplied of the drive and potential heat sources. It is also useful,
to the customer. These parameters have been defined for the cutting tests, to know the actual power available
in Appendix G. They are the natural frequency of the on the spindle at the various speeds.
dominant mode, fn, and its dynamic compliance (the In this test the spindle is run idle in five steps over
amplitude of the imaginary part of the transfer function its total speed range and, using a wattmeter, the power
at fn), Hc, in each of the two feed directions orthogonal required is recorded and a graph like the one in Fig. 9.2
to the spindle axis of rotation.1 These two feed directions is produced. The measured lost power includes losses
are called X and Y in this Standard. The natural fre- in the electric drive as well as those in the transmissions
quency data will be used for choosing the spindle speeds and bearings. It has been sufficiently established that
for the chatter test and the accuracy test. The magnitude these losses are little affected by the useful load on the
will be used for estimating the initial depth of cut in spindle. The net available power shall correspond to that
the chatter test. Four examples of measured transfer provided in the specifications of the machine tool.
functions are presented in Fig. 9.1. In each case the imagi-
nary part of the transfer function, Im(G), is plotted on
a linear scale of compliance, in micrometers per newton, 9.5 CHATTER LIMITS TESTS AND FULL TORQUE
versus frequency. In graph (a), a simple transfer function TEST
in one direction is shown that contains only one domi-
nant mode. In this case the choice of the frequency and In general machine tools, their spindles and their tool
the magnitude of the compliance to be chosen is clear. holders shall be so designed as to provide enough
In graph (b), an example is shown of a transfer function dynamic stiffness to allow chatter-free milling within
where there are two modes of approximately equal com- the whole range of available torque, speed, and power.
pliance. In this case the lower frequency mode shall be Machines should not be equipped with drives with more
chosen. In cases (c) and (d), the transfer functions are torque and power than is utilizable in stable chatter-
rather complicated and differ significantly in the two free cuts.
basic directions. In cases such as these, the procedure However, it is conceivable that chatter-free machining
referred to in footnote 1 shall be followed. is obtainable under most conditions with short rigid
holders, but not under some exceptional circumstances.
At other times it also happens that machines are not
9.3 MACHINING CENTER RANGES rigid enough and chatter limits the metal removal rates
under almost any conditions. The purpose of the chatter
For selecting tools, workpiece materials, and spindle
test is to distinguish between machines with equal
speeds, machining centers are classified into several
ranges according to available spindle speed and torque. torque and power but different degrees of rigidity and
These classifications are given in Table 9.2. In general, stability.
chatter and accuracy depend on the same cutting param- Before the actual test procedure is discussed, the con-
eters as the torque. Their limits also depend on the ditions for the test are described. Conceptually, the test
dynamic stiffness between the tool and workpiece. is rather simple. The machine is used to mill test parts
Therefore, it is proper to require more stiffness from of different materials using standard tools. The depth
machines with higher torques. These machines will have of cut is varied at different radial immersions until chat-
larger diameter spindles and generally heavier struc- ter is perceived. The depth of cut where chatter occurs
tures. The torque, Tq , is related to the power, Pw , by at the different radial immersions is used as the cutting
performance criterion. The major complexity comes in
60Pw establishing the cutting conditions and the spindle
Tq p (9-1)
2␲nrpm speeds to obtain comparable results.

where 9.5.1 Materials for the Chatter Limit Test and Full
nrpm p spindle speed, rpm Torque Test
Pw p power, W
The chatter limit test is conducted using 4340 steel,
Tq p torque, N-m
300–350 Brinell hardness number (BHN), with a face
mill and an end mill with inserts, and 7075-T6 aluminum
1
In some cases there will be a number of closely spaced natural using a solid end mill. The full torque test is carried out
frequencies. In such cases the Supplier shall supply the complete using face milling 4340 steel (300–350 BHN) only. Details
real and imaginary parts of the transfer function, or a separate
agreement should be reached between User and Supplier. (See of the tooling, other machining parameters, and the test
Appendix G.) part geometry are given in the following paragraphs.

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--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

2
(a)
lm (GX), ␮m/N

Hmax

⫺2
0 1000 2 000
Frequency, Hz

1
(b)
lm (GY ), ␮m/N

H1 H2

f1 f2

⫺1
0 1000 2 000
Frequency, Hz

0.03
(c)
lm (GX ), ␮m/N

0.0

⫺0.02
0
lm (GY ), ␮m/N

(d)

0.0
⫺0.01
0 500 1000 1250
Frequency, Hz

Fig. 9.1 Typical Transfer Functions

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Table 9.2 Machine Center Ranges Table 9.3 Chip Loads for Cutting Performance
Machine Range Maximum Torque, N-m
Test
Cutting Test Chip Load, mm/Tooth
A. Very light <10
B. Light 10–25 Chatter: face mills 0.15
C. Medium light 25–65 Chatter: end mills 0.10
D. Medium 65–150 Full torque 0.30
E. Medium heavy 150–375
F. Heavy 375-750 [Note (1)]

NOTE:
(1) For machines with higher torque spindles, no recommendations periphery of a cutter that is known, for a particular
for tool dimensions and test conditions are given in this Standard. combination of workpiece/tool materials, to give satis-
For these machines, the Supplier shall provide recommendations factory tool life. From a practical point of view, this
for appropriate parameters, and they chould be specified in equiv-
limitation does not exist for aluminum because both
alent detail to those given in this Standard.
high-speed steel tools and carbide tools can cut alumi-
num at very high speeds with little wear. For the 4340
P steel (300–350 BHN) we choose a cutting speed of 120
m/min. The corresponding spindle speed, nT , is then

Pnom 120,000
nT p (9-2)
␲d

where
d p tool diameter, mm
nT p maximum spindle speed, rpm, for acceptable
tool life
Plost
From the point of view of chatter, there are two further
limitations as follows:
100% (a) Tests shall not be done at such low speeds that
Spindle Speed, % chatter is suppressed by process damping. This would
be a way of avoiding chatter by sacrificing metal removal
Fig. 9.2 Typical Plot of the Power Loss in the rate. This rule leads to the requirement of a minimum
Spindle Idle Run Loss Test spindle speed nmin for the chatter tests (see Appendix
G). To determine nmin, it is necessary to know the natural
frequency, fn , of the dominant mode in each axis direc-
9.5.2 Coolant tion, as specified in para. 9.2.1. For our purposes:
The chatter tests and the full torque test are designed
29fn
to be run without coolant; however, in the case of nmin p (9-3)
d
machining of aluminum, coolant may be used if desired
by the machine User. where
9.5.3 Chip Load d p tool diameter, mm
fn p natural frequency, Hz, of the dominant mode
Chatter limits do not depend on chip load. Therefore, nmin p minimum speed, rpm, for the chatter test
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

the test is carried out with light chip loads, c p 0.15

mm for the face mills and c p 0.1 mm for the end mills. (b) On the upper side, the choice of spindle speed is
Even so, it is necessary to watch for torque (or power) complicated by “lobing effects” (see Appendix G). At
overload during the chatter test. Once the chatter limits higher speeds, chatter may strongly depend on spindle
are found without reaching full torque (or power), the speed and stable regimes are possible. Although this is
full torque test is carried out in face milling at double definitely beneficial for the process, it may produce test
the chip load, c p 0.3 mm. For convenience, these chip results on the better side and obscure the potential of
loads are summarized in Table 9.3. much less stability at different speeds. Therefore, unless
the lobing diagram is available, it is recommended to
9.5.4 Spindle Speeds use a speed, nmax, as a general limitation for the test
The choice of spindle speed is, first of all, dictated by speed. This speed is chosen to have a cutting frequency
empirical tool life data. This limits the spindle speed of 0.8 of a third of the natural frequency of the dominant
so as not to exceed a particular cutting speed on the mode. That is,

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Table 9.4 Standard Tools and Default Machine and Cutting Parameters for the Face Milling
Chatter Test(s)
Workpiece Material: Steel 4340 (Chip Load c p 0.15 mm/Tooth)
Machine Class

Variable B C D E F
d, mm 50 75 100 100 150
m 4 6 8 8 12

Holder
Variable R L R L R L R L R L

L, mm 0 N/A 0 50 0 100 0 125 0 150

Hc, ␮m/N 0.80 N/A 0.50 0.90 0.20 0.55 0.10 0.30 0.08 0.25

fn, Hz 600 N/A 550 400 500 350 500 350 550 380
nmin, rpm 340 N/A 210 160 145 100 145 100 100 75

nmax, rpm 2 400 N/A 1 500 1 100 1 000 700 1 000 700 740 500
ns, rpm 9 000 N/A 5 500 4 000 3 750 2 650 3 750 2 650 2 750 1 900

nT , rpm 763 N/A 510 510 380 380 380 380 250 250
bcr , mm 0.45 N/A 0.5 0.3 0.95 0.35 1.9 0.65 1.5 0.5

Tcr , N-m 4.5 N/A 11.5 6.5 37.5 13.5 75 25 140 45

Pcr , W 344 N/A 585 331 1 425 513 2 850 950 3 500 1 125

GENERAL NOTES:
(a) In all instances the nT speed must be chosen.
(b) Class A machine is not included. It is designed for end milling and drilling only, no face milling.

16fn 9.5.4.2 Spindle Speed Rule 2. The characteristic data

nmax p (9-4)
m as discussed above are available, including the lobing
diagrams for only the standard tools, radial immersions,
where and feed directions. Use the formula to determine nmin
fn p natural frequency, Hz, of the dominant mode and avoid process damping. Then choose two speeds,
m p number of teeth on the cutter both greater than nmin, with the first one, n1, coinciding
nmax p maximum spindle speed for normal testing, with the highest speed available of the “stable speeds.”
rpm The stable speeds, ns, are given by
With these values of nmin and nmax, we may now for- 60fn
mulate the following rules for the choice of spindle ns p (9-5)
jm
speeds for the tests. This choice depends on the extent
of the dynamic characteristics supplied by the Supplier where
of the machine tool. The rules are labeled spindle speed fn p frequency of the dominant mode, Hz
rules 1 through 4. j p an integer (j p 1, 2, 3...)
m p number of teeth on the cutter
9.5.4.1 Spindle Speed Rule 1. The characteristic data,
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

ns p stable speed, rpm

as described in Appendix G, are available in a general
form such that they apply to the use of the standard set
This choice also must not violate the acceptable tool
of tools and to other tools and feed directions, or else
life criterion when machining steel. The second speed,
there is a provision for an automatic regulation to stable
n2, shall be the first “critical” speed lower than n1. A
speeds. In this case, use only the most stable speed
“critical” speed is a speed that corresponds to the fre-
available. (Because the stability of such a machine type
quency at the bottom of a lobe, as described in Appendix
is well characterized, only one spindle speed is required
G. In this way, the range between the “critical” stability
for the chatter test in this case.) If a separate test is
(the minimum expected stability) and the stability at
required to check the recommendations or the function-
stable speeds is determined.
ing of the speed regulating system, such a test shall be
negotiated between Supplier and User, as part of the 9.5.4.3 Spindle Speed Rule 3. Only the minimum
initial machine specification. characteristics are available, as specified in para. 9.2.1.

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Table 9.5 Standard Tools and Default Machine and Cutting Parameters for the Chatter Tests
Using Solid (HSS or Carbide) End Mills
Workpiece Material: Aluminum 7075-T6 (Chip Load cp 0.1 mm/Tooth)
Machine Class
Variable A B C D E F
d, mm 12.5 19 25 38 50 50
l, mm 30 50 75 75 75 125
m 2 4 4 6 6 6

Holder
Variable R S R S R S R S R S R S

Hc, ␮m/N 1.0 0.5 3.6 0.6 2.4 0.4 1.4 0.26 0.36 0.14 0.17 0.07
fn, Hz 1 400 1 600 700 1 300 450 1 300 600 840 600 800 900 1 000
nmin, rpm 3 250 3 700 1 100 2 000 520 1 400 460 640 350 460 520 580
nmax, rpm 11 200 12 800 2 800 5 200 2 100 5 600 1 600 2 200 1 600 2 200 2 400 2 700
ns, rpm 42 000 48 000 10 500 19 500 7 875 21 000 6 000 8 250 6 000 8 250 9 000 10 125
blim, mm 2 4 0.25 1.65 0.4 2.5 0.5 2.55 1.85 4.75 3.9 19
Tlim, N-m 0.65 1.3 0.25 1.65 0.5 3.15 1.35 7.5 7 17.5 15 70

GENERAL NOTES:
(a) In machining aluminum, none of the nmax speeds is too high to endanger tool life.
(b) Obviously, Tmax cannot be exceeded in any of the cases.

Use the fn data for each of the feed directions, X and Y. Table 9.6 Standard Tools and Default Machine
Determine nmin and nmax from formulas. Choose a speed, and Cutting Parameters for the Chatter Test for
n1, in this interval, the highest one permissible from the End Mills With Carbide Inserts
point of view of tool life. Again, as in the case of spindle Workpiece Material: Steel 4340
speed rule 1, only one spindle speed is required. For (Chip Load c p 0.15 mm/Tooth)
machining of steel this will probably be the nT speed Machine Class
and for aluminum it will be the nmax speed. If the speed
Variable D E F
n1 is not available, do not perform the chatter test.
It is also possible, in a way analogous to rule 2 above, d, mm 50 50 67.5
to use two speeds higher than nmax such that mn1 p 60 l, mm 75 100 150
fn or mn1 p 60 fn/2, and n2 p 1.33 n1 or n2 p 0.57 n1; m 4 4 6
the higher of the two that is available. If such an option Hc, ␮m/N 0.26 0.15 0.10
fn, Hz 600 700 900
is selected, it shall be made part of the original machine
nmin, rpm 350 400 400
specification as agreed upon by Supplier and User. nmax, rpm 2 400 2 800 2 400
nT , rpm 760 760 570
9.5.4.4 Spindle Speed Rule 4. No dynamic character-
bcr , mm 1.9 2.5 2.5
istics are available at all. In this case, use the default Tcr , N-m 19 25 50
spindle speeds as given in Tables 9.4, 9.5, and 9.6.
Again, it is possible to use two speeds higher than GENERAL NOTES:
nmax, in the same way as defined in spindle speed rule (a) These tools are equivalent in stiffness to the end mills of Table
3. In such a case, this option must be agreed upon as 9.5 in the short (S) holders.
part of the original machine specification, as discussed (b) Machine classes A, B, and C do not qualify for these tools.
in spindle speed rule 3.

9.5.5 Tools and Cutting Conditions With tool/holder/spindle being most significant, the
On most machining centers, the most flexible part of overhang of the cutting edge from the spindle bearing
the structural system is the tool holder/spindle/bearing plays an important role. The currently common V-flange
system and, if used, the end mill. In some instances, the holders provide a rather large overhang for face mills
mass of the workpiece together with the mounting of and even more so for end mills. For the latter, the set-
the rotary table may also have significant compliance. screw type clamping of the cutter is much stiffer than
Finally, the mass of the headstock on the “springs” of most of the collets, but its length contributes significantly
the guideway may also contribute to the machine com- to the tool overhang. New tool holders have been devel-
pliance. oped that provide lesser overhangs than the standard

113
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50 mm

140 mm

(a) Regular Face Mill (a) Set Screw Type Holder

(b) Special Short Overhang Holder (Shrunk Fit)

Extension length, L
Fig. 9.4 Typical End Mills
(b) Face Mill With Extension
a small lead angle (3 deg or 10 deg), and uniform pitch.
Fig. 9.3 Typical Face Mills The regular (R) tools are such that they are clamped on
the regular V-flange type holder. The long (L) ones are
clamped on a holder that is, by the amount of extension,
V-flange holders. These may be included in the test pro- L longer.
gram. They are designated S for short. For example, end 9.5.5.2 High Speed Steel (HSS) and Solid Carbide End
mills may be made integral with the tapered holder or Mills. End mills of high speed steel or carbide (see Fig.
clamped directly into the spindle. 9.4) with smooth continuous edges and uniform tooth
For the standard tests, the holders to use are the short- pitch shall be used. The length, l, given in the table
est V-flange holder for face mills and the V-flange set- (Table 9.5) is measured as the total overhang from the
screw type holder for end mills.2 These will be desig- face of the holder to the tool end (see Fig. 9.4). It shall
nated R, for regular. However, in many instances, for be maintained within ±5%. The standard set-screw type
practical purposes, the face mill must be clamped on a tool holder is used as the regular (R) holder. The alterna-
100-mm or a 150-mm extension holder. In that case they tive short (S) holder is one where the clamping of the
may be used for these tests if such use is clearly specified tool is much closer to the spindle face than with the
in the machine specification. They are designated L (for regular holder. An extreme case is the example of a
long) in the tables. For end mills, the smaller diameter, “shrink-fit” holder, where the face of the holder extends
longer cutters may overwhelm the rest of the structure only about 30 mm out of the spindle. Such a short holder
and provide the major part of the resulting compliance. may be used if recommended by the Supplier or
Because it is the machine that is to be tested, they are requested by the User, and made part of the original
excluded from the tests. (An exception may be made if machine specification. The default values of stiffness for
there is a provision to stabilize cutting with slender end the S holders in Tables 9.5 and 9.6 apply to the shrink-
mills, like an automatic system for regulation into stable fit holder.
speeds. In such a case, these tools may be included in
this test, as long as their expected performance in the 9.5.5.3 End Mills With Carbide Inserts. These cutter
machine is made part of the original machine specifica- bodies are made one piece with the tapered holder and
tion and is given in equivalent detail to other cutting in stiffness they are similar to the S holders in Table 9.5.
performance tests in this Standard.) When possible, such a design is to be used where the
Based on these considerations, the following tools are inserts virtually fill the cutting edge completely. The
specified for the standard tests. top end mill in Fig. 9.5 shows a typical end mill with
overlapping inserts. However, commonly these cutters
9.5.5.1 Face Mills. Face mills (see Fig. 9.3 and Table do not have edges completely filled, as there are gaps
9.4) with negative square carbide inserts will be used, between the inserts along the edge. For these cutters,
with negative/negative geometry, 0.5-mm nose radius, the number m will still express the number of cutters
2
per circumference, but the axial depth of cut b will be
Other tool holders may be used for this test as agreed between expressed as the actual depth of cut times the average
Supplier and User and made part of the original machine specifica-
tion. However, in such cases it must be warned that the tables filling factor on the edge: p p b1/b, where b1 is the
supplied in the Chapter may not fully apply. cumulative length of the cutting edges. The bottom end

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reason, a different number of effective teeth (flutes) is

specified, the value of bcr will be affected. The value of
bcr in the slotting cut represents the shallowest possible
milling pass without chatter, and it helps to set the initial
depth of cut in the test. For radial immersions a/d < 1.0,
the limit depths will be larger.
(l) Tcr (N-m), the cutting torque in a slotting cut at bcr
(m) Pcr (kW), the power in a slotting cut at the depth
bcr and spindle speed nmax or nT when applicable
(a) Overlap Type The values of Tcr and Pcr are given for face mills only
to give guidance regarding the potential for exceeding
the available torque and power.

9.5.6 General Procedure for Chatter Testing

The chatter tests are to be performed on 4340 steel
(300–350 BHN) using the face mills and the end mills
b1
p⫽ with carbide inserts and on 7075-T6 aluminum using
b
only the solid end mills. To perform each test, first select
b b1 a machine class (Table 9.2); then choose the tool from
(b) Gap Type the appropriate table (Tables 9.4, 9.5, and 9.6). If the
table does not contain a reference to your machine class,
do not perform the test. Next, select the axis for the test.
Fig. 9.5 Typical End Mills With Carbide Inserts Select the spindle speed(s) for that axis using one of the
four spindle speed rules (see para. 9.5.4). Compute the
mill in Fig. 9.5 shows these types of end mills with gaps feed rate. The feed rate is given by
between the inserts.
Machine tool and cutting tool parameters are given F p cmn (9-6)
in Tables 9.5 and 9.6. The speeds, nmin and nmax, the
dynamic stiffness, and the expected chatter limits are
where
given as default values to be used whenever the fn and
c p chip load, mm/tooth
Hc parameters are not available. The default values are
F p feed rate, mm/min
based on accumulated experimental data from measure-
m p number of teeth on the cutter
ments on a large number of spindles. The parameters are
n p spindle speed for the test, rpm
(a) d (mm), tool diameter
(b) m, number of effective teeth or flutes Then follow the procedure in para. 9.5.7 for each of
(c) l (mm), end mill length the tests.
(d) L (mm), extension length for “long” face mill
holders 9.5.7 The Chatter Test Procedure for Both End and
(e) Hc (␮m/N), dynamic compliance of the dominant Face Mills
mode. Here it is assumed that all the other structural For the chatter tests, a workpiece in the form of a
parts are stiff, this value is the same in both the basic solid block is used. For face mills this block has the
directions, and it results from the compliances of the following nominal dimensions: width, w p d; length,
system l p 3d; and height, h p 0.75d; where d is the tool diame-
(f) fn, frequency of such a dominant mode ter. For end mills, the workpiece nominal dimensions
(g) nmin, minimum spindle speed, below which pro- are w p 100 mm, l p 200 mm, and h p 75 mm. These
cess damping would affect the results; derived from fn workpieces are illustrated in Fig. 9.6.
(h) nmax, maximum spindle speed, above which the For vertical spindle machines, the workpiece is
“lobing” affects a few of the results clamped directly to the surface of the table of the
(i) ns, the spindle speed for best stability, to be used machine. For horizontal spindle machines, the work-
if spindle speed rule 1 applies piece is clamped to a rigid block or an angle plate at a
(j) nT, maximum spindle speed for satisfactory tool height Hclamp p d above the table. Furthermore, the face
life; for carbide tools and steel 4340 this will correspond of the test block shall be on the edge of the table (pallet)
to a cutting speed of v p 120 m/min closest to the spindle to minimize extension of the quill.
(k) bcr, limit depth of cut for a “slotting” cut, where Some modifications of the workpiece will be required
radial depth (width) of cut a p d. The value given applies to provide proper clamping. Possible configurations are
to the standard number of effective teeth, m. If, for any illustrated in Fig. 9.6.

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h ⫽ 0.75d h ⫽ 75 mm

3d mm
L⫽ ⫽2
00
L
w⫽d w ⫽ 100 mm

(a) Face Mills (b) End Mills

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Hclamp

(c) Horizontal Spindle (d) Vertical Spindle

Fig. 9.6 Typical Test Parts for the Chatter Tests

The chatter limits will be tested in the two feed direc- it is expected to reach the rated torque, TR, be calculated
tions orthogonal to the spindle axis, X and Y, for three from the following formula:
radial immersions (radial immersion i p a/d, where a is
the dimension of the tool actually in the cut). The radial Ksabmc
TR p (9-7)
immersions shall be i p 1.0 (slotting cuts), i p 0.5, and 1,000(2␲)
i p 0.25. The test shall also be performed for both up
where
and down milling when the radial immersion is not
a p radial depth of cut, mm
equal to 1. Each test shall also be performed for all of
b p axial depth of cut, mm
the spindle speeds selected in para. 9.5.4. For each test,
c p “chip load” or feed per tooth, mm
the chatter limit will be defined as the limiting depth
Ks p “specific force” for the given material, N/mm2
of cut, blim, where chatter occurs for that particular radial
[Ks p 2 000 for 4340 steel (300–350 BHN) and
immersion, milling direction, feed direction, and spindle
750 for 7075-T6 aluminum]
speed.
m p number of teeth on the cutter
During these tests, chatter is most easily recognized
by the characteristic sound and by the examination of Furthermore, for each given spindle speed used there
the machine surface for chatter marks. However, as an is a corresponding rated power, Pw (see para. 9.3). The
aid in recognizing the limit, the spectrum of vibrations spindle shall be connected to an appropriate wattmeter
obtained from an accelerometer on the spindle or the so that it is possible to monitor the spindle power. If the
spectrum of sound obtained from a microphone can be rated power or the rated torque is exceeded, the test shall
used.3 be immediately stopped. In addition, it is recommended,
During each test, it is necessary to watch to ensure but not required, that a circuit be installed that constantly
that the available torque is not exceeded. It is recom- monitors the speed slow-down of the spindle and stops
mended that prior to the tests, the conditions at which the feed as soon as the actual spindle speed drops below
3
the commanded speed by more than a specified percent-
It also can be valuable to measure the chatter frequencies along age. This percentage speed reduction shall be given by
with the limiting depth of cut blim, and report these results also.
This is explained in Appendix G but is not a requirement of this the machine Supplier. If such a value is not supplied,
Standard. the default speed reduction is 6%. If the rated power is

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Slotting, i ⫽ 1.0 Table 9.7 Record of the Chatter Test

blim, a–b,
Direction Case mm mm2

X 0.25U 4.5 56.25

0.50U 1.9 47.50
L1 1.00 1.1 55.00
⌬L ⌬L 0.50D 1.8 45.00
L1 ⫽ 0.75d 0.25D 3.2 40.00
⌬L ⫽ 25 mm
b1 b2 b3
Y 0.25U 3.4 42.50
0.50U 2.3 57.50
1.00 1.6 80.00
0.50D 2.6 65.00
0.25D 4.7 58.75

Down milling 1/2 immersion, i ⫽ 0.5

cut is gradually increased in subsequent passes to b2 p
2b1, b3 p 3b1, etc., until chatter occurs. The depth of cut
at which chatter first occurs shall be designated blim for
the particular spindle speed, radial immersion, direction

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
of feed, and milling direction (up or down). The starting
depth, b1, is related to the estimated chatter limit depth
of cut for slotting, b cr. For the materials here, b cr is
Up milling 1/2 immersion, i ⫽ 0.5 given by

1.5
bcr p [4340 steel (300–350 BHN)] (9-8)
Hcm
Down milling 1/4 immersion, i ⫽ 0.25
4
bcr p (7075-T6 aluminum) (9-9)
Hcm

where

bcr p estimated chatter limit depth of cut for slotting

Hc p dynamic compliance (see para. 9.2.1), ␮m/N,
Up milling 1/4 immersion, i ⫽ 0.25 for the particular cutting direction
m p number of teeth on the cutter
b1 b2 b3
In the case where the dominant natural frequencies
and compliances are not given, bcr shall be chosen to be
equal to bcr in the appropriate table (see Tables 9.4, 9.5,
L and 9.6).
Two variations of the tests are described in the proce-
dure below. The first procedure assumes that the initial
Fig. 9.7 Chatter Test for Face Mills depth of cut is such that chatter does not occur and
subsequent depths of cut are increased. The second pro-
cedure is to be used if the initial estimate of a chatter-
free depth of cut, b1, is incorrect and chatter occurs on
exceeded at cutting conditions where the predicted rated
the first pass. In this case, the sequence is reversed and
power is less than that specified for the machine, or
successive cuts are made at decreasing depths.
the spindle slows down more than the specified speed
reduction percentage or stalls, the Supplier shall be 9.5.7.1 Regular Procedure. Commence machining
responsible for correcting this condition. with b1 p bcr/2i, where i is the radial immersion. Feed
The test procedure is as follows. For each spindle ahead a length, L1, where L1 p 0.75d and d is the cutter
speed, a radial immersion is selected. A sequence of diameter. If chatter occurs, discontinue this procedure
milling passes is carried out, starting with a small depth and follow the reverse procedure. If chatter does not
of cut, b1, at which chatter does not occur. The depth of occur, return the tool to the starting position, increase

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Down
1/ 2 30
2 immersion, 1/
4 immersion, i ⫽ 0.25
i ⫽ 0.5 24
4
L ⫽ 0.75d 18

blim
Full immersion,
i ⫽ 1.0 12
1 ⌬L ⫽ 25 mm

1/ immersion, 6
2
i ⫽ 0.5
5 1/
4 immersion, i ⫽ 0.25
3 0
Up 0 0.25 0.5 1.0 0.5 0.25 0
Up Milling Down Milling

GENERAL NOTE: The top surface is remachined after the 0.25 Radial Immersion, a/d
immersion cuts (2 and 3).
Fig. 9.9 Typical Results of the Chatter Test in
Fig. 9.8 Chatter Test With End Mills One Axis Direction

the depth of cut by b1, and then feed into the workpiece cuts in the up and down directions follow to complete
to a length, L1 + ⌬L, where ⌬L p 25 mm. During the the test.
cut of the additional length, the depth of cut will be After both the X and Y directions have been tested
b2 p 2b1. If chatter occurs, stop the procedure; if it does for each tool and spindle speed, the values of blim for all
not, return feed down by b1 again, then feed ahead by the cuts are recorded as shown in Table 9.7. For each
an amount ⌬L past the end of the previous cut. In this machining axis, the limit depth of cut will be plotted
last part of the motion, the depth of cut will be b3 p versus the radial immersion as shown in Fig. 9.9. The
3b1. Continue this procedure until chatter occurs or the cross-sectional area of the cut (the product of the radial
torque limit is exceeded. The depth at which chatter first depth of cut, a, and the limit depth of cut, blim) shall also
occurs is the limit depth of cut for the particular radial be plotted versus the radial immersion as shown in Fig.
immersion, milling direction, feed direction, and spindle 9.10. The area is indicative of the metal-removal rate. The
speed. If chatter does not occur before the rated torque condition where the maximum rated torque is reached
is exceeded, then blim is designated as blim > bi, where bi before chatter occurs shall be indicated on the figure by
is the depth of cut at which the rated torque is exceeded. an arrow pointed upward and by the connection of that
point to the other points by a dashed line. This is illus-
9.5.7.2 Reverse Procedure. The reverse procedure is
trated in Fig. 9.9.
used when chatter occurs at the initial depth of cut, b1.
If chatter occurs at this depth, the tool is returned and
withdrawn from the workpiece by the amount b1/4. The
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

next pass is taken to a length, L p L1 + ⌬L, as in the 9.5.8 The Full Torque Test
regular procedure. If chatter still occurs, the tool is This test is carried out face milling 4340 steel (300–
returned and withdrawn again by the same amount, 350 BHN) using the regular (R) holders only (see para.
b1/4. The procedure is repeated until no chatter occurs. 9.5.5), under the same conditions as for the face milling
The last depth of cut at which chatter occurs is designed chatter test (see Table 9.4), except that the chip load, c,
as blim. If chatter still occurs, even at the minimum depth is 0.3 mm per tooth. The spindle speed shall be nT (see
(which is b1/4), the test is concluded and the limit depth para. 9.5.4). Before commencing this test, check the
of cut is considered to be blim < b1/4. graphs obtained of the limit cross-sectional area and
The sequence of tests with face mills shall be such torque versus radial immersion in the end milling chat-
that the slotting cut (radial immersion i p 1.0) is done ter test (see Fig. 9.10) for both the X and Y directions.
first. After this test, mill the surface flat. Then proceed If the rated torque was reached in any one of these tests,
with the radial immersion equal to 0.5 in the down no additional test is necessary. If this is not the case, a
milling direction, followed by the up milling at the same full torque test shall be performed using any one of the
radial immersion. After this test, mill the surface flat radial immersions and feed directions in the chatter test
once again and then perform the up and down milling where half the rated torque of the machine (TR/2) was
tests with a radial immersion of 0.25. This is illustrated exceeded. The other conditions of this test are as follows:
in Fig. 9.7 and is performed for each axis direction. For First the chip load is increased to 0.3 mm and the depth
end milling, start with a radial immersion of 1 in the of cut is set at one-half the depth of cut at which TR/2
center of the workpiece (see Fig. 9.8), follow this cut was reached. A series of cuts is now initiated. After each
by the 0.25 radial immersion cuts in the up and down cut, the axial depth of cut, b, is increased by the same
directions on the sides of the workpiece, and then clean amount as used previously in the chatter test (para. 9.5.7)
the sides of the workpiece. The 0.5 radial immersion until TR is obtained. If, while performing the chatter

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600 115

480 92

360 69
ablim, mm2

T, N-m
240 46

120 23

0
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

0.0 0.25 0.5 1.0 0.5 0.25 0

Up milling Down milling
Radial Immersion, a/d

Fig. 9.10 Plot of the Limit Cross-Sectional Area of Cut Versus the Radial Immersion for a Typical Chatter
Test

Form 9.1 Record of the Fill Torque Test

Direction Up/Down a, mm b, mm Tex Pmeas Tmeas

X or Y (User-selectable) Up or down

test, there was no case where half the rated torque (TR/ inclined surfaces so that the radial depth of cut will
2) was reached without chatter, do not perform this test. continuously increase for the cuts in the positive X
Note that because the chip load was changed to 0.3 mm (down milling) and negative X (up milling) directions.
per tooth, a new feed must be computed (see para. 9.5.6) In this figure, an end mill of diameter d is illustrated.
before initiating this test. The power is measured on a The same type end mill is used as in the chatter test, as
wattmeter or other such measuring device as recom- given in Table 9.5. Furthermore, the material, spindle
mended by the machine Supplier. The results of the test speeds, and feed rates are to be the same as those used
will be expressed in a form as shown in Form 9.1. previously in the end milling cutting performance test
Tex is the expected torque for the test (see para. 9.5.7). (para. 9.5.7). Also, the workpiece shall be fixtured in the
Tmeas is obtained from the measured power minus idle same location as the chatter test with the same quill
loss power as extension. The values of P, R, and h, which define the
geometry of the premachined workpiece, are selected
(Pmeas − Pidle) as 125 mm, 1.2d mm, and 1.6 mm, respectively. The axial
Tmeas p (9-10)
(2␲n/60) immersion of the cut b is selected from the results of
the solid end milling test (para. 9.5.7) to ensure the
where
maximum possible depth of cut without producing
P p spindle power, W
chatter.
The cutting pass is programmed so that the ideal sur-
face produced is 0.1 mm above the lowest point of the
9.5.9 The End Milling Deflection Test4 inclined surface. This means that the tool will first start
This test is performed by feeding in one axis at a cutting when its center has traveled about 8 mm from
time. Figure 9.11 shows a schematic of the test for the the beginning of the workpiece. The radial immersion
X direction. The other axis will be tested in the same at any given time during the cut is measured at the point
manner. The workpiece shall be premachined with two at which a tooth enters the cut (for down milling) or
the point at which a tooth leaves the cut (for up milling).
4
Note that the end mill for this test must have a corner radius The program first feeds the tool in the positive X direc-
smaller than 0.025 mm. tion until the midpoint of the workpiece is reached, then

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t3 t5
t2 t4
t1 t6

b
L2

e0 T1 T2 T3 T6 T5 T4 e0

Down milling
d Up milling
0.05 mm 1.5 mm
h
A A
B B
50 ␮m
0.1 mm
Before After
P R P
machining machining

Fig. 9.11 Test Part and Test Procedure for the End Milling Deflection Test

repositions the tool and runs a similar cut in the negative

X direction. The ideal surface left behind by these cuts
is shown as line A–A in Fig. 9.11. A reference surface is Table 9.8 Typical Results From an End Milling
then machined (line B–B), which is 50 ␮m below the Deflection Test
ideal surface using an axial depth of cut of 1.5 mm. Direction Up/Down a, ␮m emax, ␮m ⌬e, ␮m
Because of the small immersions, the deflections due to
the cutting forces are assumed minimal in the reference X Up 50 −20 27
500 +22 35
surface.
1 500 +32 38
The errors produced during the test are evaluated
using a displacement probe mounted in the headstock Down 50 −20 20
500 +43 43
of the machine. The probe traces the machined and refer-
1 500 +91 67
ence surfaces over lines T1 to T6 in the transverse direc-
tion.5 In Fig. 9.11, lines T1, T2, and T3 represent this Y Up 50 +48 23
position for radial depths of cut of 0.05 mm, 0.5 mm, 500 +46 23
and 1.5 mm, respectively, for the down milling case. 1 500 +48 30
Lines T4, T5, and T6 represent similar positions for the Down 50 +40 28
up milling case. Table 9.8 shows typical measurement 500 +50 28
results for this end milling deflection test and Table 9.9 1 500 +86 48
lists the location of the measurement lines used to obtain
these results for different tool diameters. Figure 9.12
shows examples of the displacement measurements

5
Using a machine tool to probe against a workpiece that has
been machined on that machine is generally called a “part trace
test” to distinguish the results that would be obtained from a
separate inspection. The machine probing that is described in the
Table 9.9 Location of Measurements for the End
end and face milling deflection tests is neither a part trace test nor Milling Deflection Test
a separate inspection, because the axis of the machine that is used
for the probing in the Z in the case of end milling, and X and Y T1, T6, T2, T5, T3, T4,
in the case of face milling, was not used during milling. Nonparal- d, mm e0, mm mm mm mm
lelism of the Z-axis with the spindle axis of rotation could affect
the results. Any taper in the end mill itself or conical shape in the 12.50 7.8 10.9 44.4 120.9
face mill will also affect the results. The Committee is aware of 18.75 7.8 10.7 43.9 119.9
these factors, but in the interests of keeping the instrumentation 25.00 7.8 10.6 43.4 119.1
and time required to a minimum and because the magnitude of 37.50 7.8 10.3 42.6 117.7
the milling deflection is expected to be large with respect to the 50.00 7.8 10.1 42.0 116.5
potential errors in metrology, the test is recommended.

120
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METHODS FOR PERFORMANCE EVALUATION OF COMPUTER ASME B5.54-2005
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500

425
⌬e ⫽ 67
emax ⫽ ⫹91
Deflection, ␮m

350

275 Reference

200
0 15 30 45 60
Distance, mm

Fig. 9.12 Sample Measurements of the Part Profile in the End Milling Deflection Test

obtained along lines T3 and T4, respectively. These plots diameter, d. The minimum length required is 3.5d and
show the errors of location plus surface profile (nonflat- the minimum width is 1d. The workpiece dimensions
ness) errors that arise due to the helix of the tool and its as well as some of the tool path are presented in Fig.
relationship to the vibration. The error could be positive 9.13. The machine is tested in the full radial immersion
(more material was left behind) or negative (more mate- and in half immersion up and down milling. The tool
rial was removed). These errors are expressed as a maxi- path is programmed to first cut a step 2d long with 1
mum error emax and an error range ⌬e. These are found mm axial depth of cut as shown in the figure. Then the
by using the reference surface to locate the position of tool is repositioned and the whole workpiece is milled
the ideal surface from which these errors can be directly with an additional 1 mm axial depth of cut. The axial
measured. The error is taken as positive if it represents depth then increases from 1 mm to 2 mm at the point
deviation out of the material. Table 9.8 shows an exam- at which the step occurs. The tool is further programmed
ple of the listing of the errors of position for the condi- to generate reference surfaces on both sides of the work-
tions T1 to T6 for the X- and Y-axes for a typical machine. piece as shown in Fig. 9.13. These reference surfaces are
The parameters used in defining the workpiece geom- machined 50 ␮m below the ideal surface of the test with
etry, as well as the positions at which the displacement 2 mm radial immersions.
probe should be used, change with the tool diameter. Once the machining is completed, the errors are mea-
Table 9.9 lists the values of e0 and T1 to T6 for common sured using a displacement probe. The locations for mea-
tool diameters. surements are selected at positions where no distortions
due to entry and exit phenomena occurred. The locations
T1 and T2 are selected at 0.55d and 2.05d from the begin-
9.5.10 The Face Milling Deflection Test ning of the workpiece. Examples of results from testing
This test is analogous to the end milling deflection a machine type E are presented in Form 9.2. Plots of the
test and will also be run one axis at a time. The same errors for the slotting case are presented in Fig. 9.14. In
tool as in the chatter test according to Table 9.4 is used these plots, the vertical axis is reversed so that the mate-
cutting steel 4340. Speed nT is used and chip load c p rial is above the trace and the air over the workpiece
0.15 mm. The block workpiece does not require prema- below it. These plots are strongly affected by the error
chining in this case. Instead of machining an inclined of perpendicularity of the spindle axis with respect to
surface, a horizontal plane in two steps is machined. the base plane of the workpiece. This is shown in Fig.
The dimensions of the workpiece depend on the tool 9.13. This error causes a difference in the level of the

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Form 9.2 Deflection Errors in Face Milling

emax emax
Direction Case at 1 mm (␮m) ⌬e (␮m) at 2 mm (␮m) ⌬e (␮m)

X Slot +27 18 +24 44

1
⁄2 up +15 22 +11 15
1
⁄2 down −38 38 −42 31

Y Slot
1
⁄2 up
1
⁄2 down

Reference surface 50 ␮m

Slotting

1.5 mm
T1 T2
After machining
Reference surface

Material removed by the

first pass to create a step 1.0 mm

Reference surface P 2.0 mm

50 ␮m below cut 3.5d

␦
Down milling 1/ immersion
2

Reference surface

␦
Reference surface

Up milling 1/2 immersion

Fig. 9.13 Face Milling Deflection Test

two reference ledges. To exclude this effect from the points where these projections cross the respective axes.
result of this test and to make sure that the test expresses Then, a line parallel to the reference is drawn 50 ␮m
mainly the effects of deflections due to the cutting forces, above the reference and it represents the ideal location
a reference line is drawn in the graph; the reference line of the surface. The maximum error emax and the error
is constructed by projecting the right reference surface range ⌬e are measured from this line. The error is taken
to the left-hand axis and the left reference surface to as positive if it represents a deviation out of the material.
the right-hand axis. The line is drawn between the two

122
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1 mm axial depth
600

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
500 Projection of right
reference surface

Reference
Deflection, ␮m

400
50 ␮m

300
⌬e Ideal surface emax
location

200
0 50.0 100.0 150.0 200.0
Millimeters

2 mm axial depth of cut

600

500

Reference
50 ␮m
Deflection, ␮m

400

emax

300 ⌬e
Ideal surface
location

200
0 50.0 100.0 150.0 200.0
Millimeters

Fig. 9.14 Sample Displacement Measurements for the Face Milling Deflection Test When “Slotting”
(Radial Immersion p 1)

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ASME B5.54-2005

Chapter 10
Multifunction Cycle Test

10.1 GENERAL tool changes, traverse and feed motions, contouring,

G-code canned cycles, etc. The spindle shall operate
The machine shall be cycled through all basic machine
through its entire speed range during the test. A com-
functions (see para. 10.2) for a specified time period to
plete program run (cycle) time shall not exceed 15 min,
demonstrate its complexity, capability, and short-term
unless specifically negotiated between Supplier and
reliability. Preceding this test, a subsidiary test shall be
User.
performed to check the function of the machine limit
switches, coolant cycling, etc.
10.3 FUNCTIONAL CHECK
10.2 PROCEDURE The machine and control shall cycle as specified in
The machine and control shall cycle automatically para. 10.2 with only one failure over the complete speci-
under numerical control for a specified time period and fied test period. Correction of the failure shall not take
for a specified set of functions agreed upon between more than 1⁄2 hr. If more than one failure occurs and/
Supplier and User. The program used for the cycling or the correction takes more than 1⁄2 hr, the cycle test
test must position the machine over its entire work zone must be repeated, from the beginning, until the above
and shall include all basic machine functions, such as condition is satisfied.

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ASME B5.54-2005

Chapter 11
Test Equipment and Instrumentation

11.1 GENERAL such a system shall be better than 1⁄4 of the unidirectional
repeatability, linear axes.1
The instruments specified in this Standard are for rec-
ommendation only. Other instruments with similar
11.4.2 Grid Encoders
capabilities and accuracy are acceptable for use with
this Standard. It is recommended that the accuracy of Grid encoders used for contouring performance test-
the instruments and artifacts being used shall be such ing shall be calibrated with an error of less than 1⁄4 of the
that the resulting measurement uncertainty is less than unidirectional repeatability, linear axes, of the machine.
25% of the specified value for the performance parame- Calibrations traceable to NIST are preferred.
ter being measured, unless otherwise specified. In the
paragraphs below, simplified guidelines are given to 11.4.3 Precision Reference Ball(s)
approximate this condition for individual cases. The precision reference ball(s) for ETVE, tool change
and turret repeatability, and machine performance as a
11.2 TEMPERATURE measuring tool test shall be spherical to within 1⁄4 of the
unidirectional repeatability, linear axes, of the machine
The time constant of thermometers shall be no more tool. Reference balls used for the feature measurement
than 1⁄10 of the cycle time of the highest frequency compo- accuracy test shall be calibrated for their diameter to
nent of the temperature variation of interest in a test. The within 1⁄4 of the unidirectional repeatability, linear axes,
time constant is the time required for the thermometer to of the machine. Diameter calibration, where required,
indicate 63.2% of its final change due to a step change in shall be traceable to NIST.
temperature (see ASME B89.6.2 for further clarification).
The resolution of thermometers shall be no greater 11.4.4 Precision Disks
than 1⁄10 of the amplitude of the lowest-amplitude com-
ponent of temperature variation of interest in a test. The precision disk(s) used for the contouring test shall
Thermometers used for nominal differential expan- be calibrated to an accuracy of 1⁄4 of the unidirectional
sion correction or laser wavelength correction shall be repeatability, linear axes. Calibrations traceable to NIST
calibrated by suitable means to an accuracy of ±0.1°C are preferred.
over the temperature range of use. Calibrations traceable
to the National Institute of Standards and Technology 11.4.5 Telescoping Ball Bars
(NIST) are preferred. Calibration frequency shall be that The balls on the end of the telescoping ball bar shall be
recommended by NIST for the particular sensor. spherical to within 1⁄4 of the unidirectional repeatability,
linear axes, of the machine tool and equal in diameter
to within 1⁄4 of the unidirectional repeatability, linear
11.3 RELATIVE VIBRATION
axes, of the machine. The length variation due to sag of
Relative vibration shall be measured using a high- the telescoping ball bar in any position shall be less
resolution, undamped displacement indicator. Resolu- than the resolution of the machine being tested, and the
tion of 0.1 ␮m (approximately 0.000004 in.) or better resolution of the ball bar indicator shall be equal to or
is recommended. Such indicators should also have a better than the machine resolution. Any ball bar system
bandwidth of at least 1 kHz. conforming to the requirements of this Standard shall
state, as part of the output data, the angular interval
used for ball bar length measurement during circular
11.4 DISPLACEMENT
contouring. The ball bar shall be calibrated to an accu-
11.4.1 Laser Interferometers racy of 1⁄4 of the unidirectional repeatability, linear axes.
Calibrations traceable to NIST are preferred.
Laser interferometers shall have a frequency stability
of such that this long-term stability represents an error
less than 1⁄4 of the unidirectional repeatability, linear 1
Users concerned with the suitability and accuracy of a laser
axes, of the machine (in meters), divided by the length system for their application should contact the Precision Engi-
of the longest machine axis (in meters). The resolution of neering Division, NIST, Gaithersburg, MD 20899.

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11.4.6 Displacement Indicators recommendations and constants regarding the conver-

Displacement indicators used for the ETVE test, sion of differential displacement to angle shall be fol-
machine thermal tests, critical alignment, rotary axis lowed, with particular attention to the nonlinear
alignments, tool change repeatability, and repeatability corrections required for large angles. Special attention
in drift of tool-setting systems, as specified in this Stan- should also be paid to the alignment of the optical ele-
dard, shall be calibrated to within 1⁄4 of the unidirectional ments when such alignment is performed by the User.
repeatability, linear axes, of the machine. Capacitance 11.5.6 Differential Levels
probes, laser interferometers, linear variable differential
transformers (including air-bearing types2), fiber-optic Differential levels shall be calibrated to within 1⁄4 of
proximity sensors, dial gages, or other developed instru- the unidirectional repeatability, angular positioning.
mentation that accurately measures displacement Calibrations shall be performed on a regular basis, with
throughout the range of machine displacement varia- traceability to NIST being highly recommended.
tion, are acceptable. The bandwidth of the probe(s) to
be used for these tests is unspecified, as these tests are 11.6 PRESSURE
sufficiently slow that a bandwidth of a few hertz is
sufficient. Users are cautioned to make sure the band- The accuracy and repeatability of the pressure sensor
width of the indicator being used is sufficient for the used for correction of the laser interferometer shall be
intended purpose. at least ±1 mm Hg. Calibration traceable to national
standards shall be performed at an interval recom-
mended by NIST for that particular sensor.
11.5 ANGLE
11.5.1 Autocollimators 11.7 HUMIDITY
Autocollimators used for the positioning accuracy and Humidity measurement for correction of the laser
repeatability, rotary axes, and the periodic angle posi- interferometer wavelength shall be sufficiently accurate
tioning accuracy shall be calibrated to within 1⁄4 of the that it contributes no more than 1⁄4 of the unidirectional
unidirectional repeatability, rotary axes, of the axis to repeatability, linear axes, to laser measurement error.
be measured. Calibration shall be traceable to NIST and
performed on a regular basis or after any suspected
instrumental damage. 11.8 UTILITY AIR
The utility air pressure shall be measured using the
11.5.2 Polygons gages supplied with the machine, unless specified as
Polygons used for the positioning accuracy and part of the original machine specification.
repeatability, rotary axes, shall be calibrated to within
1
⁄4 of the unidirectional repeatability, rotary axes, of the
axis to be measured.
11.9 SPINDLE ERROR MEASUREMENT
At the time of this writing, the only suitable indicators
11.5.3 Indexing Tables for spindle error measurement are high bandwidth
Indexing tables shall be calibrated to within 1⁄4 of the capacitance gages. Such gages shall be calibrated to
unidirectional repeatability, rotary axes. The calibration within 1⁄4 of the unidirectional repeatability, linear axes,
may be performed by an appropriate agency, traceable and shall have a bandwidth of at least 10 kHz. The
to NIST, or by subdivision (a self-calibration procedure). User shall specify for particular applications if a higher
bandwidth is required. Other indicators of equivalent
11.5.4 Rotary Encoders bandwidth may be substituted, with the warning that
Rotary encoders shall be calibrated to within 1⁄4 of the some such indicators may be sensitive to parameters
unidirectional repeatability, rotary axes. The calibration other than displacement, and this condition must be
may be performed by an appropriate agency, traceable investigated.3
to NIST, or by subdivision (a self-calibration procedure).
11.9.1 Commercial Instruments
11.5.5 Angle-Measuring Interferometers Commercial instruments that measure spindle error
Several manufacturers offer differential interferome- motion shall have sensors that conform to the require-
ters for the measurement of small angles. For the use ments for spindle error measurement given in para.
of these interferometers, the instrument manufacturer’s 7.5.3.1.2. Furthermore, such instruments shall provide

3
In particular, inductive sensors are also sensitive to the metal-
2
Air-bearing LVDTs are preferred for the part-trace tests on high- lurgy of the mandrel or ball used as a reference artifact when
precision machines. testing spindles.

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documentation to ensure that any internal algorithms 11.11 TEST PART MEASUREMENT
conform to the measurement procedures as described If a coordinate measuring machine is used for a test
in this Standard. part measurement it shall conform to the requirements
of ASME B89.4.1 and have a working tolerance for volu-
metric performance less than 1⁄4 of the specification zone
for the specific machining test(s). If other inspection
11.10 INDICATORS FOR STRAIGHTNESS methods are used, all instruments, gages, and proce-
MEASUREMENTS dures required for these measurements shall have cali-
brations to ensure that individually the error component
Indicators for straightness measurements shall con- that they introduce shall be at least 1⁄10 of the specified
form to the requirements of para. 11.4.6. measurement accuracy for the test part.

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ASME B5.54-2005

NONMANDATORY APPENDIX A
GUIDE FOR USING THIS STANDARD

A1 GENERAL (b) positioning accuracy and repeatability, X-axis

(para. 7.3)
The primary purpose of this Standard is to aid in
(c) angular error motion, X-axis (para. 7.4.2.3)
purchasing of machines to specification. When purchas-
(d) positioning accuracy and repeatability, Z-axis
ing a new machine, the User should clearly specify the
(para. 7.3)
desired machine classification (para. 4.2) and the
(e) angular error motion, Z-axis (para. 7.4.2.3)
machine performance (Forms 1.1 through 1.5). If desired,
the User may also describe the proposed machine envi- (f) thermal distortion caused by moving linear axes
ronment on Forms 1.1 through 1.5; however, it is the (para. 7.6.3)
responsibility of the Supplier to provide these environ- Again, after completion of these tests, the machine
mental guidelines with the machine quote. When the will be in a warmed-up thermal state and needs to be
machine is received, it should be tested and, subject to allowed to come to equilibrium.
environmental derating, the measured values for the A2.3 Group 3
tests described should be less than or equal to the specifi-
(a) interrelationship between axes (para. 7.4.4)

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
cation zones in the original machine specification. Note
that the machine should be tested in the environment (b) spindle idle run loss test (para. 9.4)
in which it will be used. Testing at the Supplier’s plant (c) multifunction cycle test (Chapter 10)
is recommended, but is not a substitute for testing after
machine installation. A2.4 Group 4
(a) chatter limits test and full torque test (para. 9.5)
(b) other test parts, as specified
A2 RECOMMENDED TESTS
The tests described in this Standard are in logical
sequence but not necessarily the most rapid sequence
A3 RECOMMENDED MINIMUM SET
in machine testing. The most rapid sequence groups When it is desired to estimate machine performance
tests in terms of similar instrumentation. The following in a relatively short period of time, the following set of
is a suggested procedure for testing that the Committee tests, taken from the body of the Standard, is recom-
currently believes would minimize the testing time, by mended. These tests are for machines with only three
grouping tests. It is assumed that programs and all nec- linear axes. Machines with more than three axes will
essary fixtures have been prepared in advance. require additional tests. The minimum set of tests also
requires advanced preparation of the machine, tooling,
A2.1 Group 1 fixturing, NC programming, and test equipment.
(a) relative vibration test (para. 6.3)
(b) ETVE test (para. 6.2) A3.1 Contouring Performance Using Circular Tests
(c) structural motion test (para. 7.5.2) (Para. 7.11)
(d) spindle thermal stability test (para. 7.6.2)
The telescoping ball bar provides a rapid and efficient
(e) spindle error motions: rotating sensitive direction
way of measuring a machine tool’s contouring accuracy
(para. 7.5.3)
along a circular contour. Contouring performance shall
(f) composite thermal error (para. 7.6.4) be measured in three different planes following the pro-
Note that the composite thermal error test requires 4 cedures in para. 7.11.2. For four- and five-axis machines,
hr to perform. After this test, the machine must be refer to Appendix J, para. J1.
allowed to come to equilibrium before other testing can
proceed. A3.2 Positioning Accuracy and Repeatability (Para.
7.3)
A2.2 Group 2
Positioning accuracy and repeatability shall be mea-
(a) contouring performance using circular tests sured for all three axes following the procedures outlined
(para. 7.11) in para. 7.3.2.1.

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ASME B5.54-2005 NONMANDATORY APPENDIX A

A3.3 Diagonal Displacement Measurements (Para. A3.4 Precision Contouring Machining Test (Para. 8.2)
7.7) For the purposes of the machine performance evalua-
tion, test parts will be machined to provide assurance
For this test, the diagonal displacement shall be mea- that the machine is functioning as expected. For this
sured along all four body diagonals, following the proce- test, a modified version of ISO 10791-7 is recommended,
dures outlined in para. 7.7.2. as shown in para. 8.2.

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ASME B5.54-2005

NONMANDATORY APPENDIX B
THERMAL ENVIRONMENT VERIFICATION TESTS

B1 PURPOSE With these constraints, the following tests should be

performed.
The performance of machine tools is strongly affected
by the detailed characteristics of the thermal environ- B2.1 Velocity
ment that surrounds them. Parameters of importance
Since air is the most widely used cooling medium in
include cooling medium (usually, but not always, air),
dimensional metrology laboratories, the following tests
velocity of cooling medium, frequency and amplitude
are structured for measuring air velocity. If some other
of temperature variations of the cooling medium, mean
medium is to be used for heat transfer, then methods
temperature of that medium, and temperature gradients
for testing its properties should be part of the machine
within that medium. The effects of these parameters and
specifications.
others are discussed in detail in ASME B89.6.2. It is
For the measurement of velocity, several types of
the thesis of ASME B89.6.2 and of this Standard that
instruments could be suitable. These instruments and a
currently it is not possible to specify a thermal environ-
discussion of the measurement problems are given in
ment that will ensure a specific value for the expanded
Tables B1 and B2 of ASME B89.6.2. It is recommended
thermal uncertainty, UT(L), para. 6.2.3. For a thorough
that the instruments used are properly calibrated and
discussion of the technical situation, refer to ASME
the test personnel are aware of both the limitations of
B89.6.2. The purpose of this Appendix is, however, to
their instruments and their operation.
specify procedures and responsibilities for testing the
Using appropriate instruments, the velocity of the
thermal environment if the ETVE, as measured in para. cooling medium around the machine shall be measured.
6.2.2, is excessive. That is, the expanded thermal uncer- Measurements shall be made at the corners of a cubic
tainty exceeds that required for the machine, and the volume that completely encompasses the machine, and
machine User contends that his/her environment meets the velocity shall be computed as the average of these
the Supplier ’s parameters. For this Standard, these eight measurements.
parameters include cooling medium velocity, nominal
mean temperature, frequency and amplitude range of B2.2 Mean Ambient Temperature
temperature variation, and horizontal and vertical tem-
The mean ambient temperature shall be measured
perature gradients. The following tests are designed to
using a thermometer with characteristics as specified in
measure these parameters for the purposes of assuring
Chapter 11. The mean ambient temperature shall be the
conformance to the Supplier’s parameters.1
time-average temperature of five readings taken at the
center of the machine work zone over a period of time
B2 TEST METHOD spanning the longest test. (The use of five readings,
rather than two, for the measurement of the mean ambi-
To ensure that the environment itself is tested rather ent temperature is justified here for diagnostic pur-
than any characteristic of the machine tool supplied, poses.)
these tests are to be conducted with the machine tool,
support computers (if supplied), and any other auxiliary B2.3 Frequency and Amplitude of Temperature
equipment related to the machine tool, turned off for 24 Variation
hr preceding the test, to allow adequate soak-out of The range of frequencies of temperature variation and
machine tool induced thermal gradients. Normal activ- the amplitude of those variations shall be determined
ity, however, should be continued about the machine as by measuring and continuously recording the tempera-
this constitutes part of the User-supplied environment. ture at the center of the work zone over a period of time
that should, at a minimum, be representative of a daily
1
This Appendix discusses only measurements of air temperature, cycle (i.e., 24 hr). The maximum peak-to-valley tempera-
and the User is warned that sometimes thermal effects are caused ture variation shall be determined from the recorded
by coupling of infrared and visible radiation to the machine. If the data. The data shall be analyzed to determine the range
environment appears to conform to the Supplier’s parameters after of temperature variation for a daily cycle and an hourly
performing the tests in these appendices and the ETVE of the
machine is still not within specification, radiation coupling should cycle, subject to the condition that isolated disturbances
be seriously examined. that are shorter in duration than the minimum period

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ASME B5.54-2005 NONMANDATORY APPENDIX B

(maximum frequency) specified by the Supplier shall temperatures. The horizontal gradient is defined to be
be ignored. The daily variation shall be defined as the the difference between the maximum and the minimum
maximum range of temperature readings in 24 hr, sub- temperatures along any horizontal line through the
ject to the condition on transients mentioned above. The machine divided by the distance between the measure-
amplitude of the superimposed hourly cycle shall be ment points of these extreme temperatures. These read-
defined as the maximum range of temperature variation ings shall be taken over a period of at least as long as
in any 1-hr interval, subject to the same condition. the longest acceptance test (or 24 hr) and the greatest
value of the gradient reported.
B2.4 Thermal Gradients
Thermal gradients shall be determined by measuring B3 ANALYSIS
the temperature at the extreme corners of the machine If any of the parameters measured in para. B2 exceed
in a horizontal plane and also at the highest and lowest the Supplier’s specified parameters, it is the responsibil-
locations of the machine. These temperatures shall be ity of the User to correct the problem in order to conform
defined as the average value of no less than five readings with those specified parameters, or else to be willing to
over an interval of 10 min. The vertical gradient shall accept the performance derating described in Chapter
be determined to be the difference between the maxi- 6. If the parameters so measured meet the Supplier’s
mum and the minimum temperatures anywhere along specified parameters, it is the Supplier’s responsibility
a vertical line through the machine divided by the dis- to correct the performance of the machine tool to meet
tance between the measurement point of these extreme the specified working tolerances.

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ASME B5.54-2005

NONMANDATORY APPENDIX C
SEISMIC VIBRATION VERIFICATION TESTS

C1 SCOPE history, which provides measurement of transient or

very low frequency vibratory events, such as beat sig-
The purpose of this Appendix is to recommend vibra-
nals. The frequency domain allows measurement over
tion measurement instrumentation and procedures for
a very short time range that provides ability to diagnose
measuring vibration at machine installation sites. Vibra-
many dynamic events.
tion levels shall be measured at the proposed machine
site(s) to compare to allowable site vibration limits estab- C3.2 Criteria Format
lished by the machine Supplier. This document also
defines the instrumentation and measurement proce- As defined in para. 5.3, the Supplier shall provide, as
dures to establish vibration on the machine for addi- part of the machine specification, a statement of accept-
tional analysis. This Appendix does not address the able vibration. The criteria should be provided by the
determination of vibration sources or reduction of vibra- Supplier or listed as part of the machine specification
tion levels. This task is usually involved and requires form (Form 1.1), if used. At least two criteria format
the knowledge of vibration specialists. options are presented: frequency response function and
time history. The supplied acceptance criteria will define
the format to present the vibration data for ease of com-
C2 DEFINITIONS parison.
To the extent possible, this document is intended to C3.2.1 Frequency Response Function. These types of
be self-defining. It is written for individuals with an criteria are specified as a vibration amplitude as a func-
engineering background. Definitions for specific vibra- tion of specific frequencies. The criteria are usually pre-
tion terminology may be found in IEST-RP-CC024.1. sented as allowable vibration amplitude versus
frequency, in hertz. The frequency range may vary from
C3 VIBRATION ACCEPTANCE CRITERIA Supplier to Supplier. In general, seismic vibrations are
applicable over a range of 0 (DC) to 100 Hz. Vibration
The machine Supplier is to provide site vibration crite- levels have large dynamic range and it is sometimes
ria of acceptability. Below these levels the machine can helpful to present amplitude data in logarithmic scale.
operate successfully, and above these levels problems If decibels are used, the standard reference values must
may occur. Each machine Supplier has different formats
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be used.
and levels of acceptance. The type of vibration measure-
ments to be taken will depend on format and vibration C3.2.2 Time History. These measurements represent
units specified by the machine Supplier. Based on the the vibration during the time period of interest. The
type of criteria, the vibration specialist should determine Supplier should specify a maximum peak-to-peak
the necessary measurement units, frequency range, mea- acceptable vibration amplitude and a time period over
surement locations, and instrumentation. which it applies.

C3.1 Criteria Units

C4 INSTRUMENTATION
Vibration is characterized by amplitude versus time
or frequency. The amplitude can be defined in displace- This paragraph describes various instruments
ment, velocity, acceleration, or power spectral density. required to perform on-site vibration measurements.
Since the machine is a cutting tool, units of displace- Various types of sensors, signal conditioners, recorders,
ment are most useful in relation to machine perform- computer programs, and signal analyzers are available
ance. Velocity and acceleration, however, are more to acquire such data. It is not intended to single out any
appropriate parameters for measuring machine site particular equipment manufacturer, but to recommend
vibration. Displacement may be suitable for specific situ- types of equipment that meet the requirements of this
ations, but it is not recommended for general vibration Standard.
measurements.
The use of time or frequency for the amplitude will C4.1 Transducers
depend on the acceptance criteria format of the machine Many types of transducers exist for various types of
Supplier. Time-based criteria are referred to as a time vibration measurements. The measurements specified

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ASME B5.54-2005 NONMANDATORY APPENDIX C

in this document require a seismic accelerometer or a (c) Dynamic Range. The dynamic range should be at
specific type of velocity transducer. least 70 dB. Better spectrum analyzers will have higher
dynamic range.
C4.1.1 Seismic Accelerometers. The two most impor-
(d) Frequency Resolution. This parameter, as it applies
tant requirements for the accelerometer are frequency
to the analyzer, is denoted in number of lines over which
response and sensitivity. Site vibration measurements
the analysis range is divided. Most analyzers can have
generally require low frequency and high sensitivity.
selectable resolution from 100 lines to 1,600 lines. The
The minimum frequency response linearity should be
resolution, in hertz, is calculated by dividing the fre-
less than 1 Hz, preferably 0.5 Hz. The frequency response
quency range by the number of lines. For example, a
should be greater than 100 Hz. The sensitivity of the
0- to 100-Hz frequency range acquired with a 400-line
accelerometer should be 10 V/g or greater, where g is
analysis will have 0.25-Hz (100/400) resolution. The fre-
equal to 9.8 m/sec2 (386 in./sec2).
quency resolution used must be compatible with the
C4.1.2 Velocity Transducers. These sensors are also resolution of the frequency response criteria. If the crite-
referred to as geophones. The sensitivity of the geophone ria are defined at every 1 Hz, the data must be acquired
should be 4 V/cm/sec (approximately 10 V/in./sec) or with a 1-Hz resolution. For example, 0- to 100-Hz criteria
greater. The frequency response linearity requirement defined every 1⁄2 Hz would need to be acquired with
of the velocity transducer is the same as the accelerome- 200 lines of resolution. This document recommends that
ter, 0.5 Hz to 100 Hz. 0–100-Hz data be acquired with 400 lines of resolution,
producing 0.25-Hz resolution data. The overall fre-
C4.2 Amplifiers and Signal Conditioners quency resolution will also be dependent on the trans-
The transducers require amplifiers and signal condi- ducer frequency response. The procedure above should
tioners. Most seismic accelerometers require an ampli- be followed, and modified only when the machine Sup-
fier, but some models may have built-in electronics that plier’s specification requests otherwise.
do not require signal conditioning. Velocity transducers (e) Anti-Aliasing Filter. This filter prevents incorrect
may require amplification and signal conditioning, reporting of frequency components due to under-sam-
depending upon the sensitivity and signal-to-noise ratio. pling of higher frequency signals. This filter is found on
It is the responsibility of the vibration specialist to use most (if not all) FFT analyzers. It should always be used.
the proper signal conditioners. (f) Averaging. Most analyzers have this feature. It is
used to reduce the effects of transient events such as
C4.3 Signal Recording/Analysis Instruments personnel or vehicular activity. It is recommended that
The type of instrumentation to use will depend on ten averages be taken for all measurements.
the type of criteria and format that have been provided Some spectrum analyzers have various types of aver-
by the machine Supplier. The frequency response criteria aging functions, such as linear, rms, peak hold, or expo-
require a fast Fourier transform (FFT) dynamic signal nential. Linear or summation averaging should be used.
analyzer or digital recorder. Time history data can be (g) Window Functions. This feature is used to force a
acquired with an oscilloscope, a digital recorder, or an generalized vibration signal into discrete time domain
FFT analyzer. periods. When window functions are not used, the fre-
quency response of the vibratory signal is incorrectly
C4.3.1 FFT Signal Analyzers. This type of analyzer is
distributed throughout the frequency range. There are
the most sophisticated means of measuring vibration,
many types of window functions. The most popular are
by providing the greatest amount of information about
Hanning, flat top, and uniform. Other windows provide
the vibration signal. In most cases, this additional infor-
excellent amplitude accuracy and poor frequency accu-
mation is necessary to understand the vibration environ-
racy, and vice versa. The Hanning should be used for
ment. Many types of FFT analyzers exist, from many
all measurements specified in this Appendix.
different manufacturers. One- and two-channel units,
hand-held, and PC-based are formats readily available. C4.3.2 Data Recorders. For ease of gathering vibra-
It should be noted that using a data recorder, as specified tion data in the field, the use of a multichannel data
in the following paragraphs, will require the use of an recorder is found to be useful and convenient. Such an
FFT analyzer after the data are acquired. It is the User’s instrument allows for three or more channels of data to
responsibility to understand the instrument, its capabili- be recorded simultaneously, while providing a perma-
ties, and its limitations. nent record for archives and verbal data annotation dur-
The following list offers guidelines for FFT analysis ing specific events. Additionally, the recorder allows a
configuration and specifications. record of the real-time response that can be most useful.
(a) Noise Floor. 100 dB/冪Hz. The data can then be processed at a later date using in-
(b) A/D Resolution. The resolution of the analog-to- house data reduction techniques such as FFT analyzers
digital converter should be at least 12 bits. The better specified in the section above. The recorder format must
analyzers will have a 16-bit A/D resolution. be digital and use Digital Audio Tape (DAT), because

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NONMANDATORY APPENDIX C ASME B5.54-2005

of its excellent signal-to-noise ratio and dynamic range C5.4.1 Time History. For time-history criteria, simply
as compared to analog tape. compare the measured peak-to-peak vibration levels to
the permissible level. The machine Supplier may provide
C4.3.3 Oscilloscopes. This piece of general laboratory
criteria for vertical and horizontal directions. It is impor-
equipment may be easily obtained to make an initial set
tant to compare the acquired data to the criteria in the
of time-history readings. Most facilities have an oscillo-
appropriate direction.
scope and personnel who can operate the equipment,
which allows a user to take baseline readings. The oscil- C5.4.2 Frequency Response Function. Comparison of
loscope is also useful for viewing beat signals, transient frequency response function criteria to frequency
events, and hourly and daily vibratory changes. The domain vibration data can be more effort than taking the
oscilloscope should be set to AC-coupled and free-run data. If the criteria have the same level at all frequencies
triggering. The vibration amplitude is determined by (straight line) or little changes in amplitude, it will be
viewing the signal and determining the peak-to-peak easy enough to draw the criteria over the printed vibra-
voltage amplitude, and using the transducer sensitivity tion levels. If the criteria are not constant or uniform, it
for converting to appropriate amplitude units. may be easier to compare data and criteria with various
software programs. This involves digitizing the criteria,
which in some cases requires entering levels at 1-Hz
C5 TEST PROCEDURE increments. The vibration data stored on the FFT ana-
The procedures for making vibration measurements lyzer must be downloaded into a PC. This requires dif-
are fairly simple, once the appropriate analysis equip- ferent steps, depending on the analyzer manufacturer.
ment is selected and configured as required. Using a spreadsheet, math, graphing, or special pro-
gram, the vibration data and criteria are combined into
C5.1 Calibration a single graph. Once the data are in a software format,
At a minimum, the vibration measurement equipment they can be manipulated, graphed, and analyzed in a
should have been calibrated by a qualified laboratory, usable format.
traceable to NIST, in the past 12 months (see Chapter
11). Site calibration of the transducers at the start of the C6 CRITERIA ASSESSMENT
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testing is required.
C6.1 Measured Vibration Below Criteria
C5.2 Transducer Mounting
If the vibration levels measured by the procedure
For all measurements, the transducers should be above are within the Supplier’s criteria, no additional
mounted directly and firmly to the floor or a common work is required. It is the sole responsibility of the Sup-
interface for measuring three mutually orthogonal axes. plier to maintain the performance of the machine in
Such mounting arrangements are referred to as triaxial. order to meet specifications.
Some accelerometers incorporate three transducers in
one device. When this mounting arrangement is used, C6.2 Measured Vibration Above Criteria
all three channels should be acquired simultaneously. If the vibration levels exceed the Supplier’s specifica-
tions, it is the responsibility of the User to isolate the
C5.3 Measurement Location
vibration to conform to the specification, or else accept
In general, the transducers should be mounted in the a performance derating as described in para. 6.3. This
general area where the machine will rest. This area Appendix does not provide information on how to
should encompass the outer envelope of the machine reduce excessive vibration levels, but vibration isolation
plus 3 m (approximately 10 ft) beyond its footprint. will reduce the levels. Before the vibration levels can be
reduced, the source of the vibration must be determined.
C5.4 Acquiring/Recording Data It may be easy to do this with the above equipment.
Vibration measurements should be made during nor- Shock and vibration isolator suppliers, who specialize
mal operations of the facility. Nearby equipment that in low-frequency vibration attenuation, should be con-
will be operating when the machine is expected to be tacted if vibration isolation or a vibration survey is
used should be running during the vibration testing. A required.
written test log or voice channel on a data recorder
should be maintained by the individual performing the
C7 REPORT
test so that any abnormal events during the test may be
recorded. A test should be repeated if abnormal events A report should be issued by the vibration specialist
occur. Normal vehicular traffic should not be excluded. within approximately three weeks. The report should
When the environmental conditions are satisfactory, the include all backup information and analyzed data, with
data should be recorded on tape, saved to memory, and a comparison to the machine specification. The report
printed or manually recorded. should include the following as a minimum:

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(a) title (f) analysis

(b) dates (issued and when data were taken) (g) summary
(c) calibration information It is important to note that the report should serve to
(d) description and diagram of test setup archive the baseline vibration data for later review, if
(e) procedure problems arise after machine installation.

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NONMANDATORY APPENDIX D
ELECTRICAL POWER MONITORING TESTS

D1 PURPOSE includes all normal or even intermittent electrical activ-

ity within the plant that could affect the machine. (As
The purpose of this Appendix is to specify test proce-
an obvious example, consider the case when arc welding
dures for analyzing the electrical power supplied to a
is done only a few days a week at a location that uses
machine tool and its support equipment if the electrical
the same feeder as the machine tool. In this case, the
power is suspected to be causing inadequate machine
power-line monitoring should include a typical arc
performance.
welding sequence.)
For making these measurements, an approved, cali-
D2 TEST EQUIPMENT brated power-line monitor of the type discussed pre-
viously should be used. Appropriate thresholds (sag,
Although the parameters describing the electrical
swell, and transients) should be set at the values corres-
power supplied to a machine can be measured by a
ponding to those levels set by the Supplier in the
variety of instruments (voltmeters, oscilloscopes, and
machine tool specification. Monitoring should continue
the like), it is the recommendation of this Standard that
for a sufficient period to ensure that all of the effects
a power-line monitor be used for these tests. Power-
mentioned are included. Seasonal changes, abnormal
line monitors are designed to monitor a wide range of
weather conditions, system operations, and other factors
disturbances and steady-state conditions in an unat-
all affect the power environment and the reliability of
tended mode of operation. Typical measured parameters
the power system.
include rms variations, transients, harmonics, and fre-
quency.
Definitions of these parameters are not provided in D4 ANALYSIS
this document. The reader is referred to IEEE 1159 for
complete definitions and explanations of each Typical power-line monitors provide printouts of both
parameter. the levels and times at which deviations from the
accepted thresholds occur. If the monitor is set with the
thresholds described above, any such deviations
D3 METHOD recorded shall constitute nonconformance with the Sup-
To ensure proper monitoring, the power supply to the plier’s specifications, and it shall be the responsibility
machine should be monitored for a period that includes of the User to correct such power-line defects. If no
the normal cycle of machine tool operation. In the one- deviations from specifications occur, then it is the
shift plant, this should include a complete shift. In the responsibility of the machine Supplier to correct the
three-shift plant, complete 24-hr monitoring is required. performance of the machine tool so that machine specifi-
Additionally, care should be taken that the power-line cations are met. For help in interpreting the power moni-
monitoring occurs over a representative period, which toring results, refer to Section 8 of IEEE 1159.

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ASME B5.54-2005

NONMANDATORY APPENDIX E
MACHINE FUNCTIONAL TESTS

E1 GENERAL Spindle speed error, %

冤 冥
measured target
The tests described in this Appendix are to verify −
spindle speed spindle speed
machine functional specifications that are important, but p ⴛ 100 (E-1)
target
do not directly influence machine accuracy. These tests spindle speed
influence the machining cycle time estimated based on
functional parameters like pallet change time and tool
change time, etc.
E3 TOOL CHANGE TIME

E2 SPINDLE RPM MEASUREMENTS This test is intended to measure the time taken for
the machine tool to perform a tool change operation.
This test is intended to verify whether the spindle is
running at the commanded revolutions per minute. E3.1 Test Procedure
E3.1.1 Equipment. A suitable timing device is used
E2.1 Test Procedure to measure the time taken by the machine tool to perform
tool change operations.
E2.1.1 Equipment. A spindle analyzer that is used to
measure spindle dynamic errors (para. 7.5) can be used, E3.1.2 Test Location. The machine shall be positioned
if available. Other instruments like strobe or rpm indica- at the center of the work zone with the spindle stopped.
tor can also be used to measure the spindle revolutions
per minute. E3.1.3 Measurement Procedure
(a) The machine shall be commanded to perform a
E2.1.2 Measurement Procedure tool change to pick up the nearest tool in the magazine,
(a) The machine shall be programmed to command and then return to the center of the work zone with
the spindle to run with no load at five different speeds, that tool.
equally spaced over the total spindle speed range (b) This process shall be repeated ten times.
(including maximum spindle speed1), and the spindle (c) The average time period between the start of the
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speed recorded. machine motion from the center of the work zone and
(b) For machines with ranges of spindle speeds, mea- the return of the machine (after picking up the nearest
surements shall be taken at the center of spindle speed tool) to the center of the work zone shall be reported as
range for each range, and at the maximum speed of the the minimum tool change time.
spindle. (d) A similar procedure is repeated ten times, with
(c) At each revolution per minute, a minimum of 100 the machine moving from the center of the work zone
revolutions shall be used to measure an average revolu- to pick up the farthest tool and then returning back to
tion per minute obtained from the spindle analyzer. the center of the work zone.
(d) The average revolution per minute shall be (e) The average time period between the start of the
recorded for each of the spindle speeds measured. machine motion from the center of the work zone and
the return of the machine (after picking up the farthest
tool) to the center of the work zone shall be reported as
E2.2 Data Analysis the maximum tool change time.2

The spindle speed error (differences between the tar- E3.2 Data Analysis
get and measured spindle speeds) shall be reported for The minimum tool change time error shall be reported
each spindle speed measured. as the difference between the nominal minimum tool

2
On most modern machine tool controllers, a look-ahead capabil-
1
Exercise cautionary measures to ensure that measurements at ity exists, minimizing the tool change time by allowing simultane-
different spindle speeds do not cause any safety concerns. ous magazine movement while cutting.

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NONMANDATORY APPENDIX E ASME B5.54-2005

change time and the measured minimum tool change (3) ZR at a position where the spindle nose is at the
time. edge of the table nearest to the column
The maximum tool change time error shall be reported (b) For vertical machining centers, the reference posi-
as the difference between the nominal maximum tool tion has the following values:
change time and the measured maximum tool change (1) XR at mid-travel of the X-axis
time. (2) YR at mid-travel of the Y-axis
(3) ZR at mid-travel of the Z-axis
E4 PALLET CHANGE TIME
E4.1.3 Measurement Procedure
This test is intended to measure the time taken for (a) The machine shall be commanded to perform a
the machine tool to perform a pallet change operation. pallet change to pick up the nearest pallet in the pallet
station, and then return to the reference position with
E4.1 Test Procedure
that pallet.
E4.1.1 Equipment. A suitable timing device is used (b) This process shall be repeated ten times.
to measure the time taken by the machine tool to perform (c) The average time period between the start of the
pallet change operations. machine motion from the reference position and the
E4.1.2 Test Location. The machine shall be positioned return of the machine (after picking the nearest pallet)
at the reference position, PR, with the spindle stopped. to the reference position shall be reported as the pallet
(a) For horizontal machining centers, the reference change time.
position is identified by the following values:
(1) XR at the mid-travel of the X-axis E4.2 Analysis of Results
(2) YR at 1⁄4 of the Y travel from its lower limit The pallet change time shall be reported.

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ASME B5.54-2005

NONMANDATORY APPENDIX F
MACHINE LEVELING AND ALIGNMENT

F1 MACHINE LEVELING are generally mounted on a thick foundation block with

adjustable wedges at each point of support. These
Most machine tools do not have to be leveled. Ships
wedges normally have a hole in their center to accommo-
have machine tools and the machines are never level.
date a grouted-in hold-down bolt to hold the machine
Schlesinger’s book on the Testing of Machine Tools, pub-
down to the block. These wedges and hold-down bolts
lished in 1927, discusses leveling and the use of levels
are adjusted “push–pull” to achieve the correct machine
at great length (pages 7, 10, 11, and 12). This emphasis
geometry. In so doing, the forces between the block and
on leveling of machines continues today. Absolute level-
the machine are indeterminate and vary widely from
ing is one method, and often a convenient method, for
point to point. Optimizing machine geometry should
achieving straightness of travel. It is rarely a require-
always be the goal. For machines of this type, it is the
ment, however. Many methods are now available for
recommendation of this Standard that the User work
measuring straightness, squareness, and parallelism that
closely with the machine Supplier to make sure the foun-
are faster and better. The use of electronic levels for
dation is adequate for the machine and is sufficiently
measuring the change in level such as the measurement
cured. Supplier’s recommendations regarding machine
of pitch or roll is, on the other hand, an important tech-
alignment shall be followed. If such procedures are fol-
nique in modern machine tool metrology. Installation
lowed, then the Supplier shall have sole responsibility
procedures that require absolute leveling should be
for meeting the functional specifications of the machine,
questioned.
derated as appropriate for thermal effects and excessive
relative vibration (see Chapter 6).
F2 DISTRIBUTION OF LOADING ON MULTIPOINT
SUPPORTED MACHINES
Uniform distribution of loading on multipoint sup-
ported machines is rarely a requirement. Such machines
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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ASME B5.54-2005

NONMANDATORY APPENDIX G
CLARIFICATIONS FOR CUTTING PERFORMANCE TESTS

G1 CHOICE OF METHODS FX(␻), GY p Y(␻)/FY(␻), where X and Y are generally

meant as vibrational displacements in two coordinate
Two fundamentally different approaches have been
axes perpendicular to the spindle axis and FX and FY
discussed for both the chatter limits test and the cutting
are periodically variable forces acting in the two axes,
force induced errors test. In one of them, the tests are
respectively. The forces act between the tool and the
made by specified machining passes and corresponding
workpiece, and the relative displacements are measured
observations and measurements. In the other approach,
between tool and workpiece.
the dynamic compliance between the tool and the work-
The individual components of the complete set are
piece is measured, and the chatter limits and surface
given in the following sections.
errors are calculated using the corresponding formulas
and computer simulations. In the latter approach, actu- G2.1 Measurement of the Transfer Functions
ally, it might be considered just to accept the main First obtain the transfer functions GX and GY over
parameters of the dynamic compliance as a measure of such frequency ranges as to contain all significant reso-
the required quality of the machine tool. This dilemma nances. It is usually sufficient to excite at spindle stand-
of the two approaches has been called the question of still, without preload. Sometimes it is also necessary to
cutting tests versus exciter tests. Each of the two has its measure with the spindle rotating and with the spindle
own pros and cons. The cutting tests are simpler to preloaded at standstill. It is often difficult to eliminate
understand and interpret, and they do not need much the effects of the excitation device on the results, espe-
special instrumentation. They have the advantage of cially when exciting at a point of low reflected mass, as
“proof of the pudding,” but their results may be affected with an end mill, and special care must be taken. Impact
by process damping and tool wear as well as by the excitation is preferable and preload may be provided
location of the chosen spindle speed in the lobing dia- by a piano wire stretched between tool and table. The
gram. Additionally, they are more time-consuming than transfer functions must be obtained for a representative
exciter tests and the cost of workpiece material and of selection of tool and tool holder combinations and for
tools is not negligible. Cutting tests must therefore be all the different basic configurations of the machine.
limited to a minimum number of tools and cutting con- This means, for example, that if the machine has an
ditions. The exciter tests, once the necessary instrumen- extendable ram, data for several selected extensions are
tation and skill is available, can be done quickly and in required. The transfer functions should be curve fitted,
many different configurations of the machine tool. Their and a table of modal parameters k (modal stiffness),
results can be used in a more general way, and provide m (modal mass), ␰ (modal damping ratio) of the most
information about chatter limits and surface accuracy for significant modes for each transfer function assembled.
various tools over the whole range of speeds. However, Four examples of measured transfer functions are pre-
because of some tricky effects like those of spindle speed, sented in Fig. G1. In each case, the imaginary part, Im(G),
thermal effects on the dynamic compliance, and nonline- of the transfer function is plotted on linear scales of
arities in bearings and guideways that need special expe- displacement (␮m) over force (N) versus frequency (Hz).
rience to account for, these tests cannot be simply In illustration (a), a simple transfer function in one direc-
recommended as fully satisfactory. tion is shown that contains only one dominant mode.
The best solution, recommended here, is to carry out In (b), an example is shown of a transfer function in
the exciter tests and complement and cross-check them one direction with two modes of approximately equal
with the cutting tests. Such a combination is considered compliances. In (c) and (d), rather complicated transfer
as the complete set. It is then recommended to use a functions are presented as measured on a tool in the
selection of the cutting tests as the verification set. The two basic directions and they differ substantially. Only
latter is the subject of this Standard. the imaginary parts are shown. These kinds of data are
then used for further processing, although they could
G2 THE COMPLETE SET be used as the final characteristics of the tested machine.

The contents of the complete set of tests are summa- G2.2 Computation of the Chatter Limits
rized here. The dynamic compliance is formally repre- In the next step, the data from para. G2.1 are used to
sented as a set of direct transfer functions GX p X(␻)/ compute the expected chatter limits. For this purpose,

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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ASME B5.54-2005 NONMANDATORY APPENDIX G

2
(a)
lm (GX ), ␮m/N

Hmax

⫺2
0 1000 2 000
Frequency, Hz

1
(b)
lm (GY ), ␮m/N

H1 H2
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

f1 f2
⫺1
0 1000 2 000
Frequency, Hz

0.03
(c)
lm (GX ), ␮m/N

⫺0.02

0.07

(d)
lm (GY ), ␮m/N

0
⫺0.01
0 500 1000 1250
Frequency, Hz

Fig. G1 Typical Transfer Functions

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NONMANDATORY APPENDIX G ASME B5.54-2005

well-established procedures may be used.1–3 The state chatter on the cut surface decreases, the slope of these
of stability of cutting (i.e., whether chatter vibrations waves increases, and a damping component of the cut-
occur) is fundamentally decided on the part of the cut- ting force prevents the regeneration of waviness.
ting process by the following parameters: the workpiece Machining at these low speeds is stable (for instance
material (the specific force, Ks), the axial depth of cut b when using high-speed steel end mills on steel) but not
(mm), the radial depth of cut (width of cut) a (mm), and very productive. Above a certain speed, nmin, dependent
even more correctly by the “radial immersion” on the frequency of the structural mode and on the
expressed by the ratio i p a/d, where d (mm) is cutter cutter diameter, the effect of process damping becomes
diameter, and by the number of teeth on the cutter, negligible. At the high speed range where the tooth
m. Increasing any one of these parameters may change frequency, ft p mn/60, approaches the natural frequency,
cutting from stable to unstable. Actually, in a good fn, of the structural mode, prominent lobes are seen in
approximation it is their product (abm/d) which is deci- the graph. They are due to the changes of phasing
sive. The change of the chip load, c (mm), does not affect between the regenerative waves related to subsequent
the state of stability, but it affects the amplitude of chatter teeth of the cutter. The highest “wedge of stability” is
once cutting is in the unstable range. Spindle speed, n, at such spindle speed at which ft p fn. We will denote
has a special effect to be explained in the following. On it the “stable speed,” ns. Other wedges of increased sta-
the part of the structure, stability is affected by the bility are found at n p ns/2, ns/3, ns/4, etc., but they
degree of dynamic compliance as expressed by the two are smaller and smaller. Over the whole range above
basic transfer functions. nmin, stability repeatedly drops to a level called the criti-
The link between the cutting process and the struc- cal depth of cut, bcr. Below a speed of nmax p 0.8ns/3,
tural parameters is the directional orientation of cut. stability varies little with speed and settles on bcr.
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Often the transfer functions in X and Y differ if even Even for more complex cases than the one with a
slightly. By changing the radial immersion, i, the direc- single dominant mode, the lobing diagram retains these
tion of the feed X or Y, or the mode of up or down characteristics. See Fig. G3, where lobing diagrams are
milling, the cutting force effect on vibrations in X and Y, compared corresponding to (a) a transfer function with
respectively, varies, as does the effect of these vibrations a single mode and (b) with one more flexible mode
back on the force. added, for a cutter with m p 8 and f1 p 300 Hz, f2 p
Considering all of these parameters, it is customary 800 Hz. In case (a), ns p (300/8)60 p 2 250 rpm and in
to express their effects in the so-called “stability lobing case (b), ns p (800/8)60 p 6 000 rpm. The thick lines
diagram.” It relates the effect of spindle speed, n, and were obtained by the more accurate method and the
of the axial depth of cut, b, on stability, and it has to thin lines by the simplified method. The bcr , ns, and nmax
be computed for all the values of radial immersion of parameters are indicated. The effect of process damping
interest, for the workpiece material of interest, for a was left out from this graph so as not to clutter it.
selected tool/tool holder combination, and for the cor- In summary, in the complete set of tests these kinds
responding structural dynamics. Computer programs of graphs are generated. If they were available for all
are readily available for plotting the diagram with a the tools to be used, one would know the ns speeds and
high degree of correspondence to reality, by repeated they could be used. It would be acceptable to also test
simulations, or to approximate it by using a “simplified the machine tool at these speeds.4
method.” Generally, however, it is useful enough to know the
Typically, for simple structural dynamics with one value bcr, which is obtainable from a simple formula,
single dominant mode, the lobing diagram looks like and the speeds nmin and nmax, and to arrange the test
the one in Fig. G2. It is plotted in coordinates: limit between them so as to check bcr and be on the “safe
depth of cut, blim, versus spindle speed, n. Its envelope, side” of stability.
shown in a thicker line, separates stable cutting (below
the curve) from chatter (above the curve). At the low G2.3 Cutting Tests
speed range, chatter generation is limited by “process Cutting tests of chatter limits are then carried out for
damping”: the wavelength of undulations created by the individual tool/tool holder and machine configura-
tion combinations to verify the most characteristic fea-
1
J. Tlusty, ”Machine Dynamics,” Handbook of High Speed
tures of the chatter limits as determined in para. G2.2.
Machining Technology, R.I. King, ed., Chapman and Hall, New
York, 1985. G2.4 Effects of Deflections on Accuracy
2
M. Weck, G. Petuelli, “Static and Dynamic Behaviour of Metal The data from para. G2.1 are further used to calculate
Cutting Machine Tools,” Vol. 3, Machine Tool Mechanics, Technol-
ogy of Machine Tools, MTTF, Oct. 1980, UCRL-52960-3, Lawrence the expected effect of deflections on accuracy of the
Livermore National Laboratory.
3 4
S. Smith, J. Tlusty, “Modeling and Simulation of the Milling S. Smith, T. Delio, “Sensor-Based Control for Chatter-free Milling
Process,” Symp. on Sensors and Controls for Manufacturing, PED by Spindle Speed Selection,” Symp. on Control Issues in Manufac-
Vol. 33, ASME 1988 WAM. turing, DSC Vol. 18, ASME 1989 WAM.

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ASME B5.54-2005 NONMANDATORY APPENDIX G

Process damping effect

Axial Depth of Cut, mm

Lobing effect

bcr

0 nmin nmax
ns ⫽ 60
m fn n

Spindle Speed, rpm

Fig. G2 Lobing Diagram for a System With a Single Dominant Structural Mode

machined surface. The relationship between the cutting helical teeth. With straight teeth, all of A–A would be
force, system deflection, and the error of the surface is generated in one simple instant, with the shift ␦ equal
not straightforward, but it has been thoroughly to a corresponding instantaneous value of the variable
explored.1,5 It is indicated in the graph in Fig. G4, which deflection y.
applies to peripheral milling (contouring) with end All of this can be computed and graphics like the one
mills. These tools commonly have helical teeth. Consider in (e) produced. This one shows how the surface error
first the diagram (a). The end mill is removing a layer varies with varying radial depth of cut a. Actually, the
a into a depth, b, and generates surface, S. Although recommended test procedure is just like this. It is impor-
every tooth removes a chip, shown in black, on the way tant to realize that the amplitude, Y, of the variable
from A to B, it contributes to the surface, S, at only the deflection and its phase shift depend on spindle speed
instant it passes through the line A–A. Actually, with and they follow the corresponding transfer function as
helical teeth the tooth contributes in an instant just one discussed in para. G2.1. These transfer functions are
little spot on line A–A. For instance, point 5 is just gener- used as inputs in the simulation program.
ated by the tooth edge shown in a thick helical line. As G2.5 The Cutting Accuracy Test
the tooth rotates, it contributes to the surface, S, along
The next step in the complete set is the experimental
1, 2, ..., 5, 6. The broken lines are snapshots of the edge
verification of the computations by the cutting accuracy
during the cutter rotation. And as the cutter moves with
test. In order to avoid the complexity of the speed effect
feed f, tooth by tooth climb subsequently along line A–A,
mentioned above and still get an assessment of the sig-
which moves along surface, S. The cutting force, graph
nificance of the errors produced by the structural deflec-
(b), has an average value Fav and a variation that is
tions under the cutting force, on the particular machine
periodic in the tooth frequency, ft. It acts on the structural
tool to be tested, it is recommended to use a low speed
system and produces an average displacement, yav , and
at which the amplitude, Y, remains constant over a wide
a variational component with amplitude, Y, frequency,
range of speeds and the phase shift, ␾, is close to zero.
ft, and phase shift, ␾. During the generating motion of
A satisfactory choice is half the nmax speed, or less.
the edge along A–A, the displacement varies through
The verification set of tests specified in Chapter 9 of
points 1 to 6, synchronized with the cutter motion. At
the Standard is formulated as a minimal set of cutting
every point on A–A, a different deflection is imprinted
tests with selected tool/tool holder combinations and
on surface S. The section through S is indicated in (d).
at cutting speeds most generally applicable as deter-
It has an average shift ␦av p yav and it is not flat but
mined by accumulated experience.
assumes a profile corresponding to the variation of the
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

deflection. The latter part of the error is related to the

G3 ESTIMATING CHATTER LIMITS
5
J. Tlusty, S. Smith, “Forced Vibration, Chatter, Accuracy in High To choose correctly the range of the test conditions,
Speed Milling,” NAMRC XIII, May 1985, SME. it is useful to estimate the test results beforehand using

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NONMANDATORY APPENDIX G ASME B5.54-2005

7
b, mm

bcr , simulation

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
bcr

nmax ns

0
(a)

7
b, mm

bcr ,
bcr simulation
bcr

nmax ns

n, rpm

0
5 000 10000
(b)

Fig. G3 Lobing Diagram for More Complicated Systems

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ASME B5.54-2005 NONMANDATORY APPENDIX G

Cutting Force
(b)
F

Fav

time
␾

(c) Y 6
3
Displacement

Y
Yav

time
1 2 5
4

(a)
f

(d)

A B
6
b

5
4
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

3
2
S
1
A

1.0

(e) 0.1

Fig. G4 Effects of Deflection in End Milling

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NONMANDATORY APPENDIX G ASME B5.54-2005

the minimum dynamic characteristics as specified in conditions are assembled for the individual classes of
para. 9.2.1. We will express the “critical” limits as machining centers, together with typical dynamic char-
encountered in the nmin, nmax range and as they represent acteristics and estimated test results.
the minimum stability in the range above n min . An
approximate formula for the limit depth of cut of a full
G4 THE SPINDLE MODE AND THE TOOL MODE
immersion milling pass, a/d p 1.0, is
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

In the analysis of the dynamics of the tool-spindle

−[1/(m/2)] system, it is common to speak about a “spindle bending
bcr p (G-1)
4KsuRe(G)min mode” or else a “tool mode.” Characteristically, for
smaller diameter tools the latter is more flexible and for
where larger diameter tools the former is more flexible. It is
Ks p specific force, N/mm2 then necessary to coordinate properly the size of the
m/2 p number of teeth cutting simultaneously tool with the size of the spindle.
in a slotting cut For illustration, a particular spindle of a machine type
Re(G)min p value of the minimum real part of the D with a tool in the S type holder is shown in Fig. G5,
transfer function between the tool and together with the main mode shapes. For each, the modal
the workpiece, measured in the direction stiffness is given in N/␮m. The tool is d p 19 mm, l p
of the feed, mm/N 75 mm. The tool mode at 2 144 Hz is the most flexible,
u p directional factor with a modal stiffness k p 9.42 N/␮m. This mode con-
This formula is based on a rather gross simplification sists mostly of vibration of the tool only, with the rest of
of the actual process and the results may be wrong by the spindle immobile. No changes in the spindle design
a factor of up to two times. However, even so it is could increase the modal stiffness of this mode. The
extremely useful. Further, assuming u p 0.33 and spindle bending mode with significant motions in the
Re(G)min p Hmax/2, front bearings at 1015 Hz has k p 62.7 N/␮m, and it is
therefore 6.6 times stiffer. All of the other modes are
3 even stiffer. The performance of this system is clearly
bcr (mm) p (G-2)
KsHm dictated by the compliance of the tool.
The same spindle and holder, but with a d p 38 mm,
where Ks is expressed in N/mm2 and H is expressed in l p 75 mm tool, is shown in Fig. G6. Now, the spindle
mm/N. mode at 839 Hz has k p 59 N/␮m, whereas the tool
For 4340 steel (300-350 BHN), we use Ks p 2 000 and modes at 2429 and 3193 Hz have k p 234 and 247 N/
1.5
␮m, four times higher. Obviously, this is the right choice
bcr (mm) p (G-3) of tool size for this spindle.
Hm
For all the machine classes, similar analyses as well
where H is expressed in ␮m/N. as measurements have been compiled and used for test
For aluminum, Ks p 750 is used and tool size choices.

4
bcr (mm) p
Hm
(G-4) G5 USE OF SENSORS TO DETECT CHATTER
Using an accelerometer or a microphone helps to
where H is expressed in ␮m/N.
improve the confidence in the test results by matching
Referring to Eq. (G-9), as given in para. G6, we may
them with the measured transfer function and assurance
now express the estimated limitations imposed by chat-
that results are not faulty. Chatter is recognized by the
ter on torque and power limitations in slotting cuts:
development of a spectral line that is not a multiple of
cd the tooth frequency; it is actually close to the natural
Tlim (N-m) p (G-5)
2H frequency of the system. So, it helps if the expected
chatter frequency is known in advance. An example of
0.05cdn
Plim (W) p p 0.1Tlimn (G-6) this distinction is shown in Fig. G7. In this figure, the
H
spectrum of a stable case (top) is compared to the spec-
where trum of an unstable (chattering) case to the bottom. The
c p chip load, mm diagrams on the right show the spectra of the vibrations
d p cutter diameter, mm (d p a for slotting cuts) obtained from simulation. The ones on the left show an
H p dynamic compliance, ␮m/N actual microphone signal spectrum as measured during
n p spindle speed, rotations/min the cut. The spectral lines in the stable case are due to
the runout and tooth frequencies and, in the case of the
The use of these formulas is illustrated in Chapter 9, microphone, also the background noise. Both methods
Tables 9.4, 9.5, and 9.6, where the recommended test show the chatter frequency at 800 Hz. Note how much

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933.7 Hz 304 N/␮m

1 014.9 Hz 62.4 N/␮m

1 596.0 Hz 126 N/␮m

2143.7 Hz 9.4 N/␮m

Fig. G5 Mode Shapes for a Spindle With a Compliant Tool

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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838.8 Hz 58.9 N/␮m

1 547.2 Hz 584 N/␮m

2 428.7 Hz 234 N/␮m

3192.6 Hz 247 N/␮m

Fig. G6 Mode Shapes for the Spindle Mode With a Stiffer, Less Compliant Tool

the vertical scales increase in the chattering case. More- From the point of view of the drive, the torque, T
over, the microphone signal can be used for automating (N-m), determines the size of the motor and the dimen-
the test in which the chatter recognition system deter- sions of the transmissions. The spindle drives generally
mines the limits of the operation. Equipment for this possess characteristics of type (a) or (b) in Fig. G8. In (a),
kind of test is commercially available. the power available on the tool increases in proportion to
the spindle speed over the whole speed range. This
means that over the whole speed range, the maximum
G6 BASIC PARAMETERS OF THE MACHINE TOOL available torque is constant. It is
OF A MILLING PASS
T (N-m) ⴛ 2␲n (rpm)
For the purpose of selecting tools, workpiece materi- P (W) p (G-7)
60
als, and spindle speeds, machining centers have been
classified in Table 9.2 of this Standard into several ranges In most cases, however, the (a) type of characteristic
according to speed and torque. extends only over the lower range of spindle speeds up

149
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ASME B5.54-2005 NONMANDATORY APPENDIX G

10
RT SPEC Microphone signal
3 000 rpm SLOT B ⫽ 1 mm
CH 2 (actual cut) 7.0E-07
LIN Stable cut X vibration (simulation)
1X
5.6E-07
Millivolts

Meters
4.2E-07

2.8E-07
Tooth frequency
1.4E-07 (380 Hz)

0 00E-00
0.0 LIN 2 048 0 400 800 1200 1600 2 000
Frequency, Hz Frequency, Hz

10
RT SPEC Microphone signal
5 000 rpm SLOT B ⫽ 1 mm
CH 2 (actual cut) 7.8E-05
LIN Unstable cut X vibration (simulation)
1X
5.6E-05
Millivolts

Meters
4.2E-05 Chatter frequency
(800 Hz)
2.0E-05

1.4E-05

0 0.0E-00
0.0 LIN 2 048 0 400 800 1200 1600 2 000
Frequency, Hz Frequency, Hz

Fig. G7 Vibration Spectra of Stable (Top) and Unstable (Bottom) Milling

to the corner speed nc. From there on, power remains Ks p specific force for the given material
constant and equal to Pmax and the torque decreases 兵it is also the specific power, Ks [W/(cm3/s)]其,
hyperbolically: N/mm2
m p number of teeth on the cutter
60P (W)
T (N-m) p (G-8)
2␲n (rpm) In this way, torque signifies how “heavy” the cut is,
irrespective of spindle speed, n (rpm), or cutting speed,
For face milling we are then usually again in the con-
v (m/min), as these are not involved in the formula [Eq.
stant torque part of the range, whereas end milling often
(G-9)]. Once the speed is chosen in addition to the torque,
falls into the constant power range.
the needed power is obtained.
From the point of view of the milling operation, the
Here we will yet mention that, in general, chatter and
necessary torque is obtained as
accuracy depend on the same cutting parameters as the
Ksabmc torque and their limits also depend on the dynamic
T (N-m) p (G-9) stiffness between the tool and workpiece. In this way,
1 000(2␲)
it is proper to require more stiffness from machines with
where higher torques. These machines will have larger diame-
a p radial depth of cut, mm (see Fig. G9) ter spindles and generally heavier structures. These con-
b p axial depth of cut, mm cepts were used to develop the machining center ranges
c p chip load, or feed per tooth, mm (Table 9.3) used in this Standard.

150
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NONMANDATORY APPENDIX G ASME B5.54-2005

Pmax

Tmax ⫽ const

P⫽0
0 nmax
2␲n (rpm)
P (W) ⫽ T (N/m) ⫻
60
(a)

Tconst

Pconst
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Pmax
T

t
ons

T
Tc

P⫽0
0 nc nmax
(b)

Fig. G8 Characteristics of Spindle Drives

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ASME B5.54-2005 NONMANDATORY APPENDIX G

Face Milling
b
Full immersion

d
Down milling

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
End
Milling

d
a

Up milling

n p spindle speed, rpm

v p peripheral velocity cutting speed
c p chip load (feed/tooth)
i p rack radial immersion (a/d)

Fig. G9 Parameters Relevant in Milling

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ASME B5.54-2005

NONMANDATORY APPENDIX H
LASER AND MACHINE SCALE CORRECTIONS

冤 冥
H1 LASER AND SCALE CORRECTIONS 1 + 7.86 ⴛ 10−4Ps
CLR p LDR
If the laser interferometer used has environmental (Ta + 273) − 1.5 ⴛ 10−11RH(T2a + 160)
compensation features, the instrument manufacturer’s (H-1)
recommendations regarding the use of these accessories
shall be followed, with the material sensor placed on where
the appropriate machine scale or at some other position CLR p corrected laser reading
known to yield a measurement of the average scale tem- LDR p laser display reading
perature. Here the scale can be a lead screw, a ball screw, Ps p air pressure, kPa
a linear scale, or an inductive scale (see Chapter 4). RH p relative humidity of air, %
It is a requirement of this Standard that independent Ta p mean air temperature, °C
calibration of the temperature and pressure sensors of
such compensation devices be performed on a regular The preceding equation is a linearization of the modified
basis (see Chapter 11). Edlen equation and is accurate to approximately 0.1 ⴛ
If the corrections are to be performed manually, they 10−6. Other forms of this equation are equally accurate
shall be computed according to the following equation and for the purpose of this Standard are also suitable.

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
for a laser measurement system set to read correctly at To compare the corrected laser reading to the machine
20°C (68°F), 760 mm Hg air pressure, and 10 mm Hg readings, the machine readings must also be corrected
partial pressure of water vapor:1,2 for temperature. The corrected machine readings are
given by

CMR p MDR[1 + ␣(T − 20)] (H-2)

1
This form of equation also assumes atmospheric air with the
normal mixture of gases. Atmospheres that deviate significantly, where
particularly in regard to CO2 and aromatic hydrocarbon concentra-
tion, have been observed and can lead to measurable errors. If this CMR p corrected machine reading
situation is suspected, appropriate corrections should be applied. MDR p machine display reading
2
The partial pressure of water vapor can be calculated from the T p scale temperature during measurements, °C,
relative humidity by multiplying the saturated vapor pressure at in the case where the machine was set up
a particular temperature by the relative humidity expressed as a at 20°C (68°F)
fraction. The saturated vapor pressure at 20°C (68°F) is 17.6 mm
Hg. Thus, for example, 50% relative humidity at 20°C would yield ␣ p effective thermal expansion coefficient of
a partial pressure of 0.5 ⴛ 17.6 p 8.8 mm Hg. machine scales

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ASME B5.54-2005

NONMANDATORY APPENDIX I
DRIFT CHECKS FOR SENSORS, INCLUDING LASERS

I1 GENERAL Electronic drift tests have been useful in proving that

in many cases where electronic indicators have been a
Many tests in this Standard involve the use of dis-
suspected source of drift, the real cause was thermal
placement sensors over long periods of time. These
drift.
include the ETVE test (para. 6.2.1), spindle thermal sta-
bility test (para. 7.6.2), thermal distortion caused by I1.2 Drift Check for Laser Interferometer Optics
moving linear axes (para. 7.6.3), and composite thermal
error test (para. 7.6.4). Three of these tests require the Some optical systems have excessive drift apparently
use of short-range indicators, and one of these tests caused by thermal instabilities in the optic mounts and
(thermal distortion caused by moving linear axes) mismatched glass paths. The exact cause of these effects
requires the use of a laser interferometer. For the results is not known, but experiments have been made that
of these tests to be most meaningful, it is advised that show that, for precision applications, the drifts inherent
the User perform a stability test on the sensor before in the laser interferometer optics should be measured.
using it for the measurement. Such stability tests have To perform this drift check, the two retroreflectors are
traditionally been called cap tests. Two tests are rigidly mounted to the remote interferometer as shown
described below. in Fig. I2. The laser is then aligned with this interferome-
ter and adjusted for maximum signal strength. The laser
I1.1 Drift Check for Short-Range Electronic or Short- is zeroed, and the drift of the system is recorded over
Range Displacement Indicators similar periods of time as used for the ETVE test (para.
Aside from the usual calibration checks, short-range 6.2.1). If the drift is excessive for the application, then
displacement indicators should be checked for possible the laser interferometer Supplier should be contacted
sensitivity to a thermal environment in which the test and the situation rectified.
is to be performed. A drift check should be conducted
by blocking the transducer and recording the output for I1.3 Drift Check for Laser Interferometer Systems
at least the same period of time as the test to be per- When used for displacement measurement, a laser
formed using the indicator. “Blocking” a transducer is interferometer can have several sources of drift. First
used to make it effectively indicate on its own frame there is drift in the laser frequency; second, thermal
base or cartridge. Figure I1 shows a cartridge-type linear drifts in the interferometer optics and mounting; and
variable differential transformer (LVDT) blocked by finally, drifts caused by incorrect calibration of the laser
means of a cap or capture device that holds the indicator system temperature and pressure sensors. In this
armature in a fixed position relative to the cartridge. Appendix, two simple tests are proposed to check the
The figure also shows a similar clamp on a finger-type drift of most system components. In the first test, the
electronic indicator and on a capacitance gage. laser is set up to read with a remote interferometer as
During the electronics drift check, the entire displace- shown in Fig. I3. The spacer between the interferometer
ment recording system should be located as nearly as and the retroreflector is made of steel, and the laser
possible to where it will be used during machine testing. system temperature and pressure sensors are placed as

Clamping
screws

Cartridge- Finger-type Capacitance

type LVDT indicator gage

Fig. I1 Capture Devices for Several Displacement Indicator Types

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
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NONMANDATORY APPENDIX I ASME B5.54-2005

close as possible to the steel path. The steel spacer should then the laser system and/or its supporting sensors
contain holes to allow the free flow of ambient air and should be repaired.
be at least 200 mm (approximately 8 in.) long. The tem- The second test is to be used for those laser systems
perature and pressure compensation of the laser is set, where the interferometer is an inseparable part of the
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

the part temperature sensor is attached to the steel laser head. In these cases, the laser and the retroreflector
spacer, and the laser interferometer is preset to the nomi- or sensor assembly are set up on, and rigidly attached
nal length of the spacer. The appropriate expansion coef- to, a steel plate. The steel plate should be at least 25
ficient for the spacer shall be entered into the laser mm (approximately 1 in.) thick and mounted at three
interferometer system.1 The drift of the system is then points. The face of the laser should be at least 200 mm
measured over a period of time corresponding to the (approximately 8 in.) from the retroreflector or sensor
time of the proposed test (4 hr for the thermal distortion assembly. The environmental sensors should be placed
caused by moving linear axes test). The drift of the sys- as close as is possible to the laser beam path and the
tem should be less than 1⁄4 of the repeatability for uni- test conducted as described in the paragraph above.
directional positioning, linear axes. If the drift is larger, The drift of the system should be less than 1⁄4 of the
1 repeatability for unidirectional positioning, linear axes.
The Supplier of the steel spacer shall provide an accurate mea-
surement of its nominal length and its thermal expansion coeffi- If the drift is larger, then the laser system and/or its
cient. supporting sensors should be repaired.

Retroreflector

Retroreflector

Laser

Remote
interferometer

Table

Fig. I2 Setup for Measuring the Drift of the Laser Interferometer Optics

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ASME B5.54-2005 NONMANDATORY APPENDIX I

Weather station
Retro (temperature and pressure sensors)

Steel spacer Retro

Interferometer

Steel base plate Part temperature

sensor

Fig. I3 Setup for Measuring Laser Measurement System Stability

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`--- 156
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ASME B5.54-2005

NONMANDATORY APPENDIX J
EXAMPLE BALL BAR PATTERNS FOR
FOUR- AND FIVE-AXIS MACHINING CENTERS

J1 PURPOSE
Several telescoping ball bar patterns have been
devised for four- and five-axis machining centers. These
are illustrated in Figs. J1 through J7. In the current Stan-
dard, the ball bar is used only for verification of the
contouring performance of the machine.

157
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ASME B5.54-2005 NONMANDATORY APPENDIX J

Machine work
spindle

Telescoping ball bar

L ⫽ approximately 1/2
Fixed socket nominal work zone

CL nominal
Y
work zone

Free socket
Z

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Ball bar test patterns for
three- and four-axis
horizontal spindle and
five-axis machining centers

Fig. J1 YZ Plane Positioning Check

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NONMANDATORY APPENDIX J ASME B5.54-2005

Approximately
1/ table diameter
3

360 deg trace

X
CL nominal
work zone
Y

B
Telescoping ball bar
L ⫽ approximately 1/2 Fixed socket
nominal work zone

Free socket

X Machine work
spindle

Ball bar test patterns for three-

and four-axis horizontal spindle
and five-axis machining centers

Fig. J2 XY Plane Positioning Check

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`--- 159
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ASME B5.54-2005 NONMANDATORY APPENDIX J

Approximately 2/3 table diameter

Fixed socket

CL nominal
work zone
X
Y

Telescoping ball bar

L ⫽ approximately 1/2
B nominal work zone
Test path #2
(rotate ”B“ axis
table 180 deg between Test path #1
test #1 and test #2) (180 deg sweep)

Free socket

Machine work
X
spindle

Ball bar test patterns for four-axis horizontal

spindle and five-axis machining centers
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

Fig. J3 XZ Plane Positioning Check

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NONMANDATORY APPENDIX J ASME B5.54-2005

Approximately 2/3
table diameter
Fixed socket Free socket

CL nominal
Y
work zone

Z
Machine work
B
spindle

Test path #1
(180 deg sweep)
illustrated
Telescoping
ball bar
X L ⫽ approximately 1/2
nominal work zone
Test path #2
B
(180 deg sweep)
Mirror image of Z
test path #1

Ball bar test patterns

for four-axis horizontal spindle
and five-axis machining centers

Fig. J4 B-Axis Rotary Positioning Check

161
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ASME B5.54-2005 NONMANDATORY APPENDIX J

Fixed socket

CL nominal
work zone

Telescoping ball bar Y

L ⫽ approximately 1/2
nominal work zone

Free socket

Z
B
Machine work
spindle

Ball bar test patterns for five-axis machining centers

Fig. J5 A-Axis Rotary Positioning Check

162
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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NONMANDATORY APPENDIX J ASME B5.54-2005

Telescoping ball bar Free socket

CL nominal Z

work zone
Fixed socket

Machine work
spindle

X
Z

Ball bar test patterns for four-axis horizontal spindle

and five-axis machining centers

Fig. J6 B-Axis Plane of Rotation Parallel to XZ Plane

163
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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ASME B5.54-2005 NONMANDATORY APPENDIX J

Y
CL nominal
work zone

Machine work
spindle

Z
B
Ball bar test patterns for
five-axis machining centers

Telescope ball bar

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
Fixed socket

Free socket

Fig. J7 A-Axis Plane of Rotation Parallel to YZ Plane

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ASME B5.54-2005

NONMANDATORY APPENDIX K
DISCUSSION OF THE UNDE AND THERMAL UNCERTAINTY

K1 GENERAL The second component is related to the effective scale

temperature due to time and positioning-varying tem-
When calibration or measurement is performed at
perature gradients and their effect on the machine geom-
temperatures other than 20°C, nominal differential
etry and scales. For the purposes of this Appendix, this
expansion (NDE) corrections must be made if the object
second component is represented as a rectangular distri-
to be calibrated or measured and the standard have
bution with bounds ±(ETVE/2)/La for machine calibra-
different coefficients of thermal expansion
tion, or ±(ETVE/2)/(Ls␣s) when the machine is used as
NDE p ␣L(T − 20) − ␣sLs(Ts − 20) (K-1) the measurement standard. Therefore, for the calibration
of the machine axis,
where variables are defined in para. 6.2.3.3.
The first term applies to the object being calibrated 2

冤 冥
ETVE/2
or measured. The second term applies to the standard. u2(T)eff p + u2(T) (K-6)
L␣冪3
For laser calibration of a machine axis, the first term
applies to the machine scale, while the second term and
applies to the laser. For on-machine part measurement
using a probe, the first term applies to the part and the u2(Ts)eff p u2(Ts) (K-7)
machine scale is the standard.
To estimate the uncertainty in making NDE correction, For use of the machine as the measurement standard,
the ISO Guide to the Expression of Uncertainty in Measure-
ment (1993) is used. The uncertainty depends on the u2(T)eff p u2(T) (K-8)
uncertainty in each of the variables of Eq. (K-1). It also
depends on the sensitivity of the NDE result to variation and
in each variable. For the purposes of this Appendix, it
2
is assumed that no correlation exists between variations
冤 L ␣ 冪3 冥
ETVE/2
u2(Ts)eff p + u2(Ts) (K-9)
in individual variables. Therefore, four terms come s s
directly from the uncertainty analysis.
In either case, the combined standard thermal uncer-
L(T − 20)u(␣) p uncertainty of nominal expansion
tainty is written as
of the object being
calibrated or measured (K-2)
u2cT(L) p L2(T − 20)2u2(␣) + L2s (Ts − 20)2u2(␣s)
Ls(Ts − 20)u(␣s) p uncertainty of nominal expansion + L2␣2u2(T) + L2s ␣2s u2(Ts) + u2ETVE (K-10)
of the standard (K-3)
where u2ETVEp ETVE2/12 arises from either Eq. (K-4) or
L␣ u(T)eff p length uncertainty due to (K-5).
uncertainty in temperature of The combined standard thermal uncertainty is used
the object being calibrated to derate performance specifications (Chapter 6) or to
or measured (K-4) calculate a thermal error index (TEI) for any situation
where NDE correction applies. The following examples
Ls␣su(Ts)eff p length uncertainty due to
demonstrate the calculation procedure.
uncertainty in temperature of
the standard (K-5)
K2 CALCULATION OF EXPANDED THERMAL
The subscript eff is used to indicate that this term
UNCERTAINTY FOR PURPOSES OF DERATING
contains not only the uncertainty in temperature mea-
PERFORMANCE SPECIFICATIONS
surement, but also the range of temperatures that proba-
bly occurred during a test or measurement. One The following calculations are meant to be representa-
component of this uncertainty is related to the accuracy tive of a measurement of positioning accuracy and
of temperature measurement. This is the length uncer- repeatability, linear axes (para. 7.3). The specification
tainty due to temperature measurement (see Chapter 4). zone is for the bidirectional accuracy of positioning, A.

165
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ASME B5.54-2005 NONMANDATORY APPENDIX K

Bidirectional Accuracy u2cT(L) p u2ETVE + (UNE)2 + (UNEs)2 + (LUTM)2

Performance Parameter of Positioning
p 90.8 ␮m2 + 16.9 ␮m2 + 0.00 + 47.4 ␮m2
Specified accuracy 33 ␮m/m (FIR)
p 155 ␮m2 (K-20)
Axis length 1 016 mm
Measurement devices Laser interferometer (dis-
ucT(L) p 12.5 ␮m (K-21)
placement)
Thermocouples (tempera-
ture of air and material) Expanded thermal uncertainty (para. 6.2.3.2):
Mean temperature 26°C
ETVE 33 ␮m ±UT(L) p ±2ucT(L) p ±24.9 ␮m (K-22)
Coefficient of thermal expansion 11.7 ⴛ 10−6/°C
of the machine scale, ␣ UT(L) p 2ucT(L) p 24.9 ␮m (K-23)
Coefficient of thermal expansion 0.93 ⴛ 10−6/°C
of the laser, ␣s Derating of specified parameter (para. 6.2.3.2):
Specification zone SZ p 33 ␮m/m (1.016 m)
p 33.5 ␮m UT(L)/SZ p 24.9 ␮m/33.5 ␮m > 0.25 (K-24)

Standard uncertainty due to ETVE (para. 6.2.3.3.1): Because this ratio is greater than 0.25, a new acceptable
limit must be specified.
u2ETVE p ETVE /12 p 90.75 ␮m
2 2
(K-11)
SZ* p UT(L)/0.25 (K-25)
Uncertainty of nominal expansion of the machine
scale [para. 6.2.3.3.2, Option (c)]: SZ* p 100 ␮m (FIR) (K-26)

u(a) p 0.1a 冪 1⁄3 p 6.75 x 10−7/°C (K-12) SZ* p 100 ␮m/1.016 m p 98 ␮m/m (K-27)

u2(␣) p 4.56 ⴛ 10−13/°C2 (K-13)

K3 EXAMPLE CALCULATIONS WHEN A MACHINE IS
BEING USED FOR PART MEASUREMENT
(UNE) p L (T − 20) u (␣)
2 2 2 2

p (1 016 mm)2(26°C − 20°C)2 Two examples that apply to the use of a machine tool
ⴛ (4.56 ⴛ 10 −13
/°C )(10 ␮m/mm)
2 3 2
(K-14)
for measurement of parts are given below. The first is
in metric units and the second in English units, for those
Uncertainty of nominal expansion of the standard who prefer that system. While many other errors may
(para. 6.2.3.3.2; i.e., laser): affect the measurement results, the TEI is calculated to
estimate the expected measurement error due to thermal
u(␣s) p 0 (K-15) effects alone. In both these cases, a part tolerance (TOL)
is substituted for the specification zone (SZ).
(UNEs)2 p L2s (Ts − 20)2u2(␣s) p 0 (K-16)
K3.1 Example Calculation With NDE Correction
Length uncertainty due to temperature measurement In this example, an aluminum part is measured on a
(para. 6.2.3.3.3): machine with steel scales. The measurement conditions
are summarized in Table K1.
u2(T) p [1 − (−1)]2/12°C2
Standard uncertainty due to ETVE (para. 6.2.3.3.1):
p 1⁄3°C2 (K-17)
u2ETVE p ETVE2/12 p (3.8 ⴛ 10−5 m)2/12 (K-28)
2 2 2
u (Ts) p [1 − (−1)] /12°C
p 1⁄3°C2 (K-18) u2ETVE p 1.20 ⴛ 10−10 m2 (K-29)

(LUTM)2 p L2␣2u2(T) + L2s ␣2s u2(Ts)

Uncertainty of nominal expansion of the part [para.
2
6.2.3.3.2, Option (b)]:
冢 冣
11.7 ⴛ 10−6
p (1 016 mm)2 1
⁄3°C2(103 ␮m/mm)2
°C u(a) p 0.05a冪1⁄3 (K-30)
−6 2

冢 冣
0.93 ⴛ 10
+ (1 016 mm)2 1
⁄3°C2(103 ␮m/mm)2 u2(␣) p (0.05)2(24.3 ⴛ 10−6/°C)2(1⁄3) (K-31)
°C
p 47.1 ␮m2 + 0.30 ␮m2
(UNE)2 p L2(T − 20)2u2(␣)
p 47.4 ␮m2 (K-19) 2

冢 冣
24.3 ⴛ 10−6 1
p (4 m)2(22°C − 20°C)2(0.05)2 ( ⁄3)
Combined standard thermal uncertainty (para. °C
6.2.3.3): p 3.15 ⴛ 10 −11
m 2
(K-32)

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

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NONMANDATORY APPENDIX K ASME B5.54-2005

Table K1 Calculation of TEI for the Case When NDE Correction Is Made
Dimension p 4.0 m NDE correction: standard and part temperatures Tmin p 21.1°C
both measured as 22°C
TOL p 0.25 mm Material: aluminum 6061 Tmax p 23.3°C
␣ p 24.3 ␮m/m°C [Note (1)] Temperature measurement accuracy p ±1°F Tm p 22°C
␣s p 11.7 ␮m/m°C [Note (1)] ... ETVE p 38 ␮m

NOTE:
(1) These values are obtained from published data and may be in error by ±5%.

Uncertainty of nominal expansion of the standard For the purposes of calculating the TEI, NDE is taken
[para. 6.2.3.3.2, Option (b); i.e., machine]: as zero when NDE corrections are made. There is no
contribution to the estimated thermal error.
u(a) p 0.05 as 冪1⁄3 (K-33)
NDE p 0.00 (K-43)
u (␣s) p (0.05) (11.7 ⴛ 10 /°C) ( ⁄3)
2 2 −6 2 1
(K-34)
Thermal error index
(UNEs)2 p L2s (Ts − 20)2u2(␣s)
TEI p 兵关冨NDE冨 + UT(L)兴/TOL其(100%)
2

冢 冣
2 11.7 ⴛ 10−6 1
2 2 p (0.00 + 0.127 mm)/(0.25 mm)(100%) p 51% (K-44)
p (4 m) (22°C − 20°C) (0.05) ( ⁄3)
°C
p 7.30 ⴛ 10−12 m2 K3.2 Calculation Without NDE Correction
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

(K-35)
The second example of part measurement deals with
Note that the mean air temperature is used for both measurement of a titanium part on a machine with steel
T and Ts in the equations used to calculate uncertainty scales, where the nominal differential expansion correc-
of nominal expansion of part and machine scale, respec- tion is not made. Measurement conditions are summa-
tively. rized in Table K2. English units are used throughout.
Length uncertainty due to temperature measurement Standard uncertainty due to ETVE (para. 6.2.3.3.1):
(para. 6.2.3.3.3):
u2ETVE p ETVE2/12 p (0.0003 in.)2/12
u2(T) p [1 − (−1)]2/12°C2
p 7.50 ⴛ 10−9 in.2 (K-45)
p 1⁄3°C2 (K-36)
Uncertainty of nominal expansion of the part [para.
u2(Ts) p [1 − (−1)]2/12°C2 6.2.3.3.2, Option (b)]:
p 1⁄3°C2 (K-37)
u(a) p 0.05a冪 1⁄3 (K-46)
(LUTM) p L ␣ u (T) +
2 2 2 2
L2s ␣2s u2(Ts)
u2(␣) p (0.05)2(4.8 ⴛ 10−6 in./in. °F)2(1⁄3) (K-47)
p (4 m)2(24.3 ⴛ 10−6/°C)2 1⁄3°C2
+ (4 m)2(11.7 ⴛ 10−6/°C)2 1⁄3°C2 (UNE)2 p L2(T − 68)2u2(␣)
p 3.87 ⴛ 10 −9
m 2
(K-38) p (20 in.)2(74°F − 68°F)2(0.05)2
ⴛ (4.8 ⴛ 10−6 in./in. °F)2(1⁄3)
Combined standard thermal uncertainty (para. p 2.76 ⴛ 10−10 in.2 (K-48)
6.2.3.3):
Uncertainty of nominal expansion of the standard
u2cT(L) p u2ETVE + (UNE)2 + (UNEs)2 + (LUTM)2 (K-39) (para. 6.2.3.3.2, method b; i.e., machine):

u(a) p 0.05as冪1⁄3
冪 + 7.30 ⴛ 10
1.20 ⴛ 10−10 m2 + 3.15 ⴛ 10−11 m2 (K-49)
ucT(L) p −12
m + 3.87 ⴛ 10
2 −9
m 2

p 0.063 mm (K-40) u2(␣s) p (0.05)2(6.5 ⴛ 10−6 in./in. °F)2(1⁄3) (K-50)

Expanded thermal uncertainty (para. 6.2.3.2): (UNEs)2 p L2s (Ts − 68)2u2(␣s)

p (20 in.)2(74°F − 68°F)2(0.05)2
±UT(L) p ±2ucT(L) p ±0.126 mm (K-41)
ⴛ (6.5 ⴛ 10−6 in./in. °F)2(1⁄3)
UT(L) p 2ucT(L) p 0.127 mm (K-42) p 5.07 ⴛ 10−10 in.2 (K-51)

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ASME B5.54-2005 NONMANDATORY APPENDIX K

Table K2 Calculation of TEI for the Case When NDE Correction Is Not Made
Dimension p 20 in. No NDE correction Tmin p 70°F (measured)
Tolerance p 0.002 in. Material: Ti 6-4 Tmax p 78°F (measured)
␣ p 4.8 ␮in./in.°F [Note (1)] Temperature measurement accuracy p ±1°F Tm p 74°F (measured)
␣s p 6.5 ␮in./in.°F [Note (1)] ... ETVE p 0.0003 in.

NOTE:
(1) These values are obtained from published data and may be in error by ±5%.

Length uncertainty due to temperature measurement Combined standard thermal uncertainty (para.
(para. 6.2.3.3.3): LUTM cannot be calculated directly (see 6.2.3.3):
below).
When NDE correction is not made, the uncertainty u2cT(L) p u2ETVE + (UNE)2 + (UNEs)2 + (LUTM)2 (K-54)
related to temperature in Eq. (K-1) depends on variations

冪+ 5.07 ⴛ 10
in the air temperature. Temperature measurement accu- 7.50 ⴛ 10−9 in.2 + 2.76 ⴛ 10−10 in.2
ucT(L) p
racies of part and machine are not relevant, because −10
in.2 + 9.63 ⴛ 10−9 in.2
these measurements are not made. The uncertainty of p 0.00013 in. (K-55)
environmental temperature is introduced as
Expanded thermal uncertainty (para. 6.2.3.2):
u(Te) p (1⁄2)(Tmax − Tmin + 2a)冪1⁄3 (K-52)
±UT(L) p ±2ucT(L) p ±2(0.00013 in.) (K-56)
where it is assumed that the machine and part tempera-
tures at any time can be expected to have rectangular UT(L) p 2ucT(L) p 2(0.00013 in.)
probability distributions with bounds (Tmax − Tmin + 2a). p 0.00026 in. (K-57)
Variables are defined as
Tmax p maximum air temperature measured over Nominal differential expansion:
specified period of time
Tmin p minimum air temperature measured over NDE p 冨4.8 ⴛ 10−6 in./in. °F
specified period of time − 6.5 ⴛ 10−6 in./in. °F冨(20 in.)冨74 − 68冨°F
a p air temperature measurement accuracy p 0.00020 in. (K-58)
The variations in temperatures, T and Ts, are expected
Thermal error index:
to be correlated under these assumptions, leading to
the equation for LUTM, which includes the difference
TEI p 兵[冨NDE冨 + UT(L)]/TOL其(100%)
between scale and part expansion coefficients:
p [(0.00020 in. + 0.00026 in.)/(0.002 in.)](100%)
p 23.5% (K-59)
(LUTM)2 p (1⁄12)(Tmax − Tmin + 2␣)2(L)2(␣s − ␣)2
p (1⁄12)(78 − 70 + 2)2(°F)2(20 in.)2 K3.3 Summary
ⴛ (4.8 − 6.5)2(␮in./in. °F)2 The different cases that can occur for temperature
p 9.63 ⴛ 10−9 in.2 (K-53) measurement are summarized in Table K3.

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NONMANDATORY APPENDIX K ASME B5.54-2005

Table K3 Summary of Equations for Thermal Uncertainty Calculations

Symbol Definition Equation

TEI Thermal error index 兵关NDE + UT 共L兲兴 冫 TOL 其100%

NDE Nominal differential expansion:

standard and object same material 0
NDE correction 0
no NDE correction NE − NEs

NE Nominal expansion of the object L␣共Tm − 20兲

L Length of dimension ...

␣ Coefficient of thermal expansion of object Specified

Tm Mean environmental temperature Measured

NEs Nominal expansion of the standard L␣共Tm − 20兲

␣s Coefficient of thermal expansion of standard Specified

UT(L) Expanded thermal uncertainty 2ucT 共L 兲

ucT(L) Combined standard thermal uncertainty 冪共UNE兲2 + 共UNEs兲2 + 共LUTM兲2 + u2ETVE

UNE Uncertainty of nominal expansion of object u共␣兲 L 共Tm − 20兲

u(␣) Uncertainty of object thermal expansion coefficient 冪1/3 共0.1兲 ␣

[for method of para. 6.2.3.3.2(c)]

UNEs Uncertainty of nominal expansion of standard u共␣s兲 L 共 Tm − 20兲

u(␣)s Uncertainty of standard thermal expansion coefficient 冪1/3 共0.01兲 ␣s

[for method of para. 6.2.3.3.2(c)]

LUTM Length uncertainty due to temperature measurement:

for NDE correction 冪␣2L2u2共T 兲 + ␣2sL2su2共Ts 兲
for no NDE correction u共Te 兲 L 共␣ − ␣s 兲
a+ − a− 1
u(T) Uncertainty of object temperature measurement 冪 /3
2
a+ − a− 1
u(Ts ) Uncertainty of standard temperature measurement 冪 /3
2
u(Te ) Uncertainty of environment temperature 共1/2兲共Tmax − Tmin + 2a兲冪1/3

a Accuracy of temperature measurement (±a) Specified

Tmax Maximum air temperature Measured over specified time

Tmin Minimum air temperature Measured over specified time

uETVE Standard uncertainty due to the environmental 共1/2兲ETVE冪1/3

temperature variation error

ETVE Environmental temperature variation error Measured over specified time

TOL Tolerance For ±0.003 in., TOL p 0.003

GENERAL NOTE: The object being calibrated or measured is simply the “object” in this table. The calibrator or measuring
device is the “standard.”

169
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ASME B5.54-2005

NONMANDATORY APPENDIX L
STRAIGHTEDGE REVERSAL TECHNIQUE

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L1 GENERAL M(X): plus for motion of the machine carriage in the
+Y direction, minus otherwise
Straightedges are often provided with a calibration
S(X): plus for displacements out of the gaging surface,
chart to correct measurements for the straightness values
minus otherwise
of the straightedge. But correction using a calibration
Now define N(X) as the straightness values obtained
chart is not always necessary, since the straightedge
when measuring with the straightedge in the normal
reversal technique may provide an in-situ calibration.
position [Fig. L1, illustration (a)] and R(X) as the
However, the straightedge reversal technique does not
straightness values obtained when measuring with the
work when measuring the vertical straightness of a hori-
straightedge reversed (rotated 180 deg about its long
zontal axis when the sag of the straightedge due to
axis) [Fig. L1, illustration (b)]. With the sign convention
gravity is important. Therefore, an appropriate calibra-
mentioned above, the resulting equations are:
tion of a straightedge in this position is required.1
N(X) p M(X) + S(X) (L-1)

L2 PROCEDURE R(X) p − M(X) + S(X) (L-2)

The straightedge reversal is performed by rotating the These measurements are sufficient to determine both
straightedge 180 deg about its long axis, as shown in the machine horizontal straightness and the straight-
Fig. L1, and measuring along the same line on the edge calibration, since, by adding and subtracting these
straightedge. Two sets of readings are suitably averaged two equations, the results are:
to cancel out the straightness errors in the straightedge.
N(X) − R(X)
The Y straightness of an X-axis is measured as an exam- M(X) p (L-3)
2
ple. The machine straightness is defined as M(X) and the
straightedge straightness as S(X). The sign convention N(X) + R(X)
S(X) p (L-4)
adopted for these mathematical functions is as follows: 2

The above equations are written in continuous format;

1 however, the operations may be performed point-wise.
For more information, refer to Estler, W.T., “Calibration and use
of optical straightedges in the metrology of precision machines,” That is, for each measurement point on the straightedge,
Optical Engineering, Vol. 24, No. 3, May/June 1985. the operations above may be carried out.

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NONMANDATORY APPENDIX L ASME B5.54-2005

Straightedge

Straightedge
support points
(3), both sides n
o tio
le m
Tab

(⫺
)
Po
lar
ity (⫹
)
--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---

⫹Y (a) Normal Position

Electronic
indicator

(⫹
)
Po
lar
ity (⫺)

Machine table

⫹Y
Machine slideway

(b) Reversed Position

Fig. L1 Setup for Measuring Straightness Using an Electronic Indicator and a Mechanical Straightedge

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ASME B5.54-2005

NONMANDATORY APPENDIX M
CALCULATION OF UNCERTAINTIES

M1 GENERAL It is the purpose of this Appendix to explain the rea-

soning behind the decisions and, for Users who so desire,
In many of the tests in this Standard, uncertainties
provide the methodology for the assessment of uncer-
have been assigned to the results of a measurement
tainties in cases where it is practical to do so. Again, we
following widely accepted procedures.1 In a subtle devi-
emphasize that the intention is that these uncertainties
ation from these procedures, the uncertainties are being
be assigned to the machine tool system (including the
assigned to the machine tool, rather than the measure-
testing environment) and not to the measurement instru-
ment system. That is, it is assumed that the measurand
ment. This can only be correct if the measurement instru-
(for example, linear positioning) is uncertain when mea-
ment conforms to the requirements of Chapter 11.
sured with a perfect measurement system because of
inherent lack of repeatability in the machine itself. Since
machine tools, at the current level of accuracy, obey the M2 UNCERTAINTY CALCULATIONS CURRENTLY IN
laws of classical physics, this assumption is probably B5.54
incorrect. Machine tools are, in fact, much more repeat-
able than is commonly believed, as has been demon- In this Standard there are many tests where the uncer-

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strated on numerous occasions. In the case of machine tainties are calculated. Some of these tests, in fact, are
tool measurements, the major uncertainties arise from designed primarily to estimate the uncertainties caused
a combination of the following: by various factors. In general, these types of tests are
(a) incomplete definition of the measurand called repeatability tests. The repeatability tests include
(b) imperfect realization of the definition of the meas- the ETVE test (para. 6.2), relative vibration test (para.
urand 6.3), structural motion test (para. 7.5.2), and subsystems
(c) nonrepresentative sampling (the sample measured repeatability tests (para. 7.8), such as tool changing
may not represent the defined measurand) repeatability, pallet changing repeatability, and tool-
(d) inadequate knowledge of the effects of environ- setting repeatability.
mental conditions on the measurement or imperfect Besides these general tests for repeatability, other tests
measurement of environmental conditions.1 where the uncertainty is estimated according to the stan-
The fact is that the model normally used for the dard methodology are positioning accuracy and repeat-
machine tool does not include all of the variables that ability of linear axes (para. 7.3.2.1), angular error motions
are present when testing a machine. The “observed dis- of linear axes (para. 7.4), positioning accuracy and
persion of the measurement results” implies a calculated repeatability of rotary axes (para. 7.3.2.2), machine per-
standard deviation, which by definition is a Type A. formance as a measuring tool (para. 7.9), and geometric
Because of the current accuracy level of the instrumenta- accuracy tests (para. 7.4). These tests will not be dis-
tion (see Chapter 11), this dispersion is correctly cussed further in this Appendix.
assigned to the machine tool, rather than the instrument
system. M3 FUNCTIONAL TESTS
In the body of this Standard, uncertainties have not
been computed for a number of tests due to one of the After careful discussion, it was the opinion of the
following three reasons: Committee that the following tests may be considered
(a) The test may be considered a functional test and functional tests where it is not required to assign an
thus an assignment of uncertainty is not called for. uncertainty: setup hysteresis (para. 7.1.4), periodic linear
(b) The test was already in the process of standardiza- and angular positioning (para. 7.3.5), cutting perform-
tion, or standardized, by the International Organization ance (Chapter 9), multifunction cycle test (Chapter 10),
for Standardization (ISO) and uncertainties were not CNC performance test (para. 7.10), and machining test
computed there. parts (Chapter 8). Uncertainties could, of course, be
(c) The test duration was such that making enough assigned to the final functional test, machining test parts,
repeated measurements to have statistical significance by machining a large number of parts and applying the
is impractical. procedures of statistical process control. Users desiring
to do this should follow appropriate standardized
1
ISO Guide to the Expression of Uncertainty in Measurement, 1993(E). methods.

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NONMANDATORY APPENDIX M ASME B5.54-2005

M4 UNCERTAINTY COMPUTATIONS NOT M4.2 Machine Thermal Tests

PRESENTLY IN B5.54 All of the machine thermal tests, the spindle thermal
Several of the tests present in the current Standard stability test (para. 7.6.2), thermal distortion caused by
do not provide the User with the methodology for com- moving linear axes (para. 7.6.3), and composite thermal
puting an appropriate uncertainty. These tests are: error (para. 7.6.4) require a measurement to be per-
(a) spindle axes of rotation (para. 7.5) formed over a long period of time. If the User should
(b) machine thermal test (para. 7.6) decide that it is necessary to obtain an uncertainty, then
(c) contouring performance using circular tests the tests should be performed many times (say, a mini-
(para. 7.7.4) mum of five times) and standard uncertainties in the
These are discussed, in turn, below. In all cases, follow- reported parameters computed as described in para.
ing previously established procedures, the repeatability M4.1. It is the recommendation of this Appendix that
for a given test should be reported as four times the this would constitute unwarranted expense.
standard uncertainty.
M4.3 Contouring Performance Using Circular Tests
M4.1 Uncertainty Calculation, Spindle Axes of
Rotation For the contouring performance, it is required to
report the circular deviations for clockwise, G↑, and
In the opinion of the authors of this Appendix, follow-
counterclockwise, G↓, contouring, and the radial devia-
ing the procedure below will constitute unwarranted
tions, Fmax and Fmin, for clockwise (↑) and counterclock-
expense, as the information gained would not be partic-
wise (↓) contouring, shall be reported, as well as the
ularly relevant to machine performance.
measured feed rates in the clockwise and counterclock-
For spindle error motions, the Standard calls for per-
wise directions (see paras. 7.11.2 and 7.11.3). The circular
forming the measurements at three spindle speeds. At
deviation is the minimum radial separation of two con-
each speed, the error motions are measured for a mini-
centric circles that will envelop the actual path. Finally,
mum of 20 revolutions and averaged to obtain the aver-
the radial deviations are the maximum and minimum
age error motion value. The maximum range of
deviations from the circle radius, corrected to 20°C. To
deviations from the average error motion value is
compute the standard uncertainties of these quantities,
reported as the asynchronous error motion and not as
it is recommended that the circular test be conducted
an uncertainty in the error motion. This is because it
ten times in both the clockwise and counterclockwise
has been demonstrated that asynchronous error motion,
directions. For each set of ten measurements, the artifact
although it may appear to be random, is actually highly
(ball bar, disk, or grid encoder) temperature is measured
systematic, at least for the case of ball-bearing and roller-
bearing spindles, which constitute a very large percent- at the beginning and the end of the ten measurements
age of the spindles on machining centers. The systematic and the mean value of the temperature recorded. In
nature of the asynchronous motion is less well docu- the following discussion, it is assumed that data are
acquired at n intervals over the measured arc. After least-

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mented for aerostatic and hydrostatic spindles. Because
of the very large number of revolutions required for squares fitting to remove residual eccentricity, the data
assessing uncertainty on ball- and roller-bearing spin- are analyzed as follows. At each interval, i, compute the
dles, no procedure is recommended here. standard uncertainty in the circular deviation following
If it is desired to obtain an uncertainty from spindle the normal procedure. That is,
measurements, it is the recommendation of this technical n

冪
1
committee that the complete test (20 revolutions) for si↑ p
n−1 兺 (dij↑ − di↑)2 (M-2)
each error motion be repeated ten times. For each of jp1

these repetitions, an average error motion and an asyn- n

冪
1
chronous error motion should be computed. The esti- si↓ p
n−1 兺 (dij↓ − di↓)2 (M-3)
mate of the standard uncertainty for these quantities jp1

should then be calculated according to the following

expression:
where
n

冪
1 di p mean circular deviation at the ith angular
uq p
n−1 兺 (qj − q)2
jp1
(M-1)
position
dij p jth circular deviation at the ith angular position
where n p 10
q p mean obtained from the ten repeated trials si p estimate of the standard uncertainty of the cir-
qj p outputs of the measurement procedure for each cular deviations
complete test (average or asynchronous error ↑ p clockwise rotation
motion) ↓ p counterclockwise rotation

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ASME B5.54-2005 NONMANDATORY APPENDIX M

M4.3.1 Circular Deviation. For determining the uncer- been corrected to 20°C, using its mean temperature mea-
tainty in circular deviation, both the clockwise and coun- sured as described in para. M4.3 above. The square of
terclockwise data are treated the same. Only the the standard uncertainty (variance) is then computed
clockwise case will be given below. The procedure is to as follows (where ↑ and ↓ have been eliminated for
note the angles at which the maximum and minimum simplicity):
deviations in the mean circular deviation plot occurred
u2F p s2k +L2s (Ts − 20)2u2(␣s) +L2(T − 20)2u2(␣)
for the appropriate rotation direction. Then the uncer-
tainty is given by + L2s ␣2s u2(Ts) + L2␣2u2(T) (M-5)
where
u2G↑ p s2k ↑ + s2m↑ (M-4) k p angular position where the maximum radial
deviation occurred
L p effective machine scale length, equal to the ball
where bar length
k p angular position where the maximum circular Ls p calibrated ball bar length
deviation occurred sk p estimate of standard uncertainty of the circular
m p angular position where the minimum circular deviation at the angular position k
deviation occurred T p temperature of the machine scales that should
be assumed to be equal to Ts
M4.3.2 Radial Deviation. As with the circular devia- Ts p mean temperature of the ball bar
tion, the clockwise and counterclockwise data analysis u(q) p standard uncertainty in the quantity, q
is the same. Only the clockwise case will be given below. u2(q) p variance in the quantity, q
The procedure is to locate the angular position where uF p standard uncertainty of the radial deviation
the maximum radial deviation between the calibrated ␣ p thermal expansion coefficient of the machine
radius and the mean measured radius occurred. This scales
comparison is performed after the ball bar length has ␣s p thermal expansion coefficient of the ball bar

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ASME B5.54-2005

NONMANDATORY APPENDIX N
SIGN CONVENTIONS FOR ERROR VALUES

N1 GENERAL to the positive motion of a corresponding axis that car-

ries the tool (+Z). A positive axial error motion of the
This Standard does not require that the User use spe-
spindle indicates movement of the spindle axis away
cific signs for the error values. However, it is customary
from the workpiece in the +Z direction. For the position-
to define errors as the actual (measured) response of the
ing accuracy test of an axis that moves the table, a posi-
machine tool, minus the nominal or anticipated response
tive error indicates an error in the +Z′ direction of the

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(commanded). Errors are reported using the nominal
table (relative to the tool). Thus, +Z axial error of the
workpiece coordinate system. This method is consistent
spindle and +Z′ error of the table motion both increase
with the method used in EIA-267-C-1990. Positive values
the distance between the tool and the table.
of displacement errors (e.g., positioning and straightness
errors) indicate error motion in the positive direction of
the nominal workpiece coordinate axes. Thus, a positive N3 CRITICAL ALIGNMENTS
positioning error of an axis indicates that the tool moved
farther along that axis than commanded. Positive angu- For critical alignments, the following sign convention
lar errors (e.g., angular positioning, roll, pitch, and yaw) is used. The squareness error between two axes should
indicate positive angular motions about a coordinate be reported as positive if the angle between the respec-
axis. These are customarily defined to be positive coun- tive positive coordinate axes exceeds 90 deg. The paral-
terclockwise for rotation about an axis, using the right- lelism error of axis X2 to X1 should be reported as
hand rule. positive if the actual angle of axis X2 relative to axis X1
exceeds the respective nominal angle. A positive angle
corresponds to positive angular motion around the
N2 RELATIVE MEASUREMENTS machine coordinate axis, orthogonal to the plane of the
The sign of an error is affected by the reference relative parallelism measurement. The offset of axis X2 to X1
to which the error motion is defined and measured. If should be reported as positive if axis X2 is displaced in
a single axis is tested whose function is to carry the a positive coordinate direction relative to axis X1.
workpiece, measurements are made with respect to a NOTE: The sign convention used in the compensation tables of
tool position. The EIA standard describes the positive the machine tool controller does not necessarily comply with the
motion of this axis with a prime (+Z′), which is opposite convention outlined in this Appendix.

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ASME B5.54-2005

NONMANDATORY APPENDIX O
STATIC ERROR MOTION MEASUREMENT

O1 PURPOSE
The purpose of this test is to separate spindle bearing
errors from spindle error motion caused by dynamic
effects of the spindle drive system. The previous edition
of this Standard called for measurement of structural
error motion with the spindle running to identify the
spindle bearing errors. Static error motion measurement
accomplishes the same goal without the cost of making
special brackets and setups. See Chapter 4 for the defini-
tion of static error motion measurement.
It is important to isolate the errors caused by spindle

--```,`,`,,,,,``,,,,,,`,````,``,-`-`,,`,,`,`,,`---
bearings. They are often blamed for problems caused
by the spindle drive system. Structural error motion of
the spindle stator with respect to the tool can be as high
as 95% and typically 50% of the spindle error motion.
A static error motion measurement is strongly recom-
mended before a decision is made to change spindle
bearings.

O2 SETUP AND PROCEDURE

Fig. O1 Typical Data From a Static Error
The test setup is the same as for each of the axis Motion Measurement on a Rolling Element
motion tests described in para. 7.5.3. Two capacitance Bearing Spindle
indicators, mounted at 90 deg to each other, are set up
in a nest supported from the table to read against a test
ball mounted on the spindle rotor in general accordance
with Figs. 7.32 and 7.33. It is important to note that the
spindle error motion tests show the combined functional O3 DATA ANALYSIS
effect of bearing error motion and structural error
The data is analyzed for average and asynchronous
motion on the workpiece. After the spindle error motion
radial, tilt, and axial motion using the methods
tests at 10%, 50%, and 100% of full speed are completed,
described in para. 7.5. If an oscilloscope is used, as
the static error motion measurement procedure should
shown in Fig. 7.33, the recording can be done by photo-
be performed to determine the contribution of the bear-
graphing the oscilloscope screen at each rotational posi-
ings. The detailed procedure is as follows: tion. Figure O1 is an example of data from this test.
(a) Put the spindle drive into neutral. If the spindle If a spindle error analyzer is used, the recording can
has a nondisengageable belt drive, the belt tension be done by manual activation of the spindle error ana-
should be removed so the spindle is free of all external lyzer data recording system.
forces.
(b) Rotate the spindle, by hand, a minimum of two
revolutions, stopping at a minimum of eight points per O4 DISCUSSION
revolution. The static error motion measurement concept assumes
(c) Release all hand forces and record the average that bearings, which have acceptable performance at
indicator reading at each point. Averaging the readings zero speed, will continue to have acceptable perform-
eliminates the effect of structural motion with the spin- ance at operational speeds. Experience with rolling ele-
dle stopped. Play or loss of preload in the bearings can ment bearing analyzers has shown that this assumption
easily be identified by applying opposing forces to the is generally true. The small differences that are observed
spindle. when changing speed can be assigned to the effect of

176
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NONMANDATORY APPENDIX O ASME B5.54-2005

centrifugal forces that cause small changes in the line setup and careful attention to the design of the bracket
of contact of the balls or rollers with the races. The that holds the indicator.
concept works for hydrostatic and aerostatic bearings, A significant increase in the value of spindle error
as well as rolling element bearings. However, it does motion with an increase in speed indicates a problem
not work for hydrodynamic bearings, which depend on with the drive system. Worn belts and couplings, and
rotational velocity for their load carrying and centering unbalance and misalignment of drive motors, pulleys,
ability. and gears, are typical drive system problems. The mea-
If there is doubt about the validity of the static error surement of static error motion is strongly recom-
motion measurement, a structural error motion mea- mended before a decision is made to change spindle
surement, with the spindle running, can be performed bearings.
as a cross-check. This measurement requires a special
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ASME B5.54-2005

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