Standard Machine Performance Tests

MODULE TITLE Nominal Duration Module Code or Number Module Purpose Relationship to Competency Standards

STANDARD MACHINE PERFORMANCE TESTS One Module EA 616 To enable students to conduct acceptance and performance tests on specific machine tools. This module will be modified in line with the requirements of the national metals and Engineering Standards when they become available. The module contains the knowledge and skills identified and agreed by all state/territories. It has been developed on the assumption that these will be reflected in the Standards.

Prerequisites Summary of Content

NBB 06 Machining NM 21 Precision Measurement 1. Overview of machine tools elements General purpose parallel lathes Universal milling machine Surface and cylindrical grinding machines Vertical drilling machines Open fronted mechanical power presses Driving unit/methods of work driving Cutting speed Machine vibration signatures Work/tool feeding motion The slideways Lubrication Wear adjustment Stick-slip-jerk phenomena Methods of holding the work Methods of holding the tool Safety considerations Machine tool standards

Actrac Products Ltd/ Australian National Training Authority 1997

Standard Machine Performance Tests

2.

Geometric Acceptance Testing Check principles for: Straightness Flatness Parallelism Equidistance and coincidence Squareness and rotation Machine tool tolerances Magnitude and direction Levels Level principle Types of level Sensitivity Reversal technique Three point location principles Levelling screws Jacks Wedges Straight edges Alignment telescopes Auto-collination Alignment techniques Machine tool test mandrels Calibration Traceability ISO Standards for testing/reporting General purpose parallel lathes Universal milling machine with horizontal or vertical spindle Horizontal spindle surface grinding machine External cylindrical grinding machine Pillar type vertical drilling machine Open front mechanical power press Acceptance code for machine tools Machine tool manufacturers test result reports, verification Safety considerations

Actrac Products Ltd/ Australian National Training Authority 1997

Standard Machine Performance Tests 3. Machine Tool Performance Testing Practical test specifications Interpretation Practical test planning Lathes Knee type horizontal or vertical milling machines Surface and cylindrical grinding machines Pillar type vertical drilling machines Open fronted mechanical power presses ISO standards as for geometric acceptance testing Safety considerations Delivery For consolidation the material in this module should be linked with and complemented by relevant on-the-job skill practice or other equivalent experience. On completion of this module the learner will be able to: Identify machine tool elements and their mode of operation. Correctly adjust a parallel turning lathe, or milling machine, or mechanical power press slides, to manufacturers specifications. Compare machine toll manufacturers instructions for operation and maintenance of the lubrication system to the Quality System procedure manual. Tabulate points of conformance or nonconformance for one of the following machine tools: parallel turning lathe, or milling machine, or cylindrical grinder, or surface grinder. Conditions Contracts may need to be developed with participating employers to access specialised items of equipment. Short answer formative questions Practical exercise Assignment

Learning outcomes Learning Outcome 1 Assessment criteria

Assessment method

Actrac Products Ltd/ Australian National Training Authority 1997

Standard Machine Performance Tests Learning Outcome 2 Identify, select and apply appropriate equipment, instruments, and techniques for levelling and conducting machine tool geometric acceptance tests. With access to the nominated machine tools and equipment, perform geometric performance tests to ISO standards and compare results to machine tool manufacturers specifications for conformance or non-conformance. Complete machine tool test procedures planning sheets to ISO standards for the following nominated machine tools geometric tests: parallel turning engine lathe, universal milling machine, horizontal spindle surface grinder, cylindrical grinder, pillar type vertical drilling machine, and open fronted mechanical power press. Conditions Contracts may need to be developed with participating employers to access specialised items of equipment. Short answer questions Practical exercise Assignment Using principles of machine tool testing, carry out practical tests to verify machine tool quality specifications. Perform tests using appropriate safe working practices to verify the practical accuracy of the selected machine tool to ISO standards and machine tool manufacturers specifications. Contracts may need to be developed with participating employers to access specialised items of equipment. Practical test Written theory test

Assessment criteria

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Learning Outcome 3

Assessment criteria

Conditions

Assessment method

Actrac Products Ltd/ Australian National Training Authority 1997

Standard Machine Performance Tests Suggested Learning Resources Physical resources Texts/references Schlesinger, G: Testing Machine Tools, Machinery Publishing Co Ltd Cully, R: Fitting and Machining, Vic TAFE Browne, JW: The Theory of Machine Tools, Books 1 and 2, Cassell and Co Ltd Busch, T: Fundamentals of Dimensional Metrology (2nd ed), Delmar Publishers ISO 230/1 ISO 1708-1989 (E) ISO 1701-1974 (E) ISO 1986-1985 (E) ISO 2433-1984 (E) ISO 2773/1-1973 (E) ISO 2773/11-1973 (E) ISO 6899-1984 (E)

Actrac Products Ltd/ Australian National Training Authority 1997