ASME B5 54-2005 Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers《计算机数控组合加工中心机床的性能评价方法》.pdf

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1、AN AMERICAN NATIONAL STANDARDMethods for Performance Evaluation of Computer Numerically Controlled Machining CentersASME B5.54-2005(Revision of ASME B5.54-1992)ASME B5.54-2005(Revision of ASME B5.54-1992)Methods forPerformanceEvaluation of ComputerNumerically ControlledMachining CentersAN AMERICAN N

2、ATIONAL STANDARDThree Park Avenue New York, NY 10016Date of Issuance: March 25, 2005The 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 committeeactions to be published as n

3、ecessary. This Standard will be revised when the Society approves theissuance of a new edition.ASME is the registered trademark of The American Society of Mechanical Engineers.This code or standard was developed under procedures accredited as meeting the criteria for American NationalStandards. The

4、Standards Committee that approved the code or standard was balanced to assure that individuals fromcompetent and concerned interests have had an opportunity to participate. The proposed code or standard was madeavailable for public review and comment that provides an opportunity for additional publi

5、c input from industry, academia,regulatory agencies, and the public-at-large.ASME does not “approve,” “rate,” or “endorse” any item, construction, proprietary device, or activity.ASME does not take any position with respect to the validity of any patent rights asserted in connection with anyitems me

6、ntioned in this document, and does not undertake to insure anyone utilizing a standard against liability forinfringement of any applicable letters patent, nor assumes any such liability. Users of a code or standard are expresslyadvised that determination of the validity of any such patent rights, an

7、d the risk of infringement of such rights, isentirely their own responsibility.Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted asgovernment or industry endorsement of this code or standard.ASME accepts responsibility for only those int

8、erpretations of this document issued in accordance with the establishedASME procedures and policies, which precludes the issuance of interpretations by individuals.No part of this document may be reproduced in any form,in an electronic retrieval system or otherwise,without the prior written permissi

9、on of the publisher.The American Society of Mechanical EngineersThree Park Avenue, New York, NY 10016-5990Copyright 2005 byTHE AMERICAN SOCIETY OF MECHANICAL ENGINEERSAll rights reservedPrinted in U.S.A.CONTENTSForeword viiiCommittee Roster ixCorrespondence With the B5 Committee x1 Scope . 11.1 Gene

10、ral . 11.2 Performance Forms 12 References 183 Nomenclature . 194 Definitions 234.1 Glossary 234.2 Machine Classifications 365 Environmental Specifications . 435.1 General . 435.2 Temperature 435.3 Seismic Vibration 435.4 Electrical 445.5 Utility Air 445.6 Other . 456 Environmental Tests 466.1 Gener

11、al . 466.2 Environmental Temperature Variation Error (ETVE) 466.3 Relative Vibration Tests 516.4 Electrical Tests 536.5 Utility Air and Other Tests 537 Machine Performance 557.1 General . 557.2 Machine Compliance and Hysteresis . 567.3 Positioning Accuracy and Repeatability 617.4 Geometric Accuracy

12、Tests . 687.5 Spindle Axis of Rotation. 787.6 Machine Thermal Tests 817.7 Diagonal Displacement Test . 877.8 Subsystems Repeatability 887.9 Machine Performance as a Measuring Tool . 927.10 CNC Performance Tests . 957.11 Contouring Performance Using Circular Tests 998 Machining Test Parts 1028.1 Gene

13、ral . 1028.2 Precision Contouring Machining Test: All Machining Centers . 1038.3 Machining Tests for Four- and Five-Axis Machining Centers 1058.4 Production Parts 1059 Cutting Performance Tests 108iii9.1 General . 1089.2 Complete Set of Tests 1089.3 Machining Center Ranges . 1099.4 Spindle Idle Run

14、Loss Test 1099.5 Chatter Limits Tests and Full Torque Test 10910 Multifunction Cycle Test 12410.1 General . 12410.2 Procedure . 12410.3 Functional Check 12411 Test Equipment and Instrumentation 12511.1 General . 12511.2 Temperature 12511.3 Relative Vibration . 12511.4 Displacement 12511.5 Angle . 12

15、611.6 Pressure 12611.7 Humidity . 12611.8 Utility Air 12611.9 Spindle Error Measurement 12611.10 Indicators for Straightness Measurements 12711.11 Test Part Measurement 127Figures4.1 Schematic Diagrams of the Six Basic Degrees of Freedom of an Axis ofRotation 244.2 Four Body Diagonals of a Rectangul

16、ar Prism . 254.3 Face Diagonals of a Rectangular Prism . 274.4 Error Motion Polar Plot Showing Polar Chart (PC) Center, a MinimumRadial Separation (MRS) Center, and Error Motion Values About TheseCenters . 314.5 Example of a Structural Loop Showing a Part, Spindle, Machine Frame, andTool. 334.6 Code

17、 Numbers for Spindle Types 384.7 Code Numbers for Column Types 394.8 Code Numbers for Column Traverse . 394.9 Code Numbers for Spindle Head Traverse 404.10 Code Numbers for Table Traverse 414.11 Examples of Machining Centers Classified by Code Numbers . 426.1 Typical Setup for Environmental Temperat

18、ure Variation Error (ETVE)Measurement on a Vertical Machining Center 476.2 Temperature, Displacement, and Tilt Motion Results From a Typical ETVETest. 487.1 Setup for Measuring the Compliance and Machine Hysteresis of a LinearAxis 577.2 Setup for Measuring the Compliance and Machine Hysteresis of a

19、LinearAxis in a Vertical Direction 577.3 Typical Plot Showing Results of a Compliance and Axis Hysteresis Test . 587.4 Setup for Angular Compliance Measurement on a Rotary Positioning Axis 597.5 Setup for Angular Compliance Measurement on a Tilt Table 597.6 Application of a Laser Interferometer to T

20、est the Positioning Accuracy of aLinear Axis . 617.7 Setup for Measuring the Positioning Accuracy of a Rotary Table With aLaser Angle Interferometer and a Calibrated Indexing Table 627.8 Setup for Adjusting the Alignment of an Indexing Table and a Laser AngleInterferometer . 62iv7.9 Setup for the Po

21、sitioning Accuracy of a Rotary Axis Showing the Polygon,Autocollimator, and Rotary Table 637.10 Setup for Measuring the Positioning Accuracy of a Rotary Axis With aCalibrated Rotary Encoder. 637.11 Standard Test Cycle 647.12 Full Data Set for the Positioning Deviations of an Axis, Bidirectional 657.

22、13 Positioning Deviations of an Axis, Forward Direction Only . 667.14 Setup for the Measurement of the Periodic Angular Error With aDisplacement Indicator 687.15 Periodic Error, P, of a Linear Axis 697.16 Typical Linear Carriage Designed for Motion in the X Direction. 707.17 Setup for Measuring Stra

23、ightness Using an Electronic Indicator and aMechanical Straightedge . 707.18 Test Setup for Measuring Straightness Using Taut Wire . 717.19 Straightness Setup Showing an Alignment Laser 717.20 Typical Straightness Interferometer of the Most Common Type 727.21 An Angular Interferometer Setup to Measu

24、re Pitch on a Machine Wherethe Spindle Moves Relative to the Table 727.22 Typical Setup Showing Differential Levels to Measure the Roll of a HorizontalAxis 737.23 Differential Straightness Measurement Used to Measure the Roll of a VerticalAxis 737.24 Diagram Showing the Effect of Cross-Axial Roll on

25、 the Measurement ofRoll of a Vertical Axis Using Differential Straightness. 747.25 Setup for Measuring Squareness With an Optical Square and aStraightness Interferometer: Line 1 . 747.26 Setup for Measuring Squareness With an Optical Square and aStraightness Interferometer: Line 2 . 747.27 Conceptua

26、l Diagram Showing the Angles Obtained in a SquarenessMeasurement 757.28 Analysis of Parallelism Between Two Linear Axes (Parallelism IsCalculated From the Differences in Best-Fit Slopes of Each Profile) 757.29 Measurement of Rotary Axis Squareness Using a Mechanical or OpticalStraightedge. 767.30 Me

27、asurement of Rotary Axis Squareness (or Parallelism) Using a StraightnessInterferometer . 777.31 Measurement of Parallelism of the Z-Axis With a Rotary Table 777.32 Schematic of the Test Setup for Radial Error Motion With a Rotating SensitiveDirection 787.33 Test Method for Radial Motion With a Rota

28、ting Sensitive Direction andthe Ball Mounted Eccentric to the Spindle 797.34 Typical Total Error Motion Polar Plot Showing Asynchronous ErrorMotion and Average Error Motion Value as Utilized in This Standard. 807.35 Five-Sensor Test System for Tilt Error Motion Test on a Machining Center . 807.36 Se

29、tup for Axial Error Motion Measurement for Rotating SensitiveDirection 817.37 Sensor Data From a Typical Spindle Thermal Warm-Up Test 837.38 Tilts of the Axis Average Line, Spindle Warm-Up Test 847.39 Path for Measuring Thermal Distortion Caused by Moving Linear Axes . 857.40 Position Error Versus T

30、ime for a Typical Test for Thermal DistortionCaused by a Moving Linear Axis 867.41 Typical Results From a Composite Thermal Error Test 877.42 Tool Holders Used for Tool Change Repeatability . 887.43 Three-Sensor Nest Setup for Tool Change Repeatability . 887.44 Test Setup for Pallet Change Repeatabi

31、lity 907.45 Tool Length Measurement With No Spindle Rotation . 90v7.46 Tool Length Measurement With Rotating Spindle . 917.47 Tool Diameter Measurement . 917.48 Illustration of the Probing Pattern Used for Determining Three-DimensionalProbing Capability 937.49 Sample Results From the Small Increment

32、 Tests. 967.50 Test Setup . 977.51 Sample Acceleration Plot 997.52 Examples of Circle Test Setups . 1007.53 Typical Results From a 360 deg Circular Test . 1018.1 Precision Contouring Test Part Test Piece Blank. 1038.2 Precision Contouring Test Part Machining Dimensions 1048.3 Precision Contouring Te

33、st Part Inspection Requirements 1069.1 Typical Transfer Functions . 1109.2 Typical Plot of the Power Loss in the Spindle Idle Run Loss Test 1119.3 Typical Face Mills 1149.4 Typical End Mills 1149.5 Typical End Mills With Carbide Inserts . 1159.6 Typical Test Parts for the Chatter Tests . 1169.7 Chat

34、ter Test for Face Mills . 1179.8 Chatter Test With End Mills 1189.9 Typical Results of the Chatter Test in One Axis Direction . 1189.10 Plot of the Limit Cross-Sectional Area of Cut Versus the Radial Immersionfor a Typical Chatter Test 1199.11 Test Part and Test Procedure for the End Milling Deflect

35、ion Test 1209.12 Sample Measurements of the Part Profile in the End Milling DeflectionTest. 1219.13 Face Milling Deflection Test 1229.14 Sample Displacement Measurements for the Face Milling Deflection TestWhen “Slotting” (Radial Immersion p 1) 123Forms1.1 General Form 21.2 Chapter 5 Environmental S

36、pecifications Guidelines . 41.3 Chapter 6 Environmental Tests . 61.4 Chapter 7 Machine Performance . 71.5 Chapter 9 Cutting Performance Tests . 151.6 Multifunction Cycle Test . 178.1 Precision Contouring Test Part Inspection Results. 1079.1 Record of the Fill Torque Test 1199.2 Deflection Errors in

37、Face Milling . 122Tables4.1 Key to Unit Code 376.1 Specification Zones Derated Due to an Excessive Expanded ThermalUncertainty . 516.2 Example Calculations for Derating of Specification Zones Due to ThermalUncertainty . 526.3 Specification Zones Derated Due to an Excessive Angular Expanded ThermalUn

38、certainty . 536.4 Performance Parameters Derated Due to Excessive EnvironmentalVibration 537.1 Suggested Maximum Loads for the Machine Compliance and HysteresisTest (Not for Spindles With More Than 10,000 rpm) 577.2 Typical Test Results for the Positioning and Repeatability of a Linear Axis(Measured

39、 in H9262m). 678.1 Types and Sizes of Test Parts. 1039.1 Metric to English Conversion Used in This Standard 108vi9.2 Machining Center Ranges 1119.3 Chip Loads for Cutting Performance Test. 1119.4 Standard Tools and Default Machine and Cutting Parameters for the FaceMilling Chatter Test(s) . 1129.5 S

40、tandard Tools and Default Machine and Cutting Parameters for theChatter Tests Using Solid (HSS or Carbide) End Mills 1139.6 Standard Tools and Default Machine and Cutting Parameters for theChatter Test for End Mills With Carbide Inserts 1139.7 Record of the Chatter Test . 1179.8 Typical Results From

41、 an End Milling Deflection Test 1209.9 Location of Measurements for the End Milling Deflection Test 120Nonmandatory AppendicesA Guide for Using This Standard. 129B Thermal Environment Verification Tests 131C Seismic Vibration Verification Tests . 133D Electrical Power Monitoring Tests 137E Machine F

42、unctional Tests 138F Machine Leveling and Alignment 140G Clarifications for Cutting Performance Tests 141H Laser and Machine Scale Corrections . 153I Drift Checks for Sensors, Including Lasers 154J Example Ball Bar Patterns for Four- and Five-Axis Machining Centers. 157K Discussion of the UNDE and T

43、hermal Uncertainty 165L Straightedge Reversal Technique . 170M Calculation of Uncertainties 172N Sign Conventions for Error Values 175O Static Error Motion Measurement 176viiFOREWORDThe primary purpose of this Standard is to provide procedures for the performance evaluationof computer numerically co

44、ntrolled (CNC) machining centers. The secondary purpose is tofacilitate performance comparisons between machines and to provide for machine evaluationafter refit. Definitions, environmental requirements, and test methods are specified. This Standarddefines the test methods capable of yielding adequa

45、te results for most machines, but is notintended 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 standardfor turning centers (ASME B5.57-1998) with respect to some definitio

46、ns, data analysis, and reportedparameters. To achieve consistency, uncertainty analysis was used to analyze data and reportparameters for many of the procedures, deemed appropriate, within this Standard. Availabilityof improved measurement technology and increasing demand for greater accuracy requir

47、e morerobust procedures for assessing performance of machining centers, as provided within this revisionof 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 andJanuary 12, 2005.viiiASME

48、B5 STANDARDS COMMITTEEMachine Tools Components, Elements,Performance, and Equipment(The following is a roster of the Committee at the time of approval of this Standard.)OFFICERSC. Wax, ChairM. Lo, SecretaryCOMMITTEE PERSONNELA. M. Bratkovich, The Association for Manufacturing TechnologyD. M. King, C

49、onsultantK. J. Koroncey, General MotorsD. L. Lewis, ConsultantM. Lo, The American Society of Mechanical EngineersC. D. LovettC. J. Nuccitelli, Parlec, Inc.J. A. Soons, NIST, U.S. Department of CommerceR. C. Spooner, Powerhold, Inc.C. Wax, CTW Advisors, Inc.TECHNICAL COMMITTEE 52 MACHINING CENTERSC. D. Lovett, ChairD. Ajao, GM, North AmericaA. M. Bailey, Renishaw, Inc.K. G. Beracz, Beacon Metrology, Inc.L. Bishop, Boeing Commercial AirplanesM. Boyd, Northrup Grumman Corp.A. M. Bratkovich, The Association for Manufacturing TechnologyJ. B. Bryan, Bryan AssociatesR. P. Callaghan, Independe