Circular mould test with Quick Check from Renishaw
Get to the bottom of geometry problems with a circular form test or circular form measurement.
Do you have geometry problems? Does your machine mill an ellipse instead of a circle? Or – how accurate are your machines?
Until now, these questions could only be answered with a great deal of labour and expensive measuring equipment after carrying out the usual methods. The resulting costs are high and production downtime is long. Preventive measures to eliminate creeping machine faults unfortunately failed because they could not be recognised. Only when workpieces are manufactured incorrectly and all other influences have been checked is a ballbar test usually carried out.
You no longer need to wait until your production comes to a standstill due to geometry or servo errors, because we now offer you an accuracy check of your path-controlled NC machines with very little downtime.
The circular moulding test with the Renishaw QC10
The circular moulding test with the Renishaw QC10 provides information about the condition of the machine in the shortest possible time. We mount the QC10 system between two kinematic magnetic bearings. With minimal programming effort on your CNC-controlled machine, we travel two circular paths. Once clockwise and once anti-clockwise. The data from the QC10 is transferred directly to the PC. The diagnostic software calculates the characteristic machine faults from the detected circles. All parameters are listed in a table. This provides us with a clear statement about the condition of the axis pair or the machine. The immediate subsequent evaluation of the information in accordance with ISO 230/4 or ANSI B5.54 provides information about the static and dynamic accuracy of the machine.
In most cases, changing a few servo parameters is sufficient to adjust the machine to the tolerance range.
Checking and documenting the manufacturing accuracy of machine tools is a must for ISO 9000 certification. To prove and archive the inspection, we produce a colour printout of the graph (based on an ISO 9000 certificate) and the detailed table of parameters on site. While conventional methods can only identify static defects, the Quick Check circular mould test also offers an evaluation of dynamic deficits.
Among other things, you can recognise the following:
- Speed of the axes in relation to each other
- Radius deviation
- Circular mould behaviour
- Dimensional accuracy
- Jumps at the transition of the quadrants
- Backlash of the ball screw drive
- Tilting the axles
- Tracking error
- Cyclical errors
- Error in the orthogonality (perpendicularity)
- Linearity error ( straightness )
- Circle centre offset
We also save the data from your machine’s ballbar test. For repeat measurements, we can superimpose the previous data on the new results. This allows trends to be identified. As regular tests can be carried out at short intervals (e.g. as part of machine maintenance) without having to accept serious machine downtimes, accuracy can be permanently monitored without significant interruptions to production. Regular measurements ensure that you can produce effectively and accurately with the machines.
The ballbar test is a crucial procedure for assessing the accuracy and performance of machine tools. When performing a ballbar test, a circular motion is simulated to check the precision of the machine. This is done by using a special device developed by Renishaw. The test is known for its quick and accurate assessment of machine performance, which is why it is also known as a quick check.
The main purpose of a ballbar test is to identify the geometric errors of a machine. Such errors can be caused by various factors, including mechanical wear, thermal expansion or errors in machine calibration. By accurately measuring these errors, machine operators and technicians can take targeted measures to improve the precision and efficiency of the machine.
Performing a ballbar test begins with the installation of the Ballbar device, which is typically mounted between the spindle and the table of the machine tool. The device consists of two precision sensors that are able to measure the deviations from the ideal circular path. While the machine performs a circular movement, the Ballbar device continuously collects data and creates a detailed profile of the movement.
Key features of the ballbar test
One of the key features of the ballbar test is its ability to quickly and efficiently provide a comprehensive analysis of machine performance. Within minutes, the test can provide accurate information on various types of errors, including position errors, reverse clearance errors, scale errors and more. This ability to quickly detect errors makes the ballbar an indispensable tool in the maintenance and calibration of machine tools.
Another advantage of the ballbar is its applicability to a wide range of machines and applications. Whether it is milling machines, lathes or machining centres, the ballbar can be used to evaluate the performance and precision of the machine. This makes it an extremely versatile tool for machine operators and maintenance personnel.
The data we collect during a ballbar test can also be used to monitor the long-term performance of a machine. By conducting regular moulding tests, machine operators can identify trends in machine performance and take proactive maintenance measures to avoid potential problems. This preventative maintenance can help to extend the life of the machine and minimise production downtime.
Renishaw
Renishaw, the leading supplier of ballbar equipment, offers a variety of products and services to support ballbar testing. Their equipment is renowned for its high precision and reliability, making it the first choice for many machine operators worldwide. In addition to the Ballbar devices, Renishaw also offers software solutions that facilitate the analysis and interpretation of test data.
Overall, the ballbar test is an indispensable method for ensuring the accuracy and performance of machine tools. By using Ballbar equipment, machine operators can quickly and efficiently carry out a detailed analysis of machine performance and take targeted measures to improve precision. Carrying out regular ballbar tests can also help to monitor the long-term performance of the machine and support proactive maintenance measures. Thanks to Renishaw’s advanced technologies and services, machine operators can be confident that they have the best tools and resources at their disposal to optimise the performance of their machines.
