CNC Machine Installation and Validation

Precision Machine Level
This is a view of a machine level. This has an accuracy of 0.0002'' over 10''. It is bubble based and much more accurate than your IPhone "level application".  Level is critical to remove gravitational machine deformation.

Ball Bar Test
The Renishaw Ball Bar test (QC20-W) confirms the machine positional accuracy without a load.

Rotary Tables
Rotary tables typically measure drive motor rotation and do not directly measure the table rotation. This small error can be corrected via program, or encoder tables.  This is critical to manufacturing high accuracy parts.

Haas VF2-SSYT
One of the VMCs at Protomatic, getting ready to run parts.

Functional Verification
Machining a part allows for complete system testing under load, verifying the machine setup.

Installation of a
Vertical Milling Center (VMC)
The installation process is vital to the consistent and reliable operation of a CNC machine tool.
The process of a mill or lathe installation typically involves the following:

    
Electrical Line Voltage- Checks for AC and DC system voltages. These voltages are critical for uninterrupted operation during power glitches.

Machine Level- Typically machines are very accurately leveled  with maximum error of 0.0005'' over 10" with various table positions.

Spindle Sweep- This checks the machine tool for tram (perpendicularity to the machine table). The  spindle sweep using  an indicator mounted to the spindle shaft is rotated with a 5'' radius.  The error should be no larger than 0.0001''.

Lube System Verification- Verifies that machine lubrication system is operating correctly.

Compressed Air Check- Verifies that the system air is clean, dry and has correct pressure (PSI).
Machine Break-In and controls testing is then conducted.  This tests the main spindle and axis controls for  reliability and accuracy.

Machine Validation
We are not finished yet.  The next step confirms that the machine tool can make a part accurately.  One of the best ways to conduct a series of tests, such as:

Ball Bar Test- This will test for the combination axis. This tests three orthogonal planes. The results are then recorded and posted on the machine confirming accuracy.

Environment- Confirm that the environment is maintaining a consistent temperature.  This is critical for manufacturing consistent parts. Confirm that the machine is thermally stabilized and is  conditioned to the average 76F environment.

Rotary Table Testing- We confirm that the rotary tables move like they are programmed.  We correct for any error(s).

Test Part- Coolant is then added to the machine and a test part is manufactured. This demonstrates loaded conditions.  Machine is ready for final verification.

Verification vs Validation
Protomatic does an installation validation on all CNC equipment installations. Parts are then verified  with another means such as a Coordinate Measurement Machine (CMM) or other instruments.

We are ready to Run!
This is  a short summary of the process to setup a new machine, to make your parts precisely and accurately.