I'm a retired machinist with over half a century of experience. We built lots of things, including drilling equipment like your shop. We started out with a similar set up to what you have built. We soon learned that it was inadequate for us (way too much flex) and eventually dedicated a machine to drilling only. We removed the compound and built a piece that spanned the cross slide and bolted directly to the carriage, then line bored the mounting hole in the machine. Built a 200 gallon coolant tank with a big fan cooled heat exchanger outdoors(coolant would start steaming before coffee break) installed a 10 hp Grundfoss multi stage coolant pump and made a dumping chip pan that travelled with the tool that could be easily emptied by the operator. We also made a sort of light duty steady rest device with interchangeable bushings to suit the size being drilled. The bushings had about 1/8" clearance to the drill and were moved up close to the part. These were so the coolant could be started before the cut, (without the operator drowning)we found that when we started coolant after the cut we had a lot of insert failures from thermal cracking. Keep in mind that this is a pretty rudimentary description of the set up. Good luck, fun watching .
Great description! Man I really appreciate that comment. We are basically headed in the direction you detailed there. Our next step is to get a much bigger megabore lathe with both a turret (for external tooling) and a live tail stock & cross-slide mounted boring bar / drill tool holder. We are def pushing things to the max with the tools we have… so it’s a logical next step. The work lined up over the next 6 months is much larger than anything we’ve ever attempted. Look forward to your feedback and suggestions on future videos. Sounds like you’ve got a wealth of experience.
@@halheavyduty I'm glad to help! Be cautious of what machine that you purchase, some machines don't have enough torque at the lower speed ranges needed for drilling big holes. We found that the drilling process was specialised enough that it didn't make sense to hold up other machining work when we had lots of drilling work. We eventually went to ejector drilling, expensive to start and a serious learning curve, but OMG, will it make beautiful holes in a hurry!!! We eventually built our own machine, as we couldn't find a production unit that fit our needs. We drilled lots of different materials, 4140, 4340, H13, and a bunch of aircraft grades (landing gear) nearly all preheat treated from 30 to 45 RC. BTW, harder materials produce much better chip control. We drilled from about 1.25 inch diameter up to 4.5 inch, and from a foot deep up to just over 6 ft deep from solid, and made our own boring heads to open up to 6 inch dia. Actually, we made lots of our own special tools as well. Do some scouting in your area, we eventually had 2 drilling machines and a big hone. Once people found out about our capabilities, we couldn't keep up with demand, even running 24/7 sometimes. Once we got the process figured out drilling was very lucrative, we even did work for metal sales companies that would provide drilling services to their customers. BTW, I'm a frost bitten Canadian boy, always been my dream to visit your part of the planet!
Thank you for sharing that. I have a feeling I’m up for a wild learning curve as this all develops. Having experienced people like yourself comment and share will be really valuable - so thanks for taking the time. My Canadian Grandad Hal loved it here… except for the extreme heat in Jan / Feb. He stated going back home to Canada for a month year… from 40+ to minus in a day. We all thought he had lost it 🤣
@@halheavyduty Hey currently looking for your email to send you a message, but I figured it was worth a comment. Larry sounds like a wealth of knowledge and I would love for us to be able to create a community to share our information/experiences. Not only would it be helpful, but who doesn't like to show off a big hole they drilled 🤣 I am in the USA and have a small machine shop where I run a some old Nakamura CNC lathes. Lately I have been getting into bigger diameter parts, say 5-8" (125-200mm) with thin walls. Mostly 304SS and tube/pipe is not available. Solid Bar is wildly expensive so being able to core drill would give me a huge advantage, I know I could make 2 if not 3 separate parts out of one piece of bar stock. I have used brazed carbide tip annular cutters up to 3" with good success in 303SS/leaded mild steel, but they don't last in 304. They also have too many teeth, 9 teeth on a 3" (75mm) cutter, I'm getting servo overload alarms trying to push the cutter. I want to start making my own core drills because I know it will solve all of these issues. I have started the process by upgrading the coolant system, added 15 gallons of capacity with a reservoir and mounted a grundfos coolant pump. From 180W to 750W. Hoping 50PSI will be enough to flush chips well. My only comment on this video was you need something with more pressure. You can see the steam coming off the cutter cartridge as soon as it begins cutting, I think more pressure, and in turn flow, would keep things cool.
Really the same pleasure for me to look at your vidéos !! I am an old Electronic technicien (68 years old) but all my life I love machines, tools and nice jobs Thanks a lot to show me your workshop and incredibles homemade tools ! I never thougth that we can made tools like that.... congratulations to all the team
Check out Dave Wilks UK channel. His a bloke who has this down to a fine art, he makes his own trepanning tools. Turns them up in his lathe then finishes the off in his bridgeport mill. Trepanning performed in Titanium, 4140, monel, 316 and other tough bloody metals. Enjoy.
Hi I found you Dave Wilks channel, he stopped doing stuff here in UK. Hope you pick up a cheap pri bar rules for stirring your tea up with.😂 th-cam.com/video/VpUri-NGFyk/w-d-xo.htmlsi=qtgAaEQFmZm933uH Steve
Nice. Here's a thought. Use a steady rest at the front of the tool to stop the wobble as the bore is started. Make a 2 or 3 inch sleeve to fit around the boring bar that will ride in the steady rest and make the initial cut smooth and not an interrupted cut.
That’s a great idea. Thanks Mark. What we ended up doing was just cutting a 10mm deep face groove as a locator and it works pretty well. Where are you based mate?
Hi mate just come across your videos its great to see another Aussie job shop. I hope you can find your niche on here so you can keep making videos. As a manual machinist it was impressive watching the big lathe core out the centre of a piece of 4140! Nice Work👍 looking forward to see what else you do
Greetings from across the world! Just found the channel. Great video! You’re a natural narrator and I love shop made tools. Looking forward to more content!
I actually just built a core drill at our shop. Even living in the USA material ain’t cheap. And we have a party that has a 16in OD and a massive 13ish inch threaded ID. And we have another part made from the same material just a 10in OD and threaded 7ish in ID. It’s only made out of 1214 cold roll but it’s basically free parts for us to run the large parts first with the core drill. Originally I made the drill to use what looks to be the same insert your using. But I then found a Komet insert that also fit the pocket and that insert has chip breakers. Those chip breakers were amazing!!!! It made the surface finishes look beautiful, and the chips that came out looked like roughing endmill chips. The spindle load also dropped by about 30%
Hi from across the Tasman. Great tool and it looks like it works well. I am now retired but served my time as a fitter and turner and after a few years ended up working for Seco Tools here for the last 28 odd years. My experience with insert drills and Seco made a quality tool that operated well but you needed good coolant pressure to help get the chip out and I thinks you need to look at redirecting the coolant port so it assists with this. Otherwise it works well. Drilling with insert drills is certainly "heart in the mouth" operations as when it goes wrong it all over very quickly. Cheers and great videos. Ian
Sounds like you’ve got some incredible tooling experience there Ian. Thanks for tuning in. Looking forward to seeing your comments and suggestions in future videos
Plus 1 for Dave Wilks. On using the indicator stuck out like that, be careful top to bottom cos sag can be huge. For example, mag the base to some thick stock with the arm stretched out, zero, then turn it upside down. Its eye opening. Cheers D
Great video, thanks. I’m sure you have looked at David Wilkes videos by now. He certainly was/is (hopeing) an ‘expert’ on trepaning. Using tools he made himself, and showing how he made them! He would deep trepan shafts of exotic metals metres long!, Up to like 5m long…! He did use a steady to hold the (effin) long tool up to the face of the work, sandvic tooling and an absolute flood of coolant! Must watch. I’ve wanted to make even a ‘short’ trepaning tool for a long time but haven’t had the need really.. Keep it up, entertaining videos, thanks.
David is the absolute guru when it comes to trepanning. His videos are amazing. I haven’t had time to watch them all yet, but I’m super impressed with what I’ve seen so far. I just love how many different skill sets can develop in the machining world.
Hey you there Down Under! Wish ye all the best, good luck,fingers crossed and so on! We say here: „Only those who do nothing, do nothing wrong“… Believe me, i‘ve made A LOT mistakes in my long live as a machinst. (I‘m 100% complete,nothing broke😂😂😂).I wish you realy all the best for your hard and stony path! You can do it, i‘m sure of it.👍👍👍
Interesting Video. Great set up.Good introduction. I could not hear most of what you were saying when the lathe was running. You may need to check your sound levels. Also you may need to think of some more splash guards especially if you up the coolant flow. Thanks for sharing.
I suggest few improvements in your trepanning tool. !. Have coolant channel cut inside the bore of the tool, and supply coolant from inside. Increase flow and pressure, so chips will be flushed out better, and you may be able to increase the feed., but reduce it at the end to prevent punch out, to prevent chances of insert breakage.
Great work as alway. I've wanted to build one of these for years, just don't have a lathe with the nuts to run it. Maybe once we build the new shop and have room
Definitely an avenue worth pursuing at my job. We do a lot of large jobs often in not the cheapest materials. We have lathes comfortably big and powerful enough. Saving and reusing materials is very sensible and the way the world is going it will become more and more urgent. Although energy is also going through the roof so not looking very good in general.
Very cool😎 thanks for the vid. The tool was rocking up n down in the 6:00 minute. You can see the evidence when you look down the barrel. So no magnets or mesh in the reclaim tank.? Thats a bold choice. INSANE waste of 4140 😲. I work a forge, make blades, small town rural Vic.
She definitely rocked up and down a few times in parts of that video. We actually had to re adjust the tool height and re dial it back in properly! 99% of the swarf gets recycled - it never actually makes it to the coolant tank as it’s at the back of the lathe. Thanks for tuning in 👊👍 I bet you do some cool stuff on the forge man. Heavy duty stuff for sure
Nice one guys - so basically cutting the full width of the tip x two tips? Thanks for posting Cheers BTW, love the lathe, I'd be happy with a 105mm spindle bore!
@@halheavyduty Both Kennametal and Sandvik make these along with other Tooling manufacturers. They're usually refer to as Boring Cartridges. I ran these years ago in my shop when I was manufacturing Manifolds made from Inconel for use in the Chemical Industry. I found Sandvik made a better grade of Carbide Insert back then for cutting Inconel. Pretty much everyone copies Sandvik so everyone has much of the same thing now. Eventually the company I was manufacturing for, started copying my design and had the Manifolds made in Taiwan where NO patent or copyright law had a chance of surviving ???
Happens all too often these days hey. I’ve heard from a lot of people that Sandvik are the leader when it comes to carbide. Expensive, but the best. We tend to run a bit of a mix in the shop. Kennnametal, Iscar, Palbit and some Seco.
How do you know that the id of the core drill is concentric with the tips of the inserts? Same for id to od and od to insert tips? Also, there should be an odd number of inserts or cutting edges. The odd number of inserts cuts down the development or inducing harmonics, i.e., chatter.
Forgot to add that the only way to check roundness for od's is either a 3-point mic or a v-block and indicator. A 2-point measurement only proves diameter. Same for id's. Journeyman Tool and Die Maker. Also, have taught Geometric Dimensioning and Tolerancing.
The inserts are slightly offset. One cuts the OD, the other cuts the ID. When it’s perfectly level (which fortunately it now is) it cuts very smoothly. Just took a bit to get it working right in the new lathe. It was originally designed for our old “big lathe” which we replaced with the hulk - the big green megabore. As long as the two inserts contact at the same time and it’s aligned correctly, it tends not to chatter too much.
This is true. We are constantly upgrading our measuring equipment as time goes on… Really appreciate the comments brother. Clearly you know your stuff 💯
That's great. I've seen other guys coring out a solid piece like that and turning it all into chips. At least you can use that inner piece to make something else.
Hey Mr. Maschinist! My opinion: this / your shop floor - made wonderful BIG Core drillbit at 4041 needs a much more stable tool holder. You can‘t increase the feed rate for a better safer chip breaking. And, i think, the „Y - Slide“ ,made of welded steel plates (15-12mm???)under the tool post)is the next reason for problems with chattering/breaking inserts/jamming the tool. THIS lathe and the tool holding is NOT stabile/massive enough to resist at 4041 and higher… sorry for my realy bad english, Sir! Whish you all the best!!!Cheers !
Interesting feedback, and much appreciated. You might possibly be right. The core drill was actually used in a much smaller machine previously, and successfully cored out about 120 billets once they figured out the practicality of running it. The new machine is almost twice the size. Once we got the tool height dead on (we were originally a little out, hence the reason it didn’t perform so well at the start) It cuts like a dream now. No tip breaking and the chips come off nicely. Just took a few runs to perfect the process again. Ideally I’d mount it on the cross-slide, bolted down directly in its own HD dedicated tool holder, for the reasons you mentioned. Thanks again for commenting mate! Where are you from, and what kind of work do you do? Would love to know. Cheers brother 👊
@@halheavyduty I used to trepan big stainless blanks for valve seats using a ground down parting tool, blanks 12-16 inch o/d and 2-4 thick! Usually 303, 316 or 321 stainless and dias up to 10 inch bore. Listened to the tool note change as it began to break through. Split second too late and the core slipped cockeyed, smashed the tool and gave me a thrill. I used to lap and assemble some of the bigger valves. Once spent 9 days on one valve testing it, failing it, dismantling, relapping, retesting, failing. I told the tester guy on first day the body had a pinhole and he should pour a quart of water in to reveal it but he refused and said his test machine was super accurate. Customer had sent inspector to confirm the valves passed as they were for a refinery or very high temp. At end of each day he looked at me like I was s***! I said the tester should do the water test. Finally on 9th day we all gathered round for another test - me, tester, foreman, other people, the inspector and our 'production manager'. It failed. Tester smirked and said I hadn't lapped it perfectly. I said I had and there was a pinhole. I turned to prod man and told him to tell tester to pour some water in. Prodman didn't want to get involved but we were all looking at him. Finally he grew a pair and told tester to pour some water in - just to show me I was wrong. Tester poured the water and pinhole showed up. 'SEE! I said.. 'I've wasted 9 days costs on that for sake of a jug of water! Then people wonder why British industry died!
Once Aus has a huge amount of grid solar and batteries set up, there'll be no excuse not to vastly expand iron refineries and forges to provide more steel in more options for cheaper prices.
Hey Mate! Thanks for your FAST answer! I‘m from Germany , Trained Toolmaker (for Plastic Injektion molds plastic blow molds)turner,miller, conventional and CNC. I make chips since 1980 in 3-shift-system. I‘ve made Parts for lots of molds , later than steel parts in different sizes from round about 200 grams up to 120 tons… Sometime a shovelful of chips in 1shift… sometimes a pile that would fill a 20-foot container … i‘ve worked on machines with 600mm X-travel till 18000mm(18meter). And now i‘m making airplane-parts…
Brother that awesome. Nothing better than filling up a big container with perfect cut c chips ✌️👌 Sounds like you got some really varied experience too, which is great. Hearing from (and learning from) all the different types of machinists out there was a major reason I started the channel, so I really appreciate the comments.
I think our plasma cutter peaks out at 70mm depth of cut. Great tool for thick sheet metal, but the gear we have won’t cut a 300mm billet like the core drill can. Excellent question. Thanks for commenting mate 👊
@@halheavyduty i was wondering not to blow through, but like a ceramic bit, it should excavate directly at point of plasma contact. i was thinking if you add high pressure air, or much more argon, you should be able to clear the molten metal. i saw another group using superheated steam to excavate rock without contact. but am not in a position to try this currently . thanks for the content.
very interesting, the sounds of the cutting are just like the Chap who was doing this over in Sheffield England, I am sure you have seen his videos, doing 2 meter or more trepanning......unfortunately, he closed his shop and sold off all the equipment....cheers. Paul
First time i see a tool like this, but then again my maschine only goes up to 65mm diameter parts so i dont think its appropriate for me 😂 cool stuff tho seeing something selfmade run that well
Welcome to the channel brother. I love working on smaller pasts on some of the smaller machines we use for hydraulic repairs and random parts. It’s a lot more hands on and takes a lot of skill to get tolerances right.
It’s a truly terrifying reality of our profession. You’ve gotta have insane respect for the machines… or you’ll have a very short career. Those vids are horrendous. A cautionary tale for every machinist
@@halheavyduty worst near miss I saw was about 15 feet from me when guy put a 18ft length of one inch bar in his lathe to turn and part pieces off - rather than cut the pieces in the saw. The long end sticking out was Ok at low revs but when he upped the speed the bar bent and flailed round - just as the labourer was walking past. i still don't know how the labourers head wasn't smashed to bits! Another time a visitor was examining a new CNC lathe when untrained foreman decided to show him how it worked. He hadn't zeroed it or checked what it had been programmed to do but he hit the start button and it started at high speed and the turret ran fast into the chuck. Chuck bolts sheared and it sailed across the workshop before hitting one of the main steel girders and stopping. We get a lot of old UK industry films on tv and I watch the grime, old machines and gloomy workshops and remember the smells and sounds - and sort of wich I'd had a camera to record the normal day's activities1
For the moment, it seems EDM is prohibitively slow and expensive… and they struggle to cut depths past 185mm - at least in our neck of the woods. I think the core drill option is bang for bucks the current best way forward… but lord only knows what future tech is going to happen. We have actually purchased hollow bar billets from an international steel mill for the production job (thank God!)- the cored billets were just for initial prototypes. Great question. Hope that answers it
As a few have already commented, have a look at 'all' of David Wilkes videos, he is no longer active on YT, but he shared a wealth of knowledge on Trepanning over a few years, not just the machining, but making / modifying and repairing the tooling with all the details. In this video he is processing Inconel 718... In the video you'll see he had issues with feeds and speeds as well as clearing swarf, so it's nothing new, even for an expert like David :) th-cam.com/video/6ErOF4V2wug/w-d-xo.html
sweeping a bore like that with a noga could easily throw your readings off probably .004 to .006 thousandths out with that set up from bar sag alone. just saying
Surprisingly it works pretty well most of the time. I’m not sure how you’d mount a 186mm core drill in a turret? If you’ve seen it done (or done it) im definitely open to trying better ways 💯 We are investing in a 20t megabore lathe very soon, so it’ll be mounted in a massive boring bar holder on the cross slide.
I like to look at your work. Especially since we don't have such things here. But it hurts me when I see you using the ruler to clean chips or as a crowbar. But what am I getting upset about? It's your ruler, your workshop, your . . . . So I'll keep my mouth shut ;-) I wish you accident-free work at all times.
@@halheavyduty Since you are almost exactly on the other side of the globe, maybe you have different customs and traditions in the workshop ;-) Greetings from Austria (no kangas) to Australia.
Just stupid clickbait and not even showing the unsticking Process of the other Drill or break it the Insert. Just jo Feeling for what should be captured, just sad to do this if you have so much basic potential
He mate, thanks for the feedback. It was pretty much our first video, and the reason we started filming was genuinely because it got stuck. Although I totally see your point. Terrible sound Crappy footage No footage of it being unstuck Looking back I really wish I knew then what I know now. Would have been a much better video. Hindsight is 20/20 as they say. Again, thanks for commenting. I wish we had got more footage of the whole ordeal. Perhaps in a future video… although fingers crossed it doesn’t get stuck again now that we’ve sorted tool height and better operating processes.
@@halheavyduty okay sorry dint see that it was your first video, watched some others of them and they were genuinely better, so I assume they were later vids. With some YT recommendations flowing in you can't sometimes get if it's an old or one of the newer vids, normally they are relatively new but there are exceptions to this rule.
All good brother! I genuinely appreciate the feedback. We’ve gotta run the core drill in a few weeks again, so my goal is to get a really high quality vid of it. It’s such a good tool and fascinating to watch. I find it mesmerising. Fark I just hope I don’t have to title it “we got it stuck… again” 🤣
I'm a retired machinist with over half a century of experience. We built lots of things, including drilling equipment like your shop. We started out with a similar set up to what you have built. We soon learned that it was inadequate for us (way too much flex) and eventually dedicated a machine to drilling only. We removed the compound and built a piece that spanned the cross slide and bolted directly to the carriage, then line bored the mounting hole in the machine. Built a 200 gallon coolant tank with a big fan cooled heat exchanger outdoors(coolant would start steaming before coffee break) installed a 10 hp Grundfoss multi stage coolant pump and made a dumping chip pan that travelled with the tool that could be easily emptied by the operator. We also made a sort of light duty steady rest device with interchangeable bushings to suit the size being drilled. The bushings had about 1/8" clearance to the drill and were moved up close to the part. These were so the coolant could be started before the cut, (without the operator drowning)we found that when we started coolant after the cut we had a lot of insert failures from thermal cracking. Keep in mind that this is a pretty rudimentary description of the set up. Good luck, fun watching .
Great description!
Man I really appreciate that comment. We are basically headed in the direction you detailed there.
Our next step is to get a much bigger megabore lathe with both a turret (for external tooling) and a live tail stock & cross-slide mounted boring bar / drill tool holder.
We are def pushing things to the max with the tools we have… so it’s a logical next step.
The work lined up over the next 6 months is much larger than anything we’ve ever attempted.
Look forward to your feedback and suggestions on future videos. Sounds like you’ve got a wealth of experience.
@@halheavyduty I'm glad to help! Be cautious of what machine that you purchase, some machines don't have enough torque at the lower speed ranges needed for drilling big holes. We found that the drilling process was specialised enough that it didn't make sense to hold up other machining work when we had lots of drilling work. We eventually went to ejector drilling, expensive to start and a serious learning curve, but OMG, will it make beautiful holes in a hurry!!! We eventually built our own machine, as we couldn't find a production unit that fit our needs. We drilled lots of different materials, 4140, 4340, H13, and a bunch of aircraft grades (landing gear) nearly all preheat treated from 30 to 45 RC. BTW, harder materials produce much better chip control. We drilled from about 1.25 inch diameter up to 4.5 inch, and from a foot deep up to just over 6 ft deep from solid, and made our own boring heads to open up to 6 inch dia. Actually, we made lots of our own special tools as well. Do some scouting in your area, we eventually had 2 drilling machines and a big hone. Once people found out about our capabilities, we couldn't keep up with demand, even running 24/7 sometimes. Once we got the process figured out drilling was very lucrative, we even did work for metal sales companies that would provide drilling services to their customers. BTW, I'm a frost bitten Canadian boy, always been my dream to visit your part of the planet!
Thank you for sharing that. I have a feeling I’m up for a wild learning curve as this all develops.
Having experienced people like yourself comment and share will be really valuable - so thanks for taking the time.
My Canadian Grandad Hal loved it here… except for the extreme heat in Jan / Feb.
He stated going back home to Canada for a month year… from 40+ to minus in a day.
We all thought he had lost it 🤣
@@halheavyduty Hey currently looking for your email to send you a message, but I figured it was worth a comment. Larry sounds like a wealth of knowledge and I would love for us to be able to create a community to share our information/experiences. Not only would it be helpful, but who doesn't like to show off a big hole they drilled 🤣 I am in the USA and have a small machine shop where I run a some old Nakamura CNC lathes. Lately I have been getting into bigger diameter parts, say 5-8" (125-200mm) with thin walls. Mostly 304SS and tube/pipe is not available. Solid Bar is wildly expensive so being able to core drill would give me a huge advantage, I know I could make 2 if not 3 separate parts out of one piece of bar stock. I have used brazed carbide tip annular cutters up to 3" with good success in 303SS/leaded mild steel, but they don't last in 304. They also have too many teeth, 9 teeth on a 3" (75mm) cutter, I'm getting servo overload alarms trying to push the cutter. I want to start making my own core drills because I know it will solve all of these issues. I have started the process by upgrading the coolant system, added 15 gallons of capacity with a reservoir and mounted a grundfos coolant pump. From 180W to 750W. Hoping 50PSI will be enough to flush chips well. My only comment on this video was you need something with more pressure. You can see the steam coming off the cutter cartridge as soon as it begins cutting, I think more pressure, and in turn flow, would keep things cool.
Really the same pleasure for me to look at your vidéos !! I am an old Electronic technicien (68 years old) but all my life I love machines, tools and nice jobs Thanks a lot to show me your workshop and incredibles homemade tools ! I never thougth that we can made tools like that.... congratulations to all the team
Most welcome, and thank you for tuning in. Its much appreciated 👊🙏
Check out Dave Wilks UK channel. His a bloke who has this down to a fine art, he makes his own trepanning tools. Turns them up in his lathe then finishes the off in his bridgeport mill. Trepanning performed in Titanium, 4140, monel, 316 and other tough bloody metals. Enjoy.
I wanted to mention David's name, you nailed it, the stuff he did. I don't think he has a channel anymore. Lost art👍👌🇦🇺
Awesome. Thanks for the recommendation. Will definitely check it out.
Hi I found you Dave Wilks channel, he stopped doing stuff here in UK. Hope you pick up a cheap pri bar rules for stirring your tea up with.😂
th-cam.com/video/VpUri-NGFyk/w-d-xo.htmlsi=qtgAaEQFmZm933uH
Steve
He is awesome , for sure .
Glad to see his fame spread around ..
@@adhawk5632I think I heard somewhere that he got a job in China at a shop there
Worlds most useful ruler.
100%
did you know you can also measure things with it? 🤣
I mean we all poke, stir, pry ur cut tape with our 6inch rulers right? If everything gets bigger, no wonder the rulers become proper prybars too :)
Nice.
Here's a thought. Use a steady rest at the front of the tool to stop the wobble as the bore is started. Make a 2 or 3 inch sleeve to fit around the boring bar that will ride in the steady rest and make the initial cut smooth and not an interrupted cut.
That’s a great idea. Thanks Mark.
What we ended up doing was just cutting a 10mm deep face groove as a locator and it works pretty well.
Where are you based mate?
Hi mate just come across your videos its great to see another Aussie job shop. I hope you can find your niche on here so you can keep making videos. As a manual machinist it was impressive watching the big lathe core out the centre of a piece of 4140! Nice Work👍 looking forward to see what else you do
Thanks for the feedback brother! Appreciate the comment. Where are you based?
South Aust I have a small metal fab and machine shop, job shop
Good stuff. I bet you get a good variety of interesting work. Job shop work is good like that
Greetings from across the world! Just found the channel. Great video! You’re a natural narrator and I love shop made tools. Looking forward to more content!
Cheers my friend. Thanks for the encouragement and feedback. Much appreciated.
I actually just built a core drill at our shop. Even living in the USA material ain’t cheap. And we have a party that has a 16in OD and a massive 13ish inch threaded ID. And we have another part made from the same material just a 10in OD and threaded 7ish in ID. It’s only made out of 1214 cold roll but it’s basically free parts for us to run the large parts first with the core drill.
Originally I made the drill to use what looks to be the same insert your using. But I then found a Komet insert that also fit the pocket and that insert has chip breakers. Those chip breakers were amazing!!!! It made the surface finishes look beautiful, and the chips that came out looked like roughing endmill chips. The spindle load also dropped by about 30%
That’s awesome, and good to know the Komet inserts. I’m going to check that out. Always looking for better chip breakers! Thank you 🙏
Hi from across the Tasman. Great tool and it looks like it works well. I am now retired but served my time as a fitter and turner and after a few years ended up working for Seco Tools here for the last 28 odd years. My experience with insert drills and Seco made a quality tool that operated well but you needed good coolant pressure to help get the chip out and I thinks you need to look at redirecting the coolant port so it assists with this. Otherwise it works well. Drilling with insert drills is certainly "heart in the mouth" operations as when it goes wrong it all over very quickly. Cheers and great videos. Ian
Sounds like you’ve got some incredible tooling experience there Ian.
Thanks for tuning in. Looking forward to seeing your comments and suggestions in future videos
I didn’t know there was a Seco facility in Tassie?
Plus 1 for Dave Wilks. On using the indicator stuck out like that, be careful top to bottom cos sag can be huge. For example, mag the base to some thick stock with the arm stretched out, zero, then turn it upside down. Its eye opening.
Cheers D
Legend. Thanks for that mate!
Great video, thanks.
I’m sure you have looked at David Wilkes videos by now.
He certainly was/is (hopeing) an ‘expert’ on trepaning.
Using tools he made himself, and showing how he made them!
He would deep trepan shafts of exotic metals metres long!,
Up to like 5m long…!
He did use a steady to hold the (effin) long tool up to the face of the work, sandvic tooling and an absolute flood of coolant!
Must watch.
I’ve wanted to make even a ‘short’ trepaning tool for a long time but haven’t had the need really..
Keep it up, entertaining videos, thanks.
David is the absolute guru when it comes to trepanning. His videos are amazing.
I haven’t had time to watch them all yet, but I’m super impressed with what I’ve seen so far.
I just love how many different skill sets can develop in the machining world.
I love your detailed and soothing tour of this impressive tool! Subscribed.
Thank you!
Good vid definitely need more coolant you should look at using minimum 1” lines to get maximum flow
Cheers man!
Hey you there Down Under! Wish ye all the best, good luck,fingers crossed and so on! We say here: „Only those who do nothing, do nothing wrong“… Believe me, i‘ve made A LOT mistakes in my long live as a machinst. (I‘m 100% complete,nothing broke😂😂😂).I wish you realy all the best for your hard and stony path! You can do it, i‘m sure of it.👍👍👍
Cheers brother. Appreciate the wise words 💯
Interesting Video. Great set up.Good introduction.
I could not hear most of what you were saying when the lathe was running. You may need to check your sound levels.
Also you may need to think of some more splash guards especially if you up the coolant flow.
Thanks for sharing.
Definitely need to work on the sound. New microphones just turned up, so fingers crossed.
Ruler, scraper, and pry bar all in one.
Most useful tool in the shop 💯
Don't forget screwdriver
Not sure why I like Australian machinists, but ya. Subscribed. More worky, less talky.
Cheers mate.
I suggest few improvements in your trepanning tool. !. Have coolant channel cut inside the bore of the tool, and supply coolant from inside. Increase flow and pressure, so chips will be flushed out better, and you may be able to increase the feed., but reduce it at the end to prevent punch out, to prevent chances of insert breakage.
Great tips mate. Appreciate it!
Great work as alway.
I've wanted to build one of these for years, just don't have a lathe with the nuts to run it. Maybe once we build the new shop and have room
👊💯
Definitely an avenue worth pursuing at my job. We do a lot of large jobs often in not the cheapest materials. We have lathes comfortably big and powerful enough. Saving and reusing materials is very sensible and the way the world is going it will become more and more urgent. Although energy is also going through the roof so not looking very good in general.
I hear you brother. It’s saved us both time and material and has definitely been worth the investment to set it up.
Great bit of girth on that. 😉 excellent stuff there. Love an efficient process that just works. I’m sure there’s a high pucker factor to that though.
Dude 100% 💩 🤣
Very cool😎 thanks for the vid.
The tool was rocking up n down in the 6:00 minute. You can see the evidence when you look down the barrel.
So no magnets or mesh in the reclaim tank.? Thats a bold choice.
INSANE waste of 4140 😲. I work a forge, make blades, small town rural Vic.
She definitely rocked up and down a few times in parts of that video.
We actually had to re adjust the tool height and re dial it back in properly!
99% of the swarf gets recycled - it never actually makes it to the coolant tank as it’s at the back of the lathe.
Thanks for tuning in 👊👍
I bet you do some cool stuff on the forge man. Heavy duty stuff for sure
Nice one guys - so basically cutting the full width of the tip x two tips? Thanks for posting Cheers BTW, love the lathe, I'd be happy with a 105mm spindle bore!
Yep - one cuts the inner, the other cuts the outer. It’s a pretty solid cut when she gets motoring!
@halheavyduty they're not sanvik Cartridges are they?
@@brendanshorter5550they might be. Either that or Kennametal. I asked the guy who actually originally built it and he can’t remember either.
@@halheavyduty Both Kennametal and Sandvik make these along with other Tooling manufacturers.
They're usually refer to as Boring Cartridges.
I ran these years ago in my shop when I was manufacturing Manifolds made from Inconel for use in the Chemical Industry.
I found Sandvik made a better grade of Carbide Insert back then for cutting Inconel.
Pretty much everyone copies Sandvik so everyone has much of the same thing now.
Eventually the company I was manufacturing for, started copying my design and had the Manifolds made in Taiwan where NO patent or copyright law had a chance of surviving ???
Happens all too often these days hey.
I’ve heard from a lot of people that Sandvik are the leader when it comes to carbide. Expensive, but the best.
We tend to run a bit of a mix in the shop. Kennnametal, Iscar, Palbit and some Seco.
How do you know that the id of the core drill is concentric with the tips of the inserts? Same for id to od and od to insert tips? Also, there should be an odd number of inserts or cutting edges. The odd number of inserts cuts down the development or inducing harmonics, i.e., chatter.
Forgot to add that the only way to check roundness for od's is either a 3-point mic or a v-block and indicator. A 2-point measurement only proves diameter. Same for id's. Journeyman Tool and Die Maker. Also, have taught Geometric Dimensioning and Tolerancing.
The inserts are slightly offset. One cuts the OD, the other cuts the ID.
When it’s perfectly level (which fortunately it now is) it cuts very smoothly.
Just took a bit to get it working right in the new lathe. It was originally designed for our old “big lathe” which we replaced with the hulk - the big green megabore.
As long as the two inserts contact at the same time and it’s aligned correctly, it tends not to chatter too much.
This is true. We are constantly upgrading our measuring equipment as time goes on…
Really appreciate the comments brother. Clearly you know your stuff 💯
Don’t let the apprentice see you using the ruler like that😂😂😂
That's great. I've seen other guys coring out a solid piece like that and turning it all into chips. At least you can use that inner piece to make something else.
We do try and use trepanning as much as possible. Can’t always do it, but it’s great when we can!
Hey Mr. Maschinist! My opinion: this / your shop floor - made wonderful BIG Core drillbit at 4041 needs a much more stable tool holder. You can‘t increase the feed rate for a better safer chip breaking. And, i think, the „Y - Slide“ ,made of welded steel plates (15-12mm???)under the tool post)is the next reason for problems with chattering/breaking inserts/jamming the tool. THIS lathe and the tool holding is NOT stabile/massive enough to resist at 4041 and higher… sorry for my realy bad english, Sir!
Whish you all the best!!!Cheers !
Interesting feedback, and much appreciated. You might possibly be right.
The core drill was actually used in a much smaller machine previously, and successfully cored out about 120 billets once they figured out the practicality of running it.
The new machine is almost twice the size. Once we got the tool height dead on (we were originally a little out, hence the reason it didn’t perform so well at the start)
It cuts like a dream now. No tip breaking and the chips come off nicely. Just took a few runs to perfect the process again.
Ideally I’d mount it on the cross-slide, bolted down directly in its own HD dedicated tool holder, for the reasons you mentioned.
Thanks again for commenting mate!
Where are you from, and what kind of work do you do? Would love to know.
Cheers brother 👊
Also known as a trepanning tool I think
You’re 100% right. That’s the technical name for it 👍
Great idea the core drill, that way you can use the scrap plug for another job.
💯👊
Awesome thanks for sharing
Most welcome. Thanks for tuning in mate.
Beautiful cutting chips.
💯🙏
my friend use to trepan big gears blanks with 125mm dia trepanner at 625 revs. I used to stand well back to watch.
Holy wow. That’s nuts! I’d be standing back too 💯
@@halheavyduty I used to trepan big stainless blanks for valve seats using a ground down parting tool, blanks 12-16 inch o/d and 2-4 thick!
Usually 303, 316 or 321 stainless and dias up to 10 inch bore.
Listened to the tool note change as it began to break through. Split second too late and the core slipped cockeyed, smashed the tool and gave me a thrill.
I used to lap and assemble some of the bigger valves. Once spent 9 days on one valve testing it, failing it, dismantling, relapping, retesting, failing. I told the tester guy on first day the body had a pinhole and he should pour a quart of water in to reveal it but he refused and said his test machine was super accurate.
Customer had sent inspector to confirm the valves passed as they were for a refinery or very high temp. At end of each day he looked at me like I was s***! I said the tester should do the water test.
Finally on 9th day we all gathered round for another test - me, tester, foreman, other people, the inspector and our 'production manager'. It failed. Tester smirked and said I hadn't lapped it perfectly. I said I had and there was a pinhole. I turned to prod man and told him to tell tester to pour some water in. Prodman didn't want to get involved but we were all looking at him. Finally he grew a pair and told tester to pour some water in - just to show me I was wrong.
Tester poured the water and pinhole showed up. 'SEE! I said.. 'I've wasted 9 days costs on that for sake of a jug of water!
Then people wonder why British industry died!
@@halheavyduty I like Titan videos and how he rives metal off with super speeds and feeds!
Nice one!
Once Aus has a huge amount of grid solar and batteries set up, there'll be no excuse not to vastly expand iron refineries and forges to provide more steel in more options for cheaper prices.
Fingers crossed we get better access to more steel options in the future. Back in the day we had steel mills. All closed now.
As we’d say in Britain… ‘Cor blimey!’
Love it!
Hey Mate! Thanks for your FAST answer! I‘m from Germany , Trained Toolmaker (for Plastic Injektion molds plastic blow molds)turner,miller, conventional and CNC. I make chips since 1980 in 3-shift-system. I‘ve made Parts for lots of molds , later than steel parts in different sizes from round about 200 grams up to 120 tons… Sometime a shovelful of chips in 1shift… sometimes a pile that would fill a 20-foot container … i‘ve worked on machines with 600mm X-travel till 18000mm(18meter). And now i‘m making airplane-parts…
Brother that awesome. Nothing better than filling up a big container with perfect cut c chips ✌️👌
Sounds like you got some really varied experience too, which is great.
Hearing from (and learning from) all the different types of machinists out there was a major reason I started the channel, so I really appreciate the comments.
Great vid, shame about the scale abuse👍
Poor thing didn’t deserve such treatment 🤣
have you tried using a plasma cutter instead of the core drill?
I think our plasma cutter peaks out at 70mm depth of cut. Great tool for thick sheet metal, but the gear we have won’t cut a 300mm billet like the core drill can.
Excellent question. Thanks for commenting mate 👊
@@halheavyduty i was wondering not to blow through, but like a ceramic bit, it should excavate directly at point of plasma contact. i was thinking if you add high pressure air, or much more argon, you should be able to clear the molten metal. i saw another group using superheated steam to excavate rock without contact. but am not in a position to try this currently .
thanks for the content.
Welcome brother, and thanks again for the comment.
very interesting, the sounds of the cutting are just like the Chap who was doing this over in Sheffield England, I am sure you have seen his videos, doing 2 meter or more trepanning......unfortunately, he closed his shop and sold off all the equipment....cheers. Paul
Good to know! Thanks Paul. Appreciate the original suggestion my friend. Was a fun little video to make
He's referring to David Wilks.
He'd run sacrificial guides and the coolant evacuates the chips.
A talented man but I’m sure he’d prefer to do the job in a DSG. Great video thanks for posting!
Cheers Dan. Thanks for tuning in mate.
First time i see a tool like this, but then again my maschine only goes up to 65mm diameter parts so i dont think its appropriate for me 😂 cool stuff tho seeing something selfmade run that well
Welcome to the channel brother.
I love working on smaller pasts on some of the smaller machines we use for hydraulic repairs and random parts.
It’s a lot more hands on and takes a lot of skill to get tolerances right.
What is the cost of a completed unit
We end up saving about 6 hours of machining time, and save a $450 billet of steel.
chuck key spigot poking out like that is super dangerous! never seen that before!
Me either. Spanish lathe thing apparently…
@@halheavyduty I watched a youtube the other days with guys getting clothes caught on rotating pieces in lathes. Very gruesome.
It’s a truly terrifying reality of our profession. You’ve gotta have insane respect for the machines… or you’ll have a very short career.
Those vids are horrendous. A cautionary tale for every machinist
@@halheavyduty worst near miss I saw was about 15 feet from me when guy put a 18ft length of one inch bar in his lathe to turn and part pieces off - rather than cut the pieces in the saw.
The long end sticking out was Ok at low revs but when he upped the speed the bar bent and flailed round - just as the labourer was walking past.
i still don't know how the labourers head wasn't smashed to bits!
Another time a visitor was examining a new CNC lathe when untrained foreman decided to show him how it worked.
He hadn't zeroed it or checked what it had been programmed to do but he hit the start button and it started at high speed and the turret ran fast into the chuck. Chuck bolts sheared and it sailed across the workshop before hitting one of the main steel girders and stopping.
We get a lot of old UK industry films on tv and I watch the grime, old machines and gloomy workshops and remember the smells and sounds - and sort of wich I'd had a camera to record the normal day's activities1
Would EDM yield a larger slug with value to cover the cost of a third party doing the first process?
For the moment, it seems EDM is prohibitively slow and expensive… and they struggle to cut depths past 185mm - at least in our neck of the woods.
I think the core drill option is bang for bucks the current best way forward… but lord only knows what future tech is going to happen.
We have actually purchased hollow bar billets from an international steel mill for the production job (thank God!)- the cored billets were just for initial prototypes.
Great question. Hope that answers it
I can't believe it got as far as it did, coolant should have been washing them chips out.
It’s a wild setup.
this is wonderful.....thanks for sharing with us....Paul in the US, the other Sunshine State, Florida
Cheers Paul!
Very cool!
Thanks mate ✌️
trepan..?
💯
Watch David Wilks videos. Hes the guru on these trapanning tools. Cheers
Will definitely check it out. Appreciate the recommendation 👊
Now your ruler can measure in exponential scales
Hahaha. True that
Impressive tooling.
Wild to run
1.6 per revolution seems a bit to hard considering the diameter.
It seems to chip off pretty well. I think we ended up running it at about 1.3-1.4 though.
As a few have already commented, have a look at 'all' of David Wilkes videos, he is no longer active on YT, but he shared a wealth of knowledge on Trepanning over a few years, not just the machining, but making / modifying and repairing the tooling with all the details. In this video he is processing Inconel 718... In the video you'll see he had issues with feeds and speeds as well as clearing swarf, so it's nothing new, even for an expert like David :) th-cam.com/video/6ErOF4V2wug/w-d-xo.html
I’m definitely going to do that. Thanks mate
@@halheavyduty Plus you often get to keep all the core drops, that's a good chunk of 41-40 every time you make one of those :)
Yup. About $300-400 every core.
20 Amps at what voltage?
415V three phase
sweeping a bore like that with a noga could easily throw your readings off probably .004 to .006 thousandths out with that set up from bar sag alone. just saying
You’re dead right. Since the video we have a much more rigid setup.
Comments like yours have been really helpful. I really appreciate it.
Its called trepanning
David Wilkes for the win 💯🤣
That it is.
Long live David Wilkes. The OG ✌️
OH noe WHAT are WE going TO do?
😂
That’s a job for turret lathe. Tool holder lacks ridgidity for job like this.
Surprisingly it works pretty well most of the time.
I’m not sure how you’d mount a 186mm core drill in a turret? If you’ve seen it done (or done it) im definitely open to trying better ways 💯
We are investing in a 20t megabore lathe very soon, so it’ll be mounted in a massive boring bar holder on the cross slide.
Fresh sub today, epic mate👍👌🇦🇺#DavidWilks
Cheers mate!
why is bro whispering? cant hearyou
Typical amateur mistake. Had the bloody sound on low with the new microphone and didn’t realise.
Problem fixed for the next one 👍
#trepanning
Thanks mate 👊👍
I like to look at your work. Especially since we don't have such things here. But it hurts me when I see you using the ruler to clean chips or as a crowbar.
But what am I getting upset about? It's your ruler, your workshop, your . . . .
So I'll keep my mouth shut ;-)
I wish you accident-free work at all times.
Hahaha. That poor ruler.
Thanks for the comment mate. Appreciate it, and thanks for tuning in.
@@halheavyduty Since you are almost exactly on the other side of the globe, maybe you have different customs and traditions in the workshop ;-)
Greetings from Austria (no kangas) to Australia.
Austria! Love it. Gday from the bottom half of the world brother 👊🫡
Just stupid clickbait and not even showing the unsticking Process of the other Drill or break it the Insert. Just jo Feeling for what should be captured, just sad to do this if you have so much basic potential
He mate, thanks for the feedback.
It was pretty much our first video, and the reason we started filming was genuinely because it got stuck. Although I totally see your point.
Terrible sound
Crappy footage
No footage of it being unstuck
Looking back I really wish I knew then what I know now. Would have been a much better video.
Hindsight is 20/20 as they say.
Again, thanks for commenting. I wish we had got more footage of the whole ordeal.
Perhaps in a future video… although fingers crossed it doesn’t get stuck again now that we’ve sorted tool height and better operating processes.
@@halheavyduty okay sorry dint see that it was your first video, watched some others of them and they were genuinely better, so I assume they were later vids. With some YT recommendations flowing in you can't sometimes get if it's an old or one of the newer vids, normally they are relatively new but there are exceptions to this rule.
All good brother!
I genuinely appreciate the feedback. We’ve gotta run the core drill in a few weeks again, so my goal is to get a really high quality vid of it.
It’s such a good tool and fascinating to watch. I find it mesmerising.
Fark I just hope I don’t have to title it “we got it stuck… again” 🤣