I made some ultra flat lapping plates from 8in dia 1.5 thk cast iron using the three plate method. I started with a reasonable surface ground finish. I milled a grid of grooves and ground the plates together in the 3 plate order to make them flat. Of course thousands of strokes per plate, many combinations of plates and several grits makes this a huge job. Of course this is way too much work so I didn't do any of this. I made a fixture and programmed a CNC mill to do all the work. My polishing action included linear and rotary motion. I did clean and shuffle the plates and change abrasive. I did about 2-3 hours worth for each grit. So probably 8-10 hrs total. This would have been punishing by hand. I measured the plates with a Heiidenhan LVDT sensor and a laser interferometer. I'm not sure how you are supposed measure plates like this down in the millionths. The laser would measure a millionth and it found only one or two anywhere I looked. At this scale anything will affect the reading so I'm not sure how trustworthy these numbers are. It was a lot flatter than my surface plate when I measured it the same way. Interesting experiment and pretty flat too. I always learn interesting things from your videos, glad you take time to make them. I watch them all. Thanks JY.
Great ideas Adam, absolutely brilliant. From what I understand you teach outside of TH-cam as well, the paper cut outs are fantastic teaching aids. Thanks for sharing and take care!!
@@adamthemachinist If you can spare the time at some point in your life, tutoring at a local school / university might be extremely valuable for the next generation of machinists. I wish I had teachers like you or Robin at school that would've kept me interested in tool room work.
@@ryebis I'm personally of the opinion that you have a much larger reach with your knowledge when you create youtube-videos, rather than teaching at only one local school. The people in class would have access to the taught know-how, but nobody else would (until the knowledge trickles down). The TH-cam-content could be watched by anyone, at any time, all around the world, even by the people in class, interested in this stuff. So the benefit for the community is a lot larger.
@@felixm.8910 That is absolutely true, but vocational schools have a much focused audience that will benefit more with in-person tutors like Adam that have a wealth of industry experience. It's not something they will learn until they get a chance to apprentice at a shop with good mentors. Many like me will drop out or change tracks in school. There's a lot Adam and Robin can't cover in videos because it requires more work and certainly impossible to have a live Q&A on a regular basis. It's a big investment in time for them though, but it gives back to the next generation.
@@ryebis That is really true. I'm from Germany and used to an apprenticeship-system which is made of time spent in school and time spent in your training company over the course of usually 3½ years. I'm not used to the idea that other countrys don't have this type of an approach. Though, to be honest, I learned most of the stuff at the company I was with. Adam mentioned that the tool-and-die manufacturer he worked for uses the german systeme in NYC-CNC's Shop-Tour.
You keep presenting incredibly useful information I didn't know I needed to know. New tips and tricks in every video, and excellently presented. Thanks again Adam!
I would absolutely LOVE to see a video of you polishing the knife scales or something with a complex curve from start to finish including all the products you use. This was a very useful video!
I love your videos. I'm just getting into hobby machining and will never do projects as precise as what you are doing, but your calm/smooth delivery and mastery of your craft is a joy to watch. Thank you for sharing with us!
In the world of telescope making we have used 3d printed figuring disks for some time. For turning a the spherical surface into (usually) a parabolic, but also other aspherical surfaces. Huygens Optics on youtube recently did a video where he uses the technique. Also have to say, your 3d printed differential pitch screw actuator, is brilliant!.. and will be stolen by the DIY optics community..Thnks!
@@adamthemachinist We feel the same about precision machinists. But I`m guessing we have found common ground in the transition from micro to nano-meter. So much to learn from each others fields. The optician gives the machinist a a sharper eye, and the machinist gives the optician a sharper tool that makes a sharper lens, and so on.
I came across the FPT=stepover thing recently whilst looking for info on how to achieve a particular(theoretical) surface finish with a given size ball mill. It makes a massive difference to cycle time compared to the"normal" feed rates. Only problem for me is the mill I run has very poor Dynamic performance so often never reaches the programmed feedrate which tends to leave blemishes from the "dwelling".(Im sure the Mori NVD has no problems at fairly high feedrates) Another thing to consider is that the Maximum stepdown in the contour toolpath(or any "Z" level/waterline path) is equal to the xy stepover only at 45° for a given cusp height. at shallower angles the Stepdown will need to be less
It hadn't occurred to me that there was a polishing step after they come out of the mill looking like a mirror. For a wanna-be hobby machinist the feed vs stepover thing is a little mind blowing.
Great demonstration and really enjoyed the video! One interesting note is that diamond degrades pretty quickly when used on steel (chemical reaction of the carbon). Probably doesn't matter to you but in a production environment I would recommend investigating some other abrasives.
Summary (English, German, Chinese) *Abstract* The video explores the use of 3D printing in mold polishing, specifically for creating custom guides and laps for achieving high-quality surface finishes on complex shapes. The video also discusses the importance of optimizing CAM toolpaths for surface finish by matching step over and feed per tooth. Several examples are shown, including polishing a conical section with three lands, a large radius on a knife handle, and a dome segment on a punch. *Summary* *3D Printed Polishing Guides* * 0:00: Introduction to the use of 3D printed guides for protecting sharp corners during mold polishing. * 0:27: Comparison to traditional methods like machining custom material or using a second insert. * 0:37: Advantages of 3D printing for complex shapes and cost-effectiveness. * 1:11: Consideration of grit contamination in plastic prints and using multiple prints for different grits. *3D Printed Pitch Laps* * 1:24: Introduction to creating convex pitch laps using 3D printed molds for polishing large radii on parts like draw punches and knife scales. * 2:00: Two-piece 3D printed mold with low durometer material for forming flutes and a handle for pouring and holding the pitch. * 2:18: Demonstration of pouring molten pitch and removing the mold after solidification. *Surface Finish and Toolpaths* * 2:26: Importance of surface finish in mold polishing and the limitations of 2D representations of toolpaths. * 2:51: Explanation of cusp height and its impact on surface finish in both X and Y directions. * 3:30: Visualization of scallops created by ball end mills and the relationship between step over and feed per tooth. * 3:48: The concept of matching step over and feed per tooth for optimal surface finish and cycle time. * 4:14: Consequences of mismatched step over and feed per tooth, leading to visible lines and inefficient machining. *Machining Examples* * 5:50: Machining a large radius part with a 6mm ball mill for roughing and semi-finishing. * 6:01: Finishing with a 3mm ball mill at specific feed rate and step over for desired surface finish. * 6:22: Machining a conical segment with varying step over and feed per tooth to demonstrate their effect on surface finish and polishing time. *Polishing and Results* * 8:47: Machining a knife handle with a 6mm ball nose and using 3D printed guides for polishing. * 9:50: Demonstration of the 3D printed pitch lap with a low durometer mold and pouring molten pitch. * 10:57: Rough lapping to remove remaining feed lines and discussing challenges with smoothing settings in Fusion 360 for large radii. * 11:46: Alternative concept for a 3D printed pitch lap with pre-formed grooves. * 12:50: Using diamond slurry and exploring the potential of diamond compound for polishing. * 13:30: Final thoughts on the potential applications of this technique in tool making and other industries. *Zusammenfassung* Das Video untersucht die Verwendung des 3D-Drucks beim Polieren von Formen, insbesondere zur Herstellung von kundenspezifischen Führungen und Läppchen, um hochwertige Oberflächenveredelungen auf komplexen Formen zu erzielen. Das Video erörtert auch die Bedeutung der Optimierung von CAM-Werkzeugwegen für die Oberflächenveredelung durch Anpassung von Schrittweite und Vorschub pro Zahn. Es werden mehrere Beispiele gezeigt, darunter das Polieren eines konischen Abschnitts mit drei Stegen, eines großen Radius an einem Messergriff und eines Kuppelsegments an einem Stempel. *Zusammenfassung* *3D-gedruckte Polierführungen* * 0:00: Einführung in die Verwendung von 3D-gedruckten Führungen zum Schutz scharfer Ecken beim Polieren von Formen. * 0:27: Vergleich mit traditionellen Methoden wie der Bearbeitung von kundenspezifischem Material oder der Verwendung eines zweiten Einsatzes. * 0:37: Vorteile des 3D-Drucks für komplexe Formen und Kosteneffizienz. * 1:11: Berücksichtigung der Kornkontamination in Kunststoffdrucken und Verwendung mehrerer Drucke für verschiedene Körnungen. *3D-gedruckte Pitch-Läppchen* * 1:24: Einführung in die Herstellung von konvexen Pitch-Läppchen unter Verwendung von 3D-gedruckten Formen zum Polieren großer Radien an Teilen wie Ziehstempeln und Messerskalen. * 2:00: Zweiteilige 3D-gedruckte Form mit niedrigem Durometer-Material zur Bildung von Rillen und einem Griff zum Gießen und Halten der Tonhöhe. * 2:18: Demonstration des Gießens von geschmolzenem Pech und des Entfernens der Form nach dem Erstarren. *Oberflächenbeschaffenheit und Werkzeugwege* * 2:26: Bedeutung der Oberflächenbeschaffenheit beim Polieren von Formen und die Grenzen von 2D-Darstellungen von Werkzeugwegen. * 2:51: Erklärung der Spitzenhöhe und ihrer Auswirkungen auf die Oberflächenbeschaffenheit in X- und Y-Richtung. * 3:30: Visualisierung der von Kugelfräsern erzeugten Jakobsmuscheln und die Beziehung zwischen Schrittweite und Vorschub pro Zahn. * 3:48: Das Konzept der Anpassung von Schrittweite und Vorschub pro Zahn für optimale Oberflächenbeschaffenheit und Zykluszeit. * 4:14: Folgen von nicht übereinstimmender Schrittweite und Vorschub pro Zahn, was zu sichtbaren Linien und ineffizienter Bearbeitung führt. *Bearbeitungsbeispiele* * 5:50: Bearbeitung eines Großradiusteils mit einem 6-mm-Kugelfräser zum Schruppen und Vorschlichten. * 6:01: Schlichten mit einem 3-mm-Kugelfräser mit spezifischer Vorschubgeschwindigkeit und Schrittweite für die gewünschte Oberflächenbeschaffenheit. * 6:22: Bearbeitung eines konischen Segments mit variierender Schrittweite und Vorschub pro Zahn, um deren Auswirkungen auf die Oberflächenbeschaffenheit und die Polierzeit zu demonstrieren. *Polieren und Ergebnisse* * 8:47: Bearbeitung eines Messergriffs mit einer 6-mm-Kugelnase und Verwendung von 3D-gedruckten Führungen zum Polieren. * 9:50: Demonstration des 3D-gedruckten Pitch-Läppchens mit einer Form mit niedrigem Durometer und Gießen von geschmolzenem Pech. * 10:57: Grobes Läppen zum Entfernen verbleibender Vorschublinien und Diskussion von Herausforderungen mit Glättungseinstellungen in Fusion 360 für große Radien. * 11:46: Alternatives Konzept für ein 3D-gedrucktes Pitch-Läppchen mit vorgeformten Rillen. * 12:50: Verwendung von Diamantschlamm und Untersuchung des Potenzials von Diamantpaste zum Polieren. * 13:30: Abschließende Gedanken zu den möglichen Anwendungen dieser Technik im Werkzeugbau und in anderen Industrien. User: translate abstract and summary to chinese Model: *摘要* 该视频探讨了 3D 打印在模具抛光中的应用，特别是用于创建定制导向器和研磨盘，以在复杂形状上实现高质量的表面光洁度。视频还讨论了通过匹配步距和每齿进给量来优化 CAM 刀具路径以获得表面光洁度的重要性。展示了几个示例，包括抛光具有三个凸台的锥形截面、刀柄上的大圆角以及冲头上的圆顶段。 *总结* *3D 打印抛光导向器* * 0:00: 介绍使用 3D 打印导向器在模具抛光过程中保护锋利角落。 * 0:27: 与传统方法（如加工定制材料或使用第二个嵌件）进行比较。 * 0:37: 3D 打印对于复杂形状和成本效益的优势。 * 1:11: 考虑塑料打印件中的砂砾污染，并对不同的砂砾使用多个打印件。 *3D 打印沥青研磨盘* * 1:24: 介绍使用 3D 打印模具创建凸面沥青研磨盘，用于抛光拉伸冲头和刀柄等零件上的大圆角。 * 2:00: 采用低硬度材料制成的两件式 3D 打印模具，用于形成凹槽和用于浇注和固定沥青的手柄。 * 2:18: 演示浇注熔融沥青并在凝固后去除模具。 *表面光洁度和刀具路径* * 2:26: 表面光洁度在模具抛光中的重要性以及刀具路径二维表示的局限性。 * 2:51: 解释尖点高度及其对 X 和 Y 方向表面光洁度的影响。 * 3:30: 可视化球头立铣刀创建的扇贝形状以及步距和每齿进给量之间的关系。 * 3:48: 匹配步距和每齿进给量以获得最佳表面光洁度和循环时间的概念。 * 4:14: 步距和每齿进给量不匹配的后果，导致可见的线条和低效的加工。 *加工示例* * 5:50: 使用 6 毫米球头立铣刀加工大圆角零件，进行粗加工和半精加工。 * 6:01: 使用 3 毫米球头立铣刀以特定的进给速度和步距进行精加工，以获得所需的表面光洁度。 * 6:22: 加工具有不同步距和每齿进给量的锥形段，以演示它们对表面光洁度和抛光时间的影响。 *抛光和结果* * 8:47: 使用 6 毫米球头刀加工刀柄，并使用 3D 打印导向器进行抛光。 * 9:50: 演示采用低硬度模具的 3D 打印沥青研磨盘和浇注熔融沥青。 * 10:57: 进行粗研磨以去除剩余的进给线，并讨论 Fusion 360 中的平滑设置对于大圆角的挑战。 * 11:46: 具有预成型凹槽的 3D 打印沥青研磨盘的替代概念。 * 12:50: 使用金刚石浆料并探索金刚石研磨膏用于抛光的潜力。 * 13:30: 关于这项技术在工具制造和其他行业中潜在应用的最后思考。 summary made with gemini 1.5 pro Token count 6,459 / 1,048,576
Excellent video and a ton of helpful information. I definitely wanna try a different combination of stepover and feed. I need to see for myself :D Thank you for sharing your knowledge!
polishing the circular example really makes me want to build a thing I have no use for, a machine for this. Two spindles pointed antiparallel where one has a work holding system, the other has a big boring head mechanism to hold the lap and some kind of concentric shaft with a harmonic drive or third motor. One of the two main shafts can shift side to side, also like a boring head (it's boring heads all the way down). With encoders and computer control you could make it sweep into corners and scrub arc sections, but just spinning all the parts at different speeds would cover a circle, and driving the axial offset would create helical coverage area.
Great video, thanks mate. Re the headphones users, might be worth watching with some on and the volume up to catch those spikes, or visually scanning the wave form during edit? I didn't even notice it, but on rewatch it was obvious.
I learned something new today, did not know you use pitch for polishing. I guess it is to have a little give on the surface where the polishing particles can grab onto? Is using pitch the standard way to go? Whats the alternatives?
Excellent ideas and great explanations on that subject, Adam, thanks for that. Have you ever seen the Mauser Präzoplan 300 CNC machine in action? Check it out here on youtube...what do you think of that machine?. I think the sled with the vises rides on air. Very impressive apparatus.
Thank you! I l have used these techniques as a precision optician but haven't seen them applied to tooling. How do you go about selecting polishing slurries and compounds? I'm mostly familiar with alumina and ceria used for glass. I may also be able to help with forming laps for domed tools if you can show or sketch an example.
I generally have a small selection of Diamond slurry for lapping on cast iron and copper laps and then Diamond paste is what I have a larger range of kept around for polishing with felt bobs on my micro motor . The slurry is thinner and less likely to distort geometry but the paste has more Diamond per volume and can cut faster at times .
@@adamthemachinist if spherical is what you're after, pitch polishing will often actually improve geometry rather than distort it. A skilled optician can achieve total sphericity/flatness of about a micro inch with pitch. A fraction of a tenth is almost free.
Have you tried printing with TPU? it's kind of a pain but it is really low durometer and you can adjust the overall stiffness of the part with infill settings.
Robin, I’m pretty new to the pitch as well , I got 64 on the recommendation of extra minty Matt on Instagram . That seemed to work well on the large part but I notice some wear when going over the corner on the knife handle example . I also have some 55 and 91 I want to play with
Great video. Very interesting what was that pitch stuff? Gugol? Your surface finish appeared excellent so.. nice work thanks for the content have a great day.and keep up the good work
I never did any polishing but I'm a bit confused about the 3d printed jig to prevent round corners. Unless the 3d printed part is flush with the soon to be polished part, then either it's higher and you polish the 3d printed part and not the part or it's lower and you are actually rounding the part. I think I missed something in the process.. That said, very interesting video, thanks for the knowledge!
The error isn’t a big concern , usually a tiny bit lower and I shim it up . Talking about gross corner rounding to the extent that could allow plastic to flash , in excess of 25 microns .
Well endmills can be a little trickery to have follow 3D surfaces and get a even looking result . With a bullnose endmill you can do well with z level finishes but low angle curved faces can be difficult to get a even looking face . Check out sturz milling for more in 3D profiles with bullnose endmills
The point about step over and feed per tooth is very interesting and something I hadn’t realised, but it’s very important for me when I’m machining mould tools and need to get surface finish as high as possible, do you find this works well on soft tool steel too, I usually work on p20 pre hard, thanks again
It’s what telescope makers use to form and polish their lenses, similar to asphalt on consistency. Soft enough to take the shape of the part being polished yet hard enough to rub off the high spots of the part
Hi Adam, if I wanted to polish a copper square (40mm by 40mm by 2.5mm) and wanted it to be very flat while getting a true mirror finish, would you try the 3D printed support and then polishing stone, or would the tar be a better option? I am new to polishing so a bit confused, but I am intrigued by the 3D printed support idea!
@@adamthemachinist what I wonder after doing some digging is why you couldn't use a mix of abrasive grit and thermoplastic instead. I'll check if the Gugolz pitch is available locally. Do you have CAD for the prints you used?
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I don’t have a CNC or any machining equipment at all, but I love your work and I love your teaching style. Thanks for sharing your ideas.
I made some ultra flat lapping plates from 8in dia 1.5 thk cast iron using the three plate method. I started with a reasonable surface ground finish. I milled a grid of grooves and ground the plates together in the 3 plate order to make them flat. Of course thousands of strokes per plate, many combinations of plates and several grits makes this a huge job. Of course this is way too much work so I didn't do any of this. I made a fixture and programmed a CNC mill to do all the work. My polishing action included linear and rotary motion. I did clean and shuffle the plates and change abrasive.
I did about 2-3 hours worth for each grit. So probably 8-10 hrs total. This would have been punishing by hand. I measured the plates with a Heiidenhan LVDT sensor and a laser interferometer. I'm not sure how you are supposed measure plates like this down in the millionths. The laser would measure a millionth and it found only one or two anywhere I looked. At this scale anything will affect the reading so I'm not sure how trustworthy these numbers are. It was a lot flatter than my surface plate when I measured it the same way. Interesting experiment and pretty flat too.
I always learn interesting things from your videos, glad you take time to make them. I watch them all. Thanks JY.
I will second that, very glad you take the time to show and teach. Thank you!
Any videos on that process?
Great ideas Adam, absolutely brilliant. From what I understand you teach outside of TH-cam as well, the paper cut outs are fantastic teaching aids. Thanks for sharing and take care!!
No, I work by myself mostly and could feel myself getting worse at explaining things so I do these videos to stay on top of it
@@adamthemachinist If you can spare the time at some point in your life, tutoring at a local school / university might be extremely valuable for the next generation of machinists. I wish I had teachers like you or Robin at school that would've kept me interested in tool room work.
@@ryebis I'm personally of the opinion that you have a much larger reach with your knowledge when you create youtube-videos, rather than teaching at only one local school.
The people in class would have access to the taught know-how, but nobody else would (until the knowledge trickles down).
The TH-cam-content could be watched by anyone, at any time, all around the world, even by the people in class, interested in this stuff.
So the benefit for the community is a lot larger.
@@felixm.8910 That is absolutely true, but vocational schools have a much focused audience that will benefit more with in-person tutors like Adam that have a wealth of industry experience. It's not something they will learn until they get a chance to apprentice at a shop with good mentors. Many like me will drop out or change tracks in school.
There's a lot Adam and Robin can't cover in videos because it requires more work and certainly impossible to have a live Q&A on a regular basis. It's a big investment in time for them though, but it gives back to the next generation.
@@ryebis That is really true.
I'm from Germany and used to an apprenticeship-system which is made of time spent in school and time spent in your training company over the course of usually 3½ years.
I'm not used to the idea that other countrys don't have this type of an approach.
Though, to be honest, I learned most of the stuff at the company I was with.
Adam mentioned that the tool-and-die manufacturer he worked for uses the german systeme in NYC-CNC's Shop-Tour.
If I could set up a masterclass it would probably have you, Mr Lipton and Robrenz teaching it.
awe ... I'd hoped to see the end results (polishing results) before it ended.
Next time please Adam. Thank you again for another informative video.
I never considered the feed per tooth and step over ratio, great bit of information. Thanks.
You keep presenting incredibly useful information I didn't know I needed to know. New tips and tricks in every video, and excellently presented. Thanks again Adam!
I would absolutely LOVE to see a video of you polishing the knife scales or something with a complex curve from start to finish including all the products you use. This was a very useful video!
Brilliant ideas, I’d never heard of speed & feeds trick or the resin pitch compound. Thank you dearly for the info !
Adam, you have of the greatest tips and tricks. This is super clever! Well done. Can’t wait to see your next video!
I love your videos. I'm just getting into hobby machining and will never do projects as precise as what you are doing, but your calm/smooth delivery and mastery of your craft is a joy to watch. Thank you for sharing with us!
In the world of telescope making we have used 3d printed figuring disks for some time. For turning a the spherical surface into (usually) a parabolic, but also other aspherical surfaces. Huygens Optics on youtube recently did a video where he uses the technique. Also have to say, your 3d printed differential pitch screw actuator, is brilliant!.. and will be stolen by the DIY optics community..Thnks!
I’ll have to check them out, opticians fascinate me with their abilities
@@adamthemachinist We feel the same about precision machinists. But I`m guessing we have found common ground in the transition from micro to nano-meter. So much to learn from each others fields. The optician gives the machinist a a sharper eye, and the machinist gives the optician a sharper tool that makes a sharper lens, and so on.
Clever approaches to machine finishing and lapping!
It all makes sense. You explained everything very clearly!
Thank you! 🙂
Witnessing the birth of a successful channel.
Love the insight into this arcane wizardly art. I'd never heard of pitch lapping, and now I'm down a new rabbit hole.
Check out amateur telescope making if you're interested in pitch laps!
Incredible process thanks for sharing!
Thank you for putting up this video. I love seeing the use of new materials and techniques that are easily accessible by the home shop.
Clever! We shared this video on our homemade tools forum this week 😎
I came across the FPT=stepover thing recently whilst looking for info on how to achieve a particular(theoretical) surface finish with a given size ball mill.
It makes a massive difference to cycle time compared to the"normal" feed rates. Only problem for me is the mill I run has very poor Dynamic performance so often never reaches the programmed feedrate which tends to leave blemishes from the "dwelling".(Im sure the Mori NVD has no problems at fairly high feedrates)
Another thing to consider is that the Maximum stepdown in the contour toolpath(or any "Z" level/waterline path) is equal to the xy stepover only at 45° for a given cusp height.
at shallower angles the Stepdown will need to be less
It hadn't occurred to me that there was a polishing step after they come out of the mill looking like a mirror. For a wanna-be hobby machinist the feed vs stepover thing is a little mind blowing.
Polishing gives you time to think about things, especially how you can make adapters for your CNC mill to do the polishing for you. 😁
Great demonstration and really enjoyed the video! One interesting note is that diamond degrades pretty quickly when used on steel (chemical reaction of the carbon). Probably doesn't matter to you but in a production environment I would recommend investigating some other abrasives.
Its the pitch...
Hey Adam, please do more videos. Your channel will explode.
Summary (English, German, Chinese)
*Abstract*
The video explores the use of 3D printing in mold polishing, specifically for creating custom guides and laps for achieving high-quality surface finishes on complex shapes. The video also discusses the importance of optimizing CAM toolpaths for surface finish by matching step over and feed per tooth. Several examples are shown, including polishing a conical section with three lands, a large radius on a knife handle, and a dome segment on a punch.
*Summary*
*3D Printed Polishing Guides*
* 0:00: Introduction to the use of 3D printed guides for protecting sharp corners during mold polishing.
* 0:27: Comparison to traditional methods like machining custom material or using a second insert.
* 0:37: Advantages of 3D printing for complex shapes and cost-effectiveness.
* 1:11: Consideration of grit contamination in plastic prints and using multiple prints for different grits.
*3D Printed Pitch Laps*
* 1:24: Introduction to creating convex pitch laps using 3D printed molds for polishing large radii on parts like draw punches and knife scales.
* 2:00: Two-piece 3D printed mold with low durometer material for forming flutes and a handle for pouring and holding the pitch.
* 2:18: Demonstration of pouring molten pitch and removing the mold after solidification.
*Surface Finish and Toolpaths*
* 2:26: Importance of surface finish in mold polishing and the limitations of 2D representations of toolpaths.
* 2:51: Explanation of cusp height and its impact on surface finish in both X and Y directions.
* 3:30: Visualization of scallops created by ball end mills and the relationship between step over and feed per tooth.
* 3:48: The concept of matching step over and feed per tooth for optimal surface finish and cycle time.
* 4:14: Consequences of mismatched step over and feed per tooth, leading to visible lines and inefficient machining.
*Machining Examples*
* 5:50: Machining a large radius part with a 6mm ball mill for roughing and semi-finishing.
* 6:01: Finishing with a 3mm ball mill at specific feed rate and step over for desired surface finish.
* 6:22: Machining a conical segment with varying step over and feed per tooth to demonstrate their effect on surface finish and polishing time.
*Polishing and Results*
* 8:47: Machining a knife handle with a 6mm ball nose and using 3D printed guides for polishing.
* 9:50: Demonstration of the 3D printed pitch lap with a low durometer mold and pouring molten pitch.
* 10:57: Rough lapping to remove remaining feed lines and discussing challenges with smoothing settings in Fusion 360 for large radii.
* 11:46: Alternative concept for a 3D printed pitch lap with pre-formed grooves.
* 12:50: Using diamond slurry and exploring the potential of diamond compound for polishing.
* 13:30: Final thoughts on the potential applications of this technique in tool making and other industries.
*Zusammenfassung*
Das Video untersucht die Verwendung des 3D-Drucks beim Polieren von Formen, insbesondere zur Herstellung von kundenspezifischen Führungen und Läppchen, um hochwertige Oberflächenveredelungen auf komplexen Formen zu erzielen. Das Video erörtert auch die Bedeutung der Optimierung von CAM-Werkzeugwegen für die Oberflächenveredelung durch Anpassung von Schrittweite und Vorschub pro Zahn. Es werden mehrere Beispiele gezeigt, darunter das Polieren eines konischen Abschnitts mit drei Stegen, eines großen Radius an einem Messergriff und eines Kuppelsegments an einem Stempel.
*Zusammenfassung*
*3D-gedruckte Polierführungen*
* 0:00: Einführung in die Verwendung von 3D-gedruckten Führungen zum Schutz scharfer Ecken beim Polieren von Formen.
* 0:27: Vergleich mit traditionellen Methoden wie der Bearbeitung von kundenspezifischem Material oder der Verwendung eines zweiten Einsatzes.
* 0:37: Vorteile des 3D-Drucks für komplexe Formen und Kosteneffizienz.
* 1:11: Berücksichtigung der Kornkontamination in Kunststoffdrucken und Verwendung mehrerer Drucke für verschiedene Körnungen.
*3D-gedruckte Pitch-Läppchen*
* 1:24: Einführung in die Herstellung von konvexen Pitch-Läppchen unter Verwendung von 3D-gedruckten Formen zum Polieren großer Radien an Teilen wie Ziehstempeln und Messerskalen.
* 2:00: Zweiteilige 3D-gedruckte Form mit niedrigem Durometer-Material zur Bildung von Rillen und einem Griff zum Gießen und Halten der Tonhöhe.
* 2:18: Demonstration des Gießens von geschmolzenem Pech und des Entfernens der Form nach dem Erstarren.
*Oberflächenbeschaffenheit und Werkzeugwege*
* 2:26: Bedeutung der Oberflächenbeschaffenheit beim Polieren von Formen und die Grenzen von 2D-Darstellungen von Werkzeugwegen.
* 2:51: Erklärung der Spitzenhöhe und ihrer Auswirkungen auf die Oberflächenbeschaffenheit in X- und Y-Richtung.
* 3:30: Visualisierung der von Kugelfräsern erzeugten Jakobsmuscheln und die Beziehung zwischen Schrittweite und Vorschub pro Zahn.
* 3:48: Das Konzept der Anpassung von Schrittweite und Vorschub pro Zahn für optimale Oberflächenbeschaffenheit und Zykluszeit.
* 4:14: Folgen von nicht übereinstimmender Schrittweite und Vorschub pro Zahn, was zu sichtbaren Linien und ineffizienter Bearbeitung führt.
*Bearbeitungsbeispiele*
* 5:50: Bearbeitung eines Großradiusteils mit einem 6-mm-Kugelfräser zum Schruppen und Vorschlichten.
* 6:01: Schlichten mit einem 3-mm-Kugelfräser mit spezifischer Vorschubgeschwindigkeit und Schrittweite für die gewünschte Oberflächenbeschaffenheit.
* 6:22: Bearbeitung eines konischen Segments mit variierender Schrittweite und Vorschub pro Zahn, um deren Auswirkungen auf die Oberflächenbeschaffenheit und die Polierzeit zu demonstrieren.
*Polieren und Ergebnisse*
* 8:47: Bearbeitung eines Messergriffs mit einer 6-mm-Kugelnase und Verwendung von 3D-gedruckten Führungen zum Polieren.
* 9:50: Demonstration des 3D-gedruckten Pitch-Läppchens mit einer Form mit niedrigem Durometer und Gießen von geschmolzenem Pech.
* 10:57: Grobes Läppen zum Entfernen verbleibender Vorschublinien und Diskussion von Herausforderungen mit Glättungseinstellungen in Fusion 360 für große Radien.
* 11:46: Alternatives Konzept für ein 3D-gedrucktes Pitch-Läppchen mit vorgeformten Rillen.
* 12:50: Verwendung von Diamantschlamm und Untersuchung des Potenzials von Diamantpaste zum Polieren.
* 13:30: Abschließende Gedanken zu den möglichen Anwendungen dieser Technik im Werkzeugbau und in anderen Industrien.
User: translate abstract and summary to chinese
Model: *摘要*
该视频探讨了 3D 打印在模具抛光中的应用，特别是用于创建定制导向器和研磨盘，以在复杂形状上实现高质量的表面光洁度。视频还讨论了通过匹配步距和每齿进给量来优化 CAM 刀具路径以获得表面光洁度的重要性。展示了几个示例，包括抛光具有三个凸台的锥形截面、刀柄上的大圆角以及冲头上的圆顶段。
*总结*
*3D 打印抛光导向器*
* 0:00: 介绍使用 3D 打印导向器在模具抛光过程中保护锋利角落。
* 0:27: 与传统方法（如加工定制材料或使用第二个嵌件）进行比较。
* 0:37: 3D 打印对于复杂形状和成本效益的优势。
* 1:11: 考虑塑料打印件中的砂砾污染，并对不同的砂砾使用多个打印件。
*3D 打印沥青研磨盘*
* 1:24: 介绍使用 3D 打印模具创建凸面沥青研磨盘，用于抛光拉伸冲头和刀柄等零件上的大圆角。
* 2:00: 采用低硬度材料制成的两件式 3D 打印模具，用于形成凹槽和用于浇注和固定沥青的手柄。
* 2:18: 演示浇注熔融沥青并在凝固后去除模具。
*表面光洁度和刀具路径*
* 2:26: 表面光洁度在模具抛光中的重要性以及刀具路径二维表示的局限性。
* 2:51: 解释尖点高度及其对 X 和 Y 方向表面光洁度的影响。
* 3:30: 可视化球头立铣刀创建的扇贝形状以及步距和每齿进给量之间的关系。
* 3:48: 匹配步距和每齿进给量以获得最佳表面光洁度和循环时间的概念。
* 4:14: 步距和每齿进给量不匹配的后果，导致可见的线条和低效的加工。
*加工示例*
* 5:50: 使用 6 毫米球头立铣刀加工大圆角零件，进行粗加工和半精加工。
* 6:01: 使用 3 毫米球头立铣刀以特定的进给速度和步距进行精加工，以获得所需的表面光洁度。
* 6:22: 加工具有不同步距和每齿进给量的锥形段，以演示它们对表面光洁度和抛光时间的影响。
*抛光和结果*
* 8:47: 使用 6 毫米球头刀加工刀柄，并使用 3D 打印导向器进行抛光。
* 9:50: 演示采用低硬度模具的 3D 打印沥青研磨盘和浇注熔融沥青。
* 10:57: 进行粗研磨以去除剩余的进给线，并讨论 Fusion 360 中的平滑设置对于大圆角的挑战。
* 11:46: 具有预成型凹槽的 3D 打印沥青研磨盘的替代概念。
* 12:50: 使用金刚石浆料并探索金刚石研磨膏用于抛光的潜力。
* 13:30: 关于这项技术在工具制造和其他行业中潜在应用的最后思考。
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Thanks Adam. Another great tip video wit useful stuff. And your explanations are excellent.
Top notch teaching, Adam. Thank you so much.
Excellent video and a ton of helpful information. I definitely wanna try a different combination of stepover and feed. I need to see for myself :D Thank you for sharing your knowledge!
Thank you for sharing your knowledge.
Adam,
I like this idea and can see useful applications in watchmaking.
Cheers!
polishing the circular example really makes me want to build a thing I have no use for, a machine for this. Two spindles pointed antiparallel where one has a work holding system, the other has a big boring head mechanism to hold the lap and some kind of concentric shaft with a harmonic drive or third motor. One of the two main shafts can shift side to side, also like a boring head (it's boring heads all the way down). With encoders and computer control you could make it sweep into corners and scrub arc sections, but just spinning all the parts at different speeds would cover a circle, and driving the axial offset would create helical coverage area.
Excellent content. Thank you Adam
Thank you for the great content Adam. Very informative as always.
Very interesting!
There are still people in the world who make their own telescope lenses and mirrors. Seems like a good match.
Great video, thanks mate. Re the headphones users, might be worth watching with some on and the volume up to catch those spikes, or visually scanning the wave form during edit? I didn't even notice it, but on rewatch it was obvious.
I found that very well explained (and communicated) ;)
(Thanks for the beautiful microscope pics !)
I was wondering how it was done 100 years ago...
Fantastic. Thank you!
Also TIL, lapping pitch. I don't think I'll ever need it but good to know 👌
Oooh, I’ve designed some 3D printed laps that work pretty well, similar idea
Very cool and informative thanks!
Could you elaborate more on the radius smoothing feature/setting to reduce the “steps” you mentioned on the knife scale sample?
8:24 -- isn't that one tooth cutting up and one cutting down, as opposed to runout?
nice video
Interesting…thanks for sharing
totally cool
I learned something new today, did not know you use pitch for polishing. I guess it is to have a little give on the surface where the polishing particles can grab onto? Is using pitch the standard way to go? Whats the alternatives?
Fascinating!
Very cool!
any advice on cutting both ways? you know to reduce cycle time? does it kill the finish?
Why do you use a ball mill for finishing cheers.
The low durometer piece is removed after the pitch hardens?
What software were you using while showing the model? Thanks for the video! I can see how one can get obsessive over the perfection of these finishes.
That’s fusion 360
Excellent ideas and great explanations on that subject, Adam, thanks for that. Have you ever seen the Mauser Präzoplan 300 CNC machine in action? Check it out here on youtube...what do you think of that machine?. I think the sled with the vises rides on air. Very impressive apparatus.
I’ve checked it out before , very cool machine and I like that it doesn’t have the x and y axis stacked up
Thank you! I l have used these techniques as a precision optician but haven't seen them applied to tooling. How do you go about selecting polishing slurries and compounds? I'm mostly familiar with alumina and ceria used for glass.
I may also be able to help with forming laps for domed tools if you can show or sketch an example.
I generally have a small selection of Diamond slurry for lapping on cast iron and copper laps and then Diamond paste is what I have a larger range of kept around for polishing with felt bobs on my micro motor . The slurry is thinner and less likely to distort geometry but the paste has more Diamond per volume and can cut faster at times .
@@adamthemachinist if spherical is what you're after, pitch polishing will often actually improve geometry rather than distort it. A skilled optician can achieve total sphericity/flatness of about a micro inch with pitch. A fraction of a tenth is almost free.
That is how telescope mirrors are done and you can reach ridiculous levels of precession polishing and shaping
Have you tried printing with TPU? it's kind of a pain but it is really low durometer and you can adjust the overall stiffness of the part with infill settings.
Learned some things Adam, Thanks. What hardness pitch do you use most?
ATB, Robin
Robin, I’m pretty new to the pitch as well , I got 64 on the recommendation of extra minty Matt on Instagram . That seemed to work well on the large part but I notice some wear when going over the corner on the knife handle example . I also have some 55 and 91 I want to play with
Great video. Very interesting what was that pitch stuff? Gugol? Your surface finish appeared excellent so.. nice work thanks for the content have a great day.and keep up the good work
Opticians and telescope makers use it to form laps for lenses and mirrors , I was curious to see how it did in steel
"Gugolz Optical Lapping Pitch" by Meller Optics.
Where do you get the pitch from please?
I never did any polishing but I'm a bit confused about the 3d printed jig to prevent round corners. Unless the 3d printed part is flush with the soon to be polished part, then either it's higher and you polish the 3d printed part and not the part or it's lower and you are actually rounding the part.
I think I missed something in the process..
That said, very interesting video, thanks for the knowledge!
The error isn’t a big concern , usually a tiny bit lower and I shim it up . Talking about gross corner rounding to the extent that could allow plastic to flash , in excess of 25 microns .
Adam the Wizard making magic happen
So an end mill wouldn't leave a better smoother finish that's closer to a polished surface than a ball nose endmill?
Well endmills can be a little trickery to have follow 3D surfaces and get a even looking result . With a bullnose endmill you can do well with z level finishes but low angle curved faces can be difficult to get a even looking face . Check out sturz milling for more in 3D profiles with bullnose endmills
thanks for the heart attack within the first 30 seconds...
Radiuses? Fine.. but what about splines (bezier curves)? No way to start lapping that - polishing is the only option.
That’s correct
The point about step over and feed per tooth is very interesting and something I hadn’t realised, but it’s very important for me when I’m machining mould tools and need to get surface finish as high as possible, do you find this works well on soft tool steel too, I usually work on p20 pre hard, thanks again
Works fine in soft materials
best content always has low subscribers for some reason
All the polishing I've done has been with stones or wood and diamond paste. Can you tell us a little more about the pitch?
It’s what telescope makers use to form and polish their lenses, similar to asphalt on consistency. Soft enough to take the shape of the part being polished yet hard enough to rub off the high spots of the part
Excellent video - thanks. What tool are you using at 9:23 to polish the angled segments?
That one was stoned to 600 grit them appeared to 1200 and then polished with brushes and felt bobs to 8k grit
I think it is time I get a 3D printer...
Fusion for cam?
Yep
Hi Adam, if I wanted to polish a copper square (40mm by 40mm by 2.5mm) and wanted it to be very flat while getting a true mirror finish, would you try the 3D printed support and then polishing stone, or would the tar be a better option? I am new to polishing so a bit confused, but I am intrigued by the 3D printed support idea!
If you need true flatness than I wouldn’t recommend the 3D printing , you may want to look at proper lapping plates and how to make a set
@@adamthemachinist I see, thank you for clearifying :) I will take a look at lapping plates then.
What are the materials I need to purchase to apply to the 3D printed laps? Is the pitch the abrasive? I'm very new to this.
Gugolz lapping pitch . Poke around the diy telescope community for way more in depth info
@@adamthemachinist what I wonder after doing some digging is why you couldn't use a mix of abrasive grit and thermoplastic instead. I'll check if the Gugolz pitch is available locally. Do you have CAD for the prints you used?
Is a ball nose really the best for creating a flat surface? I am surprised.
The surface wasn’t flat
@@adamthemachinist I was referring to 06:05
Is that knife scale from a ZT? (Edit: or a Hinderer?)
Just drew something up