Replacing a Badly Worn Shaft and Saving My Customer a Pile of Money - Manual Machining & Welding
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- เผยแพร่เมื่อ 22 มี.ค. 2024
- $2700.00! Yes you read that right. That is what the OEM wants for this axle with wheel. But, the wheel isn't bad.
I replaced this axle and saved my customer a pile of money. A simple job, that nobody else in my region could do.
If you are interested in trying out Anchorlube, here is a link to their amazon store.
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#machineshop #machinistlife #manualmachinist - แนวปฏิบัติและการใช้ชีวิต
I have a confession to make, I was a 2nd year Apprentice when my rotation into the Machine Shop,
Lathes , Milling , Cylindrical and Surface Grinders, Bolt Nut and Screw production and Glass Mould Servicing, were the main duties , I was handed this shaft to make a new one , so I made an exact replica, I had spent three entire hours , measuring the differing Diameters , taper lengths , chamfer shapes , I even asked the shop Foreman what tolerances I could work within, 0.005 thousandths of an inch . I ensured all measurements were taken of the initial piece was at 22* Celsius and that I only touched the insulation on the Micrometer’s and Vernier Callipers. I made the shaft and I was as proud as punch, Happy as Larry , My first ever Foreign Order , it has taken another three hours to machine it up, I took it to the Shop Foreman , Who burst out laughing, and the entire shop joined in even the labourers, all of those differing diameters and tapers were actually bearing wear marks , I was supposed to hand the Foreman a Length of untouched 3/4 inch bar, After the laughing died off the foreman opened a drawer and pulled out the previous apprentice's attempts, In the end I was given 99% mark for duplication, less the 1% for not asking for a Finished Product Sketch, before starting a " Job Card ". Lesson Learned.
I actually asked the customer if I had to duplicate the original. I thought the wear was on the other end where the bearing was and the worn end was a feature. Lol. Glad I clarified it.
@@TopperMachineLLC Had you not actually said it I'd have spent a fair chunk of the video trying to decide if that could actually all be wear or not. That's a heck of a worn part.
@@TopperMachineLLCI thought that worn(short) end was a feature and not very excessively worn.
Very common mistake notasking for the original specification
@@toddhazell925 I thought so too! When it was a finished piece of 1 1/2 SS round bar stock, I felt like a fool! I looked around and made sure no one was looking!🤣🤣🤣🤣 Then again, I’m not a machinist!
Stripped out a worn shaft like that from a conveyor one day shift. Left the shaft on the bench with a note for night shift "Make a new one of these please" came back the next morning to a brand new shaft with the exact same "tapered end" machined in !
Lol
There's an old joke in the computer programming field. Programmer calls in a customer to demonstrate a program he asked for. After working with it a while the customer says, "Oh, no, this won't do at all." Programmer says, "What? I made it exactly to your specs." Customer, "Yes. Yes, it's just what I asked for, but not at all what I need."
Had the same thing in Dubai with a broken BMW motorcycle drive shaft had an Indian operated machine shop make me a new shaft "Same same" complete with the break in the middle!
u wantes exactly the same. haha
@@josephcote6120the real joke is that people actually think tech people do actual work 😂😂😂
Came here from a cutting edge engineering video, so nice to see the smaller scale stuff done so well, that threaded hole was simply butter.
Not sure how I stumbled onto this or why I ended up watching this, but found it very interesting. Guess I have a new channel to watch!
Saving the customer will surely be on their minds when more machine shop work is needed .
No joke, even for big companies, the turnaround is more important usually.
I know we have paid local shops good money because they could get it back to us that evening.
$2700 is nothing when the machine is losing $xxx,xxx for every shift it's down.
The anchor lube product placement reminds me of Wayne’s world when Garth was wearing the full Reebok outfit and saying it’s really a shame when people sellout 😂
Put a center in the end. Just in case you need it later. Makes things easier.
I have a friend who has a 25 year old Dixon ZTR mower and I was fixing leaky hydro gearboxes when I discovered that one of the axle shafts had been eaten away by a loose inner bearing. Obsolete part - naturally. Local machine shop was able to weld it up and turn it to size. I re-assembled it with some red Loctite to try and keep it from happening again. So far, so good. 👍
Kudos to the algorithm that brought me here. You have a new subscriber.
LORDY ... The 'Ol Monarch runs AWESOME
Computer skills will never replace basic machining skills. Especially when the concept of just in time delivery applies to replacement spares.
I totally agree, i’ve done many weld repairs at work on worn shafts then machined them back. Sometimes you just can’t wait a week for a new shaft.
The shaft you make here is relatively easy for a California lathe /mill guy however a shaft four feet long with eight journals that have to run with in one thousands of an inch takes a far larger degree of skill!@@MrProdigious1
@@MrProdigious1 Sometimes a replacement shaft is 5-6 months away. We end up fabricating a lot of things at my shop even though I work for a big OE specifically because our factory lead times can be really long.
My father in law was a machinist for 40 years and retired when his back was shot. He said they were getting rid of all the old guys and replacing them with brand new guys that got paid much less. Gleason then found themselves with all these new guys who were taught on new equipment and there was no one who could run the manual "old" machines. So they had to hire some people back and pay them very well to try and teach.
I live near a massive salt mine (new York) and they've had an ad for forever looking for someone who can use the old machines.
@@allenrussell6135 There is a big difference between a production machinist and a prototype machinist. On traditional production machines including the computer controlled ones you have to make a quite a few set up parts before getting everything adjusted and making the first good one.A prototype guy makes the first one perfect, with no set up parts or scrap.
My thought would put a key in the drive wheel so that down the road they could just have another shaft made and pressed back in and not have to weld it back together.
That's exactly what I would have done.Also eliminate bending stresses induced by welding.
I'm a retired Software Engineer. I have NO idea why I watched this. I know nothing about machining and have NO desire to learn. I thought it was interesting. Good job!!!!
Tig welding is one of those things that you must do every day or two I think to be good at it. I tig about 5-6 times a year and find a few mins of practice on some scrap is helpful. Just to get the motion down and the memory working again. Nice Job Josh, Your typical job shop repair right there. I need this can you help me out.
I think you're right about TIG welding. It always seems to take a bit to get back into it. But if you do it everyday, it goes great.
After 5 years of daily welding I have the muscle memory. I’m a decent tig welder. I do a lot of fabrication now so I weld a lot less. But when I need it it’s there.
I took machine shop in both Jr. High and High School. This was back in the 1960's when they actually had that in US public school. I really enjoyed that. I went into electronics, but still have a little lathe to keep my hand in.
I remember metal shop in middle school and high school. We learned to use a lathe, Mill, foundry, gas and stick weld what a shame all that had to go away. They even got rid of woodshop and auto shop at my high school.
Your content is fascinating since it is amazing that the steel just seems to melt onto your hands like putty. Also, it’s very calming to see somebody actually creating product. Keep up the great work.
Thank you very much!
That looked like a fun project. It is always good to be able to replicate a OEM part
When I got out of the Service I apprenticed in Tool & Die shop. Where the owner of the small shop taught me how to run all machines! He would take in small repair jobs like this and talk me through setup of the repair. I worked in the trades for 32 years, had a family, home and sent my kids through engineering schools. I miss working on the lathe or Bridgeport and making hot chips? And still think about sweeping up shop at the end of day! Thanks for the content!
It always mesmerizing to watch a manual machinist who knows what he's doing. All your cuts are so good. Nice not to hear all the CNCs running at max all day. That screech......
Great job Josh! I know you don't have much time... but it would be nice if a customer here and there would let you go see your work after they have re-installed it and gotten back up and running.
Also saw The Apprentice working hard in the background. I think at one point he was on the Lion lathe. Its nice that he has gotten to the point where he can work on his own for some things, without constant oversight.
Some of it is my time to go film, often it is more about privacy of the customer. I have seen most applications of my work, but they don't want their processes filmed. Or rather the potential glimpse of it.
Conner is doing great. He has a lot of jobs he will be doing coming up. He really enjoys welding and his skills are improving greatly.
I agree with that. I would love to see what some of those oddball things are used for.
Thanks, Josh. I think you just made yourself a new long-term customer. Funny how "gettin' it done right the first time" seems to make that happen... See you in the next one. Be well.
13:56 - Thank you. Do not cut it often, but it's good to know which side of feed/speed to err on.
15:02 - My old Jet didn't either, but it seems that since the chuck was thread-fitted to the spindle, that was a good idea.
21:48 - Hang the harness on my shoulder also; takes the weight off the wrist.
There’s something really satisfying about a hydraulic press: No miss, no fuss, it just calmly says “you *are* coming out” 😂
TIG welding is something I have never done. Back in my 20's. I used to do a lot of rust repairs on cars with oxy welding and I also did a lot of stick welding on other things. I only started MIG welding around 30 years ago and these days I mostly do MIG welding on my own projects.
Absolutely amazing job
Well done, Josh. Thank you for the video.
The luxury of a shop to work in instead of up on a roof, rebuilding blower motors, and changing bearings i’m serving a process cause me to remember the good old days
Well done!! Nice machining.
Thank you Josh!
Lovely to see at least one of you guys not afraid to use cutting lubricants. One of my pet hates one most you tube engineering videos is the neglect of lubricants when either cutting or assembling components. Well done that man
Coolants and oils are not always necessary. Drilling and tapping, yes. Turning and milking with carbide, it really depends on your tooling. Most carbide will cut dry just as good and last just as long, as it would with using coolant. Dealing with the mess of coolant is the biggest reason not to use it. When I started out, I thought coolant was a requirement. I learned from some amazing people it was not.
Makes filming a bit more difficult.
Still, we love Josh Vanover, aka “Captain Dry”
@@TopperMachineLLC You neglected to mention that if you use coolant with carbide it HAS to be flooded with coolant, tapping of course is excepted.
@@Zzrdemon6633 Nonsense. Carbide is just fine using brushed on oil or spray mist.
What does not work is confusing coolant with lube, like why would you tap with coolant?
I am impressed with the clutter free shop you keep. Nice work on the shaft. Great video thumbs up.
Looks good, great repair !
Enjoyed that. Thanks for the video keep on keeping on.
Well done ...your customer is very lucky
Crazy that no one out in your neck of the woods could do that!
Good business to have in WI. I know both industrial places I have worked the last 20 years absolutely love small guys like you who can keep us from overpaying AND having equipment down for way too long.
There is nobody left besides me. This region is economically depressed and industry is disappearing.
Your customer should be very happy, nice job. Be well this day
Great content! Love your work
Doing it right the first time!, trying. Thanks for this.
I was always taught to cut keyways in one pass with a slot drill using slow feed to get a perfect size.
P.S. I’m not saying I’m correct but it’s what I was taught.
Nice work !
It's always nice when someone can save another shop a few dollars like you did there I'm sure you will get repeat business from them ! Great job ! Very professional looking ! 👍👍
Great video thanks for sharing
awesome job
Brings back memories of when we still had a lathe at work and I could actually do something instead of shipping everything out to a shop like this! And had they tightened the set screws in the bearings it wouldn't have spun down like that, not to mention that was months of spinning in the bearing unobserved
Good job! That shaft really was shafted! I'm sure the customer was very pleased. Thanks for the video.
They saved a boat load of money on this one. Crazy what the OEM wanted for this.
Between obscene prices,lack of product availability and planned obsolescence a machine shop that is willing to take on 1 off jobs like this can stay quite busy
I agree to an extent. Try doing it in my region. It's so depressed here that it's hard to get any work.
Hi Josh Im a old retired machinist yes 1971 to 2022. I was looking on TH-cam for something to look at and you popped up. It gave me chills to hear a Monarch lathe fire up. Keep up the good work. I'm going to get some dimensions on a little 1pc lathe part I need. Ok I'm watching your videos and trying to write. Ill call you.
Well done, another part produced correctly and at a reasonable price too.
As reasonable as possible with current material prices.
Awesome work! Where i work we get a lot of worn conveyor shafts, pretty cool to see into the process of repairing them.
Great video like always Josh! 👍👍
I commented Because I like the content
Another great video, thanks Josh. I am a hobby machinist, but I have the same CBB Monarch lathe. Great machines.
This is actually a CU. I've ran and almost owned a CBB
ALORIS Tool Post R the BEST!
parabens pelo serviço oficina muito top.
Great job. A little trick I use when I weld rubber tires on trailer axles, I take an old towel and roll ice cubes in it then wrap that around around the tire. It's not perfect, but I don't have to be as careful to melt the rubber. Just gotta be a little quick because the ice will melt and drip down the side of the tire, But it's just the nature of the beast.
Depending on the assembly I use wet rags. But this one with the TIG welding I knew the heat was minimal and localized. Not much fear of harming the wheel. The shaft never really got hot on the short end. That's the cool part about TIG, very localized.
I totally agree, you did an awesome job!@@TopperMachineLLC
Nice chips. Spotted that shaper, gonna have to check out more of your vids. Id love to get into machining someday
You do nice work.
Great job for your lucky customer Josh if he has any sense he will be back to you for the next job he needs done :-) Best regards Sarah
Wow that part was worn to the nub. Awsome job. Charging 2700 bucks for such a simple piece is insane. You're goon get repeat buisness to be sure ❤
I like the old Monarch lathes.
I love doing repair machining not vary many of us out there anymore or at least in my area
Good stuff
Most excellent.
hello Josh & it's is Randy and i like yours video is cool & Thanks Josh & Friends Randy
Josh I really like the looks of that work stop you have on your mill vise.
GoStop from Go Manufacturing in Minnesota.
@@TopperMachineLLC thanks brother!
late to the premier, but here, had to work all day, best wishes Josh, ....Paul down in central Florida
I think your tall stock moved sideways a smidge when your center drill touched at about 12:32 on your video. Don't know if that is an issue or not. Great video.
boy I think the customer really for the shaft this time! lol good work!
Great repair Josh and a great video. Love the repair content videos. I wonder if the area of the shaft that you questioned whether on purpose of just wear may have been on purpose for clearance to allow ease of getting say the bearing to its final position. In many repairs we tackled in the past we would take the extra step to have the shaft turned smaller in areas that had to be moved across when installing in the field for ease of installation. Doesn't hurt anything if nothing is mounted in those areas but makes for quick and easier installation of bearings or other shaft mounted components along the length of the shaft that are long distances between mounting points. Just a thought.
Thanks for sharing.
I considered this, but not knowing anything about the final application I didn't want to chance it. They can bring it back if it needs changes.
@@TopperMachineLLCNever do more work up front than asked for.
Good morning!
Reminds me of when you as Hardinge for a price quote on a part. I remember they wanted $290 for a... BOLT. Yes, just a bolt with the head modified a bit.
Nice to have a standard size shaft that has stock available in the right size already
Interesting 2-way press. I don't think I've ever seen one you pump UP!
Thank you…
Nice👍
I noticed you've been useing the monarch more than the lion. Just wondered why. THANKS JOSH.
They both have their uses. I just chose whichever one is better suited, or is not already set up on a job.
that shaft was really nice, runout was amazing lol. not a job for the CNC lol. Stainless steel surface footages, ugh, about 300-400 sfm with 304 and flood coolant using Oemeta 875 novamet " which is nice because with the way lube,Hycut blends with the coolant and reduces tramp oiling to near zero" is about all I have ever been able to manage without killing inserts. stainless love to work harden, so fun
Stainless isn't that bad. In fact, I just finished a job that was way worse than any stainless I ever worked with. It was just 4140 Prehard,but something was off with it and it work hardened like crazy.
@@TopperMachineLLC I have been wanting to try ceramic inserts for working with prehard 4140 etc, but haven't had the need.
Good to see Conner walking by ! Did he finish up the Dragline track project? I was thinking that was an excellent project for an apprentice.
Nice save for your customer maybe suggest they run grease lines so it’s very easy to keep that lubed?
We are still working on it. The weather turned cold and we had a bunch of paying jobs to do first.
Hello from Brooklyn ny
Enjoyed watching. Your shop is so similar to the first machine shop I worked in in the late 90s. The power feed on the knee mill, the anchor lube, everything. Do you ever use an edge finder?
Take a look at the motor plate for wiring or the wiring cover in side , many motors are will run both directions by switching a few wires to the center tap of the starter winding , by adding some wire to the leads to go to a switch to flip the connections so the motor can be made to start in forward or reverse .
I did this to my lathe motor and put the switch where I could reach it to change before turning on the the on /off switch .
I use reverse alot for different things , I never have to say i wish this thing had reverse again .
I think if the motor is 3 phase it can be reversed with out even turning it off and stopping it , i am not sure what wires need changed on them .
Monarch gear head lathes are NOT designed to be run in reverse. I have seen a few destroyed because of being reversed. It is fine in an emergency, but never to be done as normal operations. Irreparable damage will be done.
@@TopperMachineLLC Yes , if it has a driven oil pump lube system that would not work for very long , as the pump would run backwards and not lube the bearings and gears .
Have to always look at the big picture of everything involved .
I almost wrecked my air compressor when changing the voltage from low to high in the motor wires and gotten the rotation reversed and didn't notice it at first and it ran backwards made air pressure just fine but had no oil pressure on the gauge , sean it fairly soon after and corrected the rotation , still working fine 40+ years later, got lucky .
@@kennethnevel3263 the Monarch has a cam actuated pump, but the problem is the internal clutches are designed for one direction and will cause damage if run backwards
They are more like the jobs I used to do as we never really had any bigger machines. The machines were a little smaller than what you have.
On old auto rebuilt generators the end of the armature wore they cut the end down welded a sleeve on the end if course they werre doing multiple items same problem .
Good, straightforward job - when will people learn to grease ?!?
Probably not until they have to pay for the damages out of their own pockets.
I probably drive my employees crazy with multiple white boards with to-do lists and maintenance schedules, but, as you imply, it’s MY sh*t !!!
Although I will never own/know how to use the majority of your machines, I still find this fascinating. I am an attorney by trade by the way. 🤣 That said, I appreciate your use of hand tools when appropriate.
Thank you.
Looks like it won't be long and you'll have to order some more Anchorlube.
Lol... Funny when you think about how many of those went to the scrap yard
did i see some movement in the tail stock when the single point engaged the bar end?
It's a really good utube channel is this...
😐🇬🇧🏴😐
A lost trade.. I'm in a philly neighborhood, we had a couple jobbing machine shops...Long gone now...We had GE right down the street, I have lots of buddies, retired from Machine shops...It's nice to see a small shop like yours...I hope you get to make a million widgets that make 5 bucks a piece...:)...Good health and success to you and yours...Subbed etc...:)
Thank you, but I'm not interested in the volume jobs. I like single parts that are $5 Million each. Lol.
Very nicely done of course!
i have 4-5 old inner tubes under my press. in case the item i want is falling
I did listen all the way through. Waiting to hear what material you used, possibly 17-4 ph. Was that a HSS endmill ?
Josh,
Your videos and presentations keep getting better and better. Maybe I missed it, what type of SS was this? The tig skills looked great. Like you I've been using more and more Anchorlube in my daily work....am almost a total convert now....was having a heck of a problem getting concentricity in an external thread mated to an internal thread and having run out of a little more than .0005...was for a medical/surgical instrument.....a 2 inch shaft extension for a 20k rpm precision bone drill.....tolerance was .00025 + - 1/10th..... finally got it...and runout down to .0002...took 3 tries but all a-ok now....been intermittent flurries all day and light dusting on the ground....stupid forecast says 4-8" maybe by morning.....fingers crossed they be wrong......
Keep up the OUTSTANDING work !
Don
Thanks Don, I wasn't sure how this video would come out, but it worked. I honestly don't remember, 304 or 316. I did that job weeks ago. Man, you do small stuff. No way I could even see that size work anymore.
Great video. I agree with Don - the production quality continues to improve. I really like the camera angles you use, and good insight into the process like the comments around speeds and feeds is very welcome. I use anchorlube a lot these days. Cheers! 👍
P.S. you pulled a Stuart not turning the end of the old shaft down. 😅
Josh
I have to admit, I cheat...have a neat set of magnifier glasses with interchangeable different power lenses. The way the SS was flowing off the cutter I sorta suspected it may be 316.......@@TopperMachineLLC
@@StuartsShed lol. I really feel dumb for not doing that. I guess I thought it was worn down. Guess I was wrong.
Classic “repair shop” work. Couple questions about the stainless welding: 1) is there concern about brittleness at the HAZ at that weld like there might be with some of the non stainless steels? Or is the HAZ less of problem with stainless? 2) just curious why TIG and not MIG?, not that I really have a horse in that race. I’ve welded stainless with MIG but never done TIG of any kind.
No real concern, not enough heat put into it. TIG is just better because it makes less HAZ and smaller weld with better penetration. The short end of the shaft didn't even get super hot after welding.
I was shouting turn down the end bit. 😅
I just went blind from watching the welding. AAARGH!
I am wondering if an auto-reverse tapping head on a Morse taper (as you would use on a drill press) would help.
I could just do it in the lion if it was a problem. But for something small like this, it is not.
What alloy are you using for the replacement? 17-4? Any heat treatment?
You save that shaaaft