Machining HUGE 10 Ton Bevel Gear with CNC Milling Machine
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- เผยแพร่เมื่อ 22 เม.ย. 2020
- Machining huge 10 Ton bevel gear using huge cnc milling machine and huge cnc lathe. Thanks to ATA Gears for letting us film this project www.atagears.fi The bevel gear is going to be used on giant steel rolling mill which makes steel slabs for shipyards
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Thanks to ATA Gears for letting us film this project www.atagears.fi The bevel gear is going to be used on giant steel rolling mill which makes steel slabs for shipyards
HA! I'm still up !! I love machining videos !!! moi moi Marky_boi
I was going to ask! Big is interesting and so is complicated, but even better, big AND complicated! 😂
@@PPYTAO It's going to be hard to go any bigger than this :D
Please can you ask ata to ask the steel mill if you can go film the gears once they are in use.
Or better still ask them if you can watch them fitting the gears!!!
We need the follow up please! 👊🍻🐈🔥
The scale of this is absolutely insane. Would love to see the whole mechanism this thing was built for
its for the gearbox to my quad
Wind turbine?
Its a ring gear for rotational props under a very large ship
@@station08 I was thinking about hydroelectric dam but yours is more probabile
@@petrimantere3288 perfect timing
Next they ship it to a volcano for heat treating.
Hahaha
xD
Then throw it to ocean for quenching.
@@gunjankumar6566 and to the burning amazon rainforest for tempering
@@dewe1462 Duude! LMAO
Finally, the last part of my wrist watch is finished
@freezeme360 It's probably his drinking arm, got to be the strong arm.
Is it an invicta
@@badabingbadaboom9251 Lol Invicta, gross. Obvious a fucking rolex.
Your momma watch u meen!
It is really heavy, you must be strong!
To see those initial cuts being made in time lapse really shows how the table has to start/move/stop 10 tons every cut ! That it does it so precisely is a testament to how robust the motors, screws, ways and frame of that machine are. Remarkable.
x- axis is a linear motor with no direct drive.
@@kizahd isn't a linear motor, by definition, direct drive? Still just as impressive
Responsible work holding and programming
That's not 10 tons, 10k lbs maybe, but not anywhere close to 10 tons
@@frankcastle1885 Why would you think 20,000 pounds is unreasonable but 10,000 pounds is reasonable? I'm not sure that from a video you can make that kind of a call. (I'm not picking on you, I just don't see your logic here.)
Knowing my luck, id set the program running, come back in in the morning and realise id set the wrong program and the ring has been reduced to a M10 washer
LOL It would suck if you put in the wrong G codes!
I'd love to watch that video, which would have to include your reaction when you arrive back in the morning. That would be a true "Vat Da Faak" moment.
I've had sleepless nights when I've left a machine running.
That’s why I’m not a machinist anymore. They used to call me Scrappy McRework.
Scooby Dont I played machinist once. Turns out you can hide a hell of a lot of broken tools in a skip of swarf.
Titan of CNC: look I'm cutting 150 pounds of titanium BOOM
Beyond the press : Hold my beer
🤣😂🤣😂
Hahah 😂😂😂
That is funny.
Lol, That's good man
They do make much more complex parts though
I buy bevel gears from ATA regularly. There is no gear company in the world which can match their quality and workmanship. Great to have an inside look at the factory.
Cheers mate!
what size? lol
china say hold my beer haaa haaa
I'm a little surprised to see such a rough finish on those gears, particularly the chamfer.
how much do you believe is the cost for one of these gear?
Lauri: "Is it better to be large or complicated?"
ME: "Yes."
I once carved a stick - into a pointed stick.
Was it a Popsicle stick? I did those.
What do you do when a maniac attacs you with the grapefruit?
My stick snapped!
Me too, and ended up with 10 stitches. :)
Be sure to make a video next time you do it, I've been thinking about trying that myself and could use some ideas about how to go about it, thanks
This really grinds my gears
gotta shim them better
but this gear is ungrindable
Lauri: "Is it better to be large or complicated?"
Subscribers: "Yes."
It's wild that the big stuff I mostly saw in 5 years of studying Engineering(4 years of Basic Engineering, 1 year of a trade skill) before starting university was usually a ~200mm diameter gear and stuff like that. At the end of the third year though, I spent the mandatory 4 weeks at the local power plant. I was sent to the Turbine Maintenance area, they wanted to send me to the Lubrication dudes, but since each area needs two people I was sent to the maintenance area. The power plant was in the middle of the maintenance of the 4th turbine. Size 70 screws and nuts, a "small" plate for the turbine cover was like 50mm thick and roughly 1.5 meter in diameter. These are common sight for those guys working there, it was a really good experience.
Though, the gap between the floor and the turbine itself wasn't fun, you could see into the basement from the 5th floor. Also we visited those basements frequently, walking around in 40+ °C heat around the pipes doing maintenance on pumps, didn't matter how much I tightened my helmet, it was slipping around from the sweat. Working on the pumps near the furnaces was also interesting, one end of the pillar you are sweating from the heat, the other side you are freezing from the crosswind in the tunnel.
Atleast I got to see the inside of the massive desulphurizating machine in the middle of one of the cooling towers.
I enjoyed this a lot, thank you for all the work and thanks to ATA for being so accommodating. I'm all for machining videos whether they're big or small or anything else!
Lauri: "What kind of machining videos do you want to see?"
Us: "Yes."
A most vehiment YES! I am a retired engineer and these two (his wife is included), have just the right balance of curiousity and quirkiness to feed my own curiousity. I forgot his wife's name, I think her name is Ana, she has her own channel where she goes into life and living in Finland, I would recommend it because she is just so nice. I must have my fill of interesting channels like this. I would also recommend Technoboom, EVLOG & Big Clive. Now I do love to laugh at utter morons who believe in a flat earth and that any god created anything let alone exist, so I love fightthefltearth FTFE, Paulogia and others in this vein, what channels do you guys recommend?
@@JonathonPawelko His wife's name is Anni.
Jonathon Pawelko I’d recommend ”this old tony” from youtube. Great guy that makes all sort of interesting stuff about machining. Greetings from Finland!
I thought they’re twins? Maybe.
Wow, suggesting thumbs down if we don't like it so you know what content to make in the future... that was refreshing. Thumbs up!
Love the large machining. Cool video.
I started my career at a machine shop programming 2 large lathes. I used to threaten the sales team that if they don't sell anything, I would put their car between centers and turn it down to a baseball bat and hand it to them...because I could. Lol
That was a sweet DMG-Mori. The last company that I used to work for bought a lot of Mori. Lathes (2 & 4 ax), Mills (3 & 4 ax), Mill-turns (15 of them). They make good machines and had a quality support team at the office that I dealt with. I programmed everything in the building (all brands) at the last place except cylindrical grinders.
Show us the lathe that turned the piece at the beginning of the video. What kind of steel are they made out of. This was so cool! More please.
fig1954 probably a vtl
I also wonder how the raw part was made, did it get rolled or forged? Don't think you can cast steel into a shape like this. Pretty insane.
Hand filed.
They would have used a vertical borer
@@CatNolara Most likely made via ring roll forging. It can be cast but the grain structure and overall strength of the material is better with a forging.
I lime these videos of culture or machines or businesses from Finland. You are voted the Happiest People on Earth. So I like learning about your country. Thank you Lady Anni and Gentleman Lori!
someone needs to edit the hand in gears safety warning sign to have a whole person in the gears
Those gears look like they're straight out of a scifi movie. Both shiny and not shiny at the same time.
Lauri want's these for the differential gears on his new truck.
I'll take a couple for my wrist watch. Truly amazing .piece of work.
I do have one of these on my bicycle
It really grinds their gears
Ok I was about to make a joke on american truck differential, but you did this one before lol
Large things make humans feel small, which creates awe, which in turn is a very pleasant emotion.
I think one of the most interesting aspects of machining on this scale is the ability to control the inertia moving these heavy pieces and maintain tolerances. Either incredibly powerful actuators and screw gears, or very complex calculations.
Bevel gear 5 million
Jason lmao
ITYM 10 million (grams)
80 hours of machining. I'm never going to complain about a 14 hour 3D printing session again.
probably just few hundredths thousands 😂
@@longshot7601 14 hour printing session.... Try 74.
Now that is a huge ring gear I would love to see the gear box that is in
*YES!*
@@ddegn Dana 6000 or maybe a GM 1400 Bolt??????
These were replacements made for Rosie O'Donnell's treadmill.
@@gavincurtis Haha, good joke.
We all know Rosie O'Donnell doesn't exercise.
Trelleborg, Sweden. måndag den 27 april 2020.
To Michael Green who asked ” Is there a reason the no lubricant is used during this machining?”.
Hello Michael!
Generally you have misunderstood. When you see machining and they spool
a liquid on the workpiece and the tool it is not for lubricating. The purpose
is cooling. The liquid you then see is practically water which is an efficient
coolant. (Yes, there are exceptions. Depending on which metal that is machined
one sometimes ned both cooling and lubricating. Then you may spool with
vegetable oil, kerosene or even alcohol. Such exceptions the mechanical
industry know.)
But water on steel create corrosion and that is not desirable. Therefore the water is mixed with special anticorrosive oils that mix with water. Approximately 3 to 5 % oil.
This workpiece and the machine is very stable. The edges in the tool cut
away “thick” chips and the chip is heated and removes most of the heat from
both tool and workpiece. ( “Thick” in this case is perhaps 0,2 to 0,6 mm.) This workpiece is large and the tool is small
so the piece is probably only
“handwarm”. The tool they call “millhead” at 2:18 minutes have yellow details.
Those are the cutting edges and are made of “hard metal”. In the middle of each
“plate” is a screw. When the sharpness
begins to be bad the plates are easy to change for new ones. More to read at www.secotools.com In the beginning of 1900
or perhaps 1940 the industry had developed HSS, High Speed Steel for cutting
edges. Also heat resistant. Hard metal increased the cutting capacity 10 to 20 times.
Best regards / tomasgidlof.se
At first I thought this was BTP's shop, was going to say Holy shit he's really upgraded over the past 5 months I haven't watched!
I'd like to see the bearing that the shaft for this rides on.
Can you get a ball bearing this large? It could also be a magnetic or air bearing.
@@qwerty13380 i have never thought about the fact that you can use buth magnetism and air as a bearing, thanks for informing me!
@@qwerty13380 imagine making that bearing magnetic
@@freppie_ PC fans usually have magnetic bearings.
@@qwerty13380 You can buy roller bearings with inner races you could stand inside.
The cnc is like the size of my whole room/workshop
Nicholas Ryabchuk and DMG builds much larger 😁
th-cam.com/video/aNFNhNoeNL0/w-d-xo.html
I visited the xxl center when I was there for training. On some maschines you can park a huge truck or 10 cars 🤣
That whole machine can fit in the table of a few turning machine i work on and gring them to dust
That gear wouldn't fit in my apartment, but if it could it would go through the floor, and I am on a slab.
Stunning. I love to work BIG ! I machined Ships Engines and Pipe Line Compressors for years. Retired now but great memories. Thanks for bringing those back.
Used to haul these machines brand new to customers. Loved the hell out it. Retired now, but miss it so much.
I just want to learn how to set the machine up to do that. It moves the tool and the piece at the same time, what a precision machine, handling all that weight too, insane
It's really nice machine. If this does well I think I could do just video about that machine
@@Beyondthepress Oh please do that! That was insane! Great video btw Thank you so much! You don't see this very often!
Brings new meaning to the term "Gear-head." huh?!! Love your shows.
Hard to believe how far we have come. Less than 200 years ago we were plowing ground with a piece of wood.
Nice to see the final drive for my BMW is coming along nicely.
Beautiful
This is absolutely crazy beautiful and the music rocks hard
Loved how you could tell it was hot as the steel scraps were blue
Heavy Metal.
Thanks for showing people the amazing things machinists make.
This was super cool! I really like seeing how these things are done. You have a great channel. Whenever my wife and teenage children do anything together someone will say, "AND HERE WE GO"!!! Love what you do. Kiitos!
Abom79 handles those baby sized gears by hand after making those in his sweet shaper ;)
Probably needed his steady rest on the big monarch
@@phillijp lmfao!
Imagine if Abom79 had made a special guest appearance in this video attempting a Finnish-English Accent...
@@1001ewaste gonna drink dis vodka right 'ere and we'll be just fine running smooth
Abom79 would appreciate this.
Good to see businesses working together.
When I was a teenager I worked with my dad in a machine shop that made steel rolls for rolling metals into sheets. Some of the largest rolls weighted 800k-900k pounds. That's 400+ tons. They had to be brought in on specially modified trains because they were so heavy. Crazy watching something that heavy being lifted.
If you read the description, you'll see that that's exactly what this gear is for too!
I'd really love to see how it's used, the product in use.
I'm thinking container ship engine.
@@Outland9000 That, or maybe heavy mining equipment.
He said it goes into a steel mills roller machine. Like when you see big thick sheets of hot steel being passed back and forth and 'squished'?
Beautiful piece
Loved seeing this. Thank you.
That was badass, great video. Thanks!
Always going to vote for more “machining 5,000,000” videos. Some large, some complicated.
Intricate machining is fascinating, but it’s the sheer scale of some of the large pieces too.
Search for *"large scale forging"* ...not only are the workpieces heavy and large...no...they are also over 1000°C hot. It's insanity.
Tip for next time: ask the personal that works there for some interesting things for your video. They definitely have some interesting things laying around, i know they would love to show :)
Thank you so much for your channel! I love your videos!
Great video. Not a lot of "extra crap" like some people post (and add bad music!) A BIG plus in showing the tooling! The tooling interest me AS MUCH as the machining itself!
Fantastic. I've been waiting for this since the community post. Excited to see what else you filmed at ATA Gears
Imagine the size of the differential it's going in. JK
Just imagine how much this would cost if they didn't make it to spec and had to discard the whole gear.. goddamn..
$1-2 per lb of steel. Remember stock material was a donut originally and had been turned down first. He said 10 tons. Cranes tons mean kg. Probably 30000 lbs. depending on the grade of steel that means $40-60000 material alone. A shop like this likely charges $200 per hour plus an overage for large parts and add padding incase material is scrap. He's saying about 40 hours of milling per gear and I'd estimate at least 20 hours of turning per gear. The cheapest they would charge without padding the material is 60*200 or 12000 per gear + 30% of the material, so about $32000 CAD per gear as a charge. ($22000-30000 USD plus material costs)
@@joshmdmd I'd say your estimate is way off. I could be wrong but I thought I heard him say 80 hours for 1 part. Also a machine that large and wear on tooling to remove at least a ton of material, is going to fetch a premium...
One of my coworkers used to work at a place that made medical implants. He left cuz he knew if he made a single mistake he'd cost the company like $40,000 worth of surgical grade titanium and he couldn't handle it
@@BadBadgerTrollAccount172 lol he said the camera was on for 80 hours of footage. Maybe they left it running through 24/7. I based it off the end of the video where he said two weeks including time on the lathe for finishing at another company. Work you can leave overnight without supervision doesn't really run off the same pricing as actual parts that require a lot of oversight. The roughing could've all been done without supervision as long as they cycled bodies based on expected wear. The second part also is much cheaper (and shorter) than the second part. If you quote too high on a job like this, you'll lose the customer to a competitor, and the chance you get to quote another job for the customer drops significantly as well.
@@brainkrieg1423
your friend is a liar or you are. there is no such thing as "surgical grade" titanium. I work in the medical device industry every day. there is not an implant that goes in the body that is made of $40000 worth of titanium. you sound like a fool when u make shit up
anything CNC is worth watching I think..loved this episode guys.
Wow that's insane. Thanks for sharing guys.
You're secretly building a flying saucer aren't you! :P
Thats one heck of a machine.
FINALLY......the differential ring for my '76 Camaro is ready.
This is actually the new crown for my divers watch. I like the industrial look
Well, realising that your press puts out the force of 15 of them stacked on top of each other is just mind-boggling...
And it weighs a fraction of the gear's weight.
There are AGC cylinders in steel mills that can exert 2-3000 tons of force. They're used to control the thickness of the steel going through the rolling mill by pushing giant rollers together, and basically squishing the steel down as it's pushed through.
Fluid mechanics is fun.
I see the differential for my new car is coming along nicely.
If you have vtech might need stronker gears mate.
It will be noisy. Needs to be helical teeth....
Astounding results from such a complex process, absolutely top notch finish on the gear teeth.
Very fascinating. Thank you for brining us this content.
The "heavy metal" music riff is effective.
Song?
@@matteoribaudo3801 Riding the Storm by Deaf Election
@@VanillaLibrarian Thanks. I know this frome somewhere else, maybe another TH-cam Channel. Any Idea whats in my mind?
The blank was 10 tons. How much did it weigh after the machining?
2-3 tons was removed during tooth cutting
Human-beings have come a long way from the wooden-wheel to milling a ten ton beveled steel-pinion such as this. Imagine if all the countries in the world focuses on technologies for the well-being of mankind instead instead of war, we could have achieved tens of years ahead more than what we have achieved today. . .
Great video. .
Greetings from India. . 🤘✌️👍
War is the reason of technology
That is awesome! That DMG MORI is amazing!
Large or complicated?
YES!!!
I just find it crazy how effortlessly those mills remove the metal.
Remek videó! Köszi!👍👍👍
OMG! That thing is huge!!
👍 More large AND more complicated, and maybe more often...!? 🤔 😎✌️
Looks like the gears are for the new crushinator 20000000
Like, throwing things into moving giant-ass gears and seeing what they look like afterwards?
Thank god, I was looking for this gear! Perfect for my custom rear differential.
Amazing!!! Thank you!!!
I wonder how much weight those gears lost after being machined.
lol probably something like a few hundred pounds at least.
it became a gear after being machined
I’d say a ton at least
yea machining is really inefficient. you could probably even have used a saw to cut out a few pieces of flat bar first out of each of these grooves but the time is not worth it.
@@excitedbox5705 They melt, cast and reuse the leftovers
The logistics of machining large parts is interesting. I've installed big parts on machinery and ships, never thought about what went into making them. Have a great day.
Parts as big as this gear?
I'd think getting the parts into position would be crazy hard.
@@ddegn yeah, but stuff that size was installed by crane, actually easier than doing something a couple of hundred pounds in a tight space by hand.
@@jerrystott7780 agreed, im working with much bigger parts (our crane is 120t) and its not that hard to set them on the table (also a vertical lathe).
More bigs and... complicated too! :) Great video, thanks!
Amazing, I like both things that you said, large and complicated will be interesting, also the heat treatment area. Thanks for taking the time. Best regards.
The machine is moving the 10T mass is quite rapidly. The servo motors must be quite powerful.
Very impressive.
It would be interesting to see the guts of that CNC. Perhaps they would let you film when they perform maintenance on it?
Ro K
Theyre Not as impressive as you think .
Mostly there are two or More dc Motors to split the load .
These tables are also hydrostatically lifted and you can Turn the table by pushing With your leg .
Look at how blue those chips are.
If you use compressed air, swarf -doh- is allways blue due to t°. Less so if coolant is used, wich mostly doesn't suit milling.
@@dannydetonator cobalt blue chips are from the type of material more than the way it was machined or coolant choice
Would ya look at that? Just look at it. Ed Bassmaster would be proud
Kory Dean well no... with coolant you do something crazy wrong if you get blue chips. The only way you should get blue chips is when you use air to cool... and material is not important as long as it is steel... stainless steel rarely goes blue but anything else does
Chips are blue due to heat generated
They're so beautiful! 👍😎👍
I'm glad to have found this amazing channel!
Here in the US I operate a DMG Mori Milltap 700, it is tiny compared to that DMG mill. The little parts (gears) I run are only about 25mm x 35mm.
Do you happen to know what % of weight is usually cut off by the end of the process, you know like before/after?
Lauri: what kind of machining videos do want to see, large or complicated.
TH-cam: More This Old Tony.
Spiral bevels are always fun, too. What I would like to see is some straight gears made on a vertical mill with an indexer without a digital readout. Maybe putting splines on a shaft. Anything with an indexer, is always fun.
Machining processes in general are great material to watch.
Large or complicated? We want large AND complicated! :)
The big question is what did the giant gear weigh AFTER the machining? I try to imagine how large 1 ton of shavings is.
Fantastic quality on those bevel gears....great work👍👍
My dad is a TV repairman and has this awesome set of tools. He could make that!
Your english is extaordinary
now thats some GEAR!!
how many tons of material was turned into chips?
All the way from upstate New York USA. Very good video. I love your Channel! We like everything that you do. Large things and complicated things. And don't forget to squish things with the Press
It's like a massive iris. Beautiful!
Atlas: I see they have finally finished the replacement gears for my wrist watch.⌚️
Imagine the cnc code got corrupted near the end and it started milling wrong. That would be very expensive and heavy piece of scrap metal
Sounds like a insurance claim to me.
g code (cnc code) doesn't run on anything apple made so no need to worry mate
The machines don't screw up, usually. It's the machinists who do.
Imagine messing up tool length measuring for the finishing pass, so the whole thing is just slightly out of spec when it's finished...
Mostly the will weld the spot up with the same material and then just finishing the whole piece
Kyle Harding my macbook generates g codes for my 3d printer just as well as my windows or linux computer mate
It is great to see the making of such huge gears.
Finally my custom bike parts