Secrets to Machining an Aerospace Part on a Tormach CNC Mill
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- เผยแพร่เมื่อ 10 ก.ค. 2024
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This video is a quick overview of how we machined out one of our landing gear parts for the DarkAero 1. We cover the machining operations, the tool paths, fixturing (work holding), and provide some good tips and tricks for machining your own components with tricky geometry.
Design for machining links:
1) 3D Hubs
www.3dhubs.com/guides/cnc-mac...
2) Xometry
pages.xometry.com/cnc-design-...
3) Protolabs
get.protolabs.com/cnc-essenti...
If you enjoyed this video and would like to see more of this type of content, follow along as we continue towards creating the fastest, longest range aircraft you can build in your garage.
More information on DarkAero can be found on our website and other social media accounts:
www.darkaero.com
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That is very impressive. Makes me think smarter on my set ups. Amazing work. What website for the fixturing ideas? Or website to see more of what your doing
Do it yourself channel thank you! We are working on another machining video which will go into more depth on fixturing. Stay tuned! It will also cover something special that we will make available for free that we think will be very helpful for machining projects. :)
Awesome.
Nyc cnc and Titans of CNC has good info to name a few
Fixturing is hard.
Hate to say this as a machinist of 15 years at my own shop, I’ve never made a part close to that. Beautiful work and process.
Dustin, wow, thank you for the kind words! 🙂
Hello, I have been following you and your company off on for quite some time, and I just want to say that what your are doing is incredibly inspiring, and I am sure it is for many people. Creating one of the most advanced light aircraft of our time, and make no excuses. You just created what is the most impressive part I have very seen someone create on a Tormach PCNC. You could have had the disposition of "Oh I need a few $50,000 Haas and $100,000 of other equipment before I can really start this", when you are already creating beautiful parts. In an aerospace startup, at that. You are doing an incredible job, and I wish for a wonderful future to you and DarkAero!
Mike Patey made the point that especially for tight tolerances on larger parts, temperature control of the machining room and equipment is very important. He brings the material into the room at least 12 hours before starting work to ensure it's at a uniform temperature. It is likewise important to keep the cutting tool from heating; the spray is not just for chip removal. Proper maintenance of the coolant management plumbing is necessary to maintain consistent flow.
Thermal expansion effects can add up quickly on a part that goes along a wingspan! It was quite impressive to see Mike Patey cut and drill wing and control surface components that fit perfectly at every rivet point without any wiggling or extra adjustment.
One of the best videos yet! So interesting to see a bit of the process required to build that piece of artwork! Great job guys! keep it up!
This one is the best tormach part i have ever seen >>>> great finishing with real engineering mind & true knowledge of machining >>>
Awesome guys!!! Really hope you guys do EXTREMELY well with your aerospace venture. Love the videos, and PLEASE, don't stop releasing content on the Tormach. Love it.
Loved this video Keegan. Great, simple explanation. I never really thought about the material having some flexibility, albeit small, and the way you kept material in place to stop flex was fascinating.
David Leslie thank you and thanks for watching!
This is some serious quality content! Awesome job! Looking forward to more updates.
Love this video. Love to see people machining parts and how they do it
This is so amazing!! I never thought about having to plan your machine paths! Thank you guys again for another fabulous and informative piece!!
I really enjoy the element that you bring to bear with building this aircraft, that you're sharing with us how you're designing and how you're building the aircraft personally to help us as purchasers and homebuilders make it a more accessible and easy and streamlined process. I still really want the DarkAero to be my first Airplane and especially first homebuilt aircraft.
Edit: had a typo.
Some people have commented on using the holes to locate, it would be a faster option if you reamed the holes out on OP1 (eg 5.2mm) then when you turned it located on 5.2mm pins with M4 tapped holes in. Just a suggestion, nothing wrong with using tags I work in F1 and we use them all the time. Nice video and best of luck.
Wish I could work with you guys :). You’re taking all the best of each technology and putting in a great project. Also you’re making aircraft design and build attractive and ‘easy’. Hats off guys.
Great video! Very knowledgeable! Can't wait for the next video!
I was looking for some info about precision machining, definitely this videos are some of the best put there thanks for the tips and the visuals
Such a great video. You asked if that made sense at one point. It surely did. You demonstrated the process very well. I don't see that much detail in other videos. The tool paths on the software, the fixturing. Kot much on fixtures, that I've come across. Thanks for the video
This is what i call machining! Good work!
Thanks for this very interesting and informative video! Lot's of great camera work with clear and concise explanations of both why and how. Loved the additional tips at the end, very nice touch. Really a great illustration of 'serious' machining being done and done well on an affordable system. You'll probably move on to Haas or better as thing take off (!), but for those of us for which a Tormach CNC mill was a stretch, this was quite inspirational.
Excellent video and excellent demonstration of fixturing. So many people overlook the steps, order of operations and planning that it takes to make a quality part. They just assume that since it is CNC that the machine will do everything for them but that's not true. It's like an old machinist making parts on a bridgeport, tighten the part too tight and its going to flex, too loose and it will vibrate. Take to big of a chip load and the part goes flying, not enough chip load and shit starts to rub instead of cut.... All that said, well done sir.
This was great man, good stuff.
Outstanding work! lots to take away from this. Thank you for uploading.
Oakwood Machine Works Thank you! Thanks for watching!
Keep it going!! you did an amazing part there, keep it humble and continue lerning!
Very impressive. Especially how you made the groove for the wiper using a 3D toolpath. I make the drawings and milling programs at a shop that makes hydraulic cylinders, all our sealing grooves are done on lathes. You make me wanna save up for my own tormach and start my own business!
I'm trying to take the jump from 3d printing to a CNC mill putting together. Great video it is really helpful
I learned so much in this video, thanks.
For some reason I wanted to say, ‘holistic machining.’ No idea why.
Nicely done! Sharing your video with my students.
Great work guys!
Respect, good work. I worked as a cnc miller for over a decade (mostly Hermle with heidenhain Controls) and i think i can judge the degree of difficulty of this component.
That's not easy. Now i'm on the programming side of the job and if i had to do something like that, i had to think about the best method for a while.
Greetings from Germany
clever method sir! i really like that op2 tab setup with the pitbulls then the bolts! definitely keeping that in the ole back pocket
Killer job man!
You have done a fantastic job there, I watch "Titans of CNC" channel. 👍 Watching from Melbourne Australia. Love it.
Super awesome work.
Well done on workholding !! With such a huge removal of material, I would consider pre-rough operation for ridding of tension in material to avoid warping.
Or at least cut the critical features last, the other way is a beginners mistake.
Martin Novák thank you for the suggestion. This was something we had considered before we started but we have struggled to find any solid information/documentation/studies on this subject. Do you have any good recommendations of sources? Something that provides guidelines based on material types, material starting vs finishing thickness ratio, how the material was formed (like cold rolled vs hot) and how these types variables play into how you plan the machining strategy or “pre-roughing” like you mention?
@@DarkAeroInc aluminium is chock full of internal stresses. It'll warp for a past time. Most of this stuff is just experience, I havn't seen anything in a book about it. General things to look for are asymmetric material removal or anything over 50% stock removal.
Hot rolled has a lot less interal stress than cold rolled(steel). If I was doing this part you can get alu thats been stress relieved(baked).
Nice work. The part came out really well and the surface finish looks good. Regards MachineNZ
Thanks for sharing this video - such a detailed explanation of all the stages. Very enjoyable to watch. Can’t wait to see the final assembly. From a layman perspective, the narrow hinge points at the top look relatively weak compared to the rest of the structure.
I wish I could like this video more than once!!!!!
You just popped up as a suggestion and I'm glad. It was great content, thanks for sharing. Subbed ;)
Same here, made my day! 👍👍👍
Dark Aero is so sick
quite possibly the best video on machining a part from start to finish on the internet.
Wow, thank you so much! :)
@@DarkAeroInc no prob! Also, just curious did you model the mitee bite clamps yourself or does mitee bite have their own 3d models that you can download?
@@noahbarrow7979 I can't remember...I believe we just modeled them based on the dimensions they provided on their site.
Great content. Very interesting.
Great Video! Very impressive.
Thank you! :)
Just stumbled on the channel, amazing stuff! love me some good machining challenge
nice channel man.... keep the sweet machining videos coming!
p.s. imma self taught machinest too. I came from engineering and fell in love with how difficult machining can be. I was hoping to make some videos too soon of the stuff I have learned over the last 3 years of machining to help out the people like me 3 years ago
This proofs the part is 95 percent machinist and 5 percent machine. :) Working/tinkering on the workholding is about as satisfying as machining the actual parts. Nice work! Thin walls are always a challenge, while flipping the part over it becomes more rigid by touching the surfaces of the workholding. In some circumstances you need to add a support frame or use a medium like lead balls to avoid resonances. Great work, There are people with a DMG that don't come this far..
Like this. Wouldn't mind seeing more on how you did the CAD for the fixture plate.
Great video!
Thank you for the very good content! cheers
Thank you for watching! Cheers!
Wow great part great fixture I love seeing this type of passion. Now I need to make a cool part on our Tormach at Titans of cnc love it
Stuart McConnachie thank you! We actually learned a lot of our machining from watching your videos. 👍🏼
DarkAero, Inc what that is awesome ! You should come to the shop one day and check it out
@@stuartmcconnachie8907 The funny thing is that when it came on my TH-cam suggestion I first thought that it's from Titan. Then, "Oh, it's not from Titan" let's see what this is! :) I connected the words Aerospace and Tormach immediately to you guys.
DarkAero, amazing. As an owner of an 1100s3 myself, I am scratching my head with astonishment and a bit of embarrassment... lol.
awesome video ,id like to see more of how you guys integrate this with your machine
That is awesome!!!
Lots of great tips that show you pay attention to precision. Pro tip is to get very close with a good tool distributor. He'll be able to sell you tools and holders with low runout, high performance geometry and coatings, and give proper feeds and speeds.
Haas is an entry level CNC. I hope you do well enough to step up to a more solid machine.
Very informative!
thanks for sharing!!
You guys are at the head of the pack!
nice work!
Thank you!
Great vid.
GREAT JOB !!!!!!!!!!!
Thank you! :)
at the end where you said you're new to machining...mind blown.
Thank you for the kind words! ☺️
Super job
Very cool
very impressive for that machine.
Nice one guys 💪👊
Jousef Murad thank you! 😁
Very nice...
Love this stuff! I would love to make a CR500 engine...if only I had one of these bad boys!
Just looked, used one's are under $10k, I'm actually wondering how I could justify this amount...maybe if I started a company making parts...how many CR500 engines do you want?
That really impressive and the end result looks great, but I cannot believe how mush work is need setting up the part before you even start the job, 3D printing make it looks easy.
Great video! Great lookin part! What tool holder do you have on your back wall? Can you provide a link? Thanks,
Beautiful work, what happens to all that excess material?
Amazing part and video. I’m sure I’ve seen it somewhere but what software do you use for CAD and CAM?
Would it be possible for me to machine a part like this on my tekcel enduro flatbed at slightly larger scale if I were to invest in additional vices and fixtures for work holding.
Thanks for sharing guys. I am wondering how long does it usually take for a similar part to be ready (from design to machining)?
Cool part! I’m a toolmaker and I would say you did a good job. I was thinking that when you machine that much material away on one opp and finish the critical features you could tend to have the part warp on the second opp. Something you could think about is just machining like .030 off of the stock in your first opp then flipping it over and then do it like you did. What that does is breaks the “scale” on the block which releases a little stress and gives you a flatter surface to sit on. The only other thing I would have done instead of using the clamps and tabs on the second opp is just put bolts in like half of your holes and modify the tool path to not machine away your bolts. Then just put in the rest of your bolts after your done and remove the original ones. Then just machine those areas. It seems like it might take away the chance of your clamps lifting your part and wouldn’t be as hard to get a wrench under your part to tighten clamps. Ether way works and it’s what works for you. Keep up the good work.
Also, instead of making an elaborate fixture you could have made some of your bolt holes more like dowel holes and just put like dowel pins and bolt holes on a flat plate for a fixture. Just ideas for future pieces.
@@brandencroy6416 thanks for watching and for the suggestions! We had considered just bolts and had a more in-depth version of the video explaining why we did both clamps and bolts but ultimately cut it out of the final video. The holes for the bolts are slightly oversized so the bolts don't provide any means of locating the part relative to any critical geometry. For this part, the ID is the most critical geometry and is why we wanted a fixture feature to use for locating the ID. Dowel pins could work but they still don't serve as the right locating feature as the bolt holes aren't the driving critical geometry. Also, the clamps are able to generate both downward and lateral force on the part so we weren't too concerned with it lifting up the part. :)
I understand what you're saying. A lot of times we we circle mill the bolt holes so that they are a nice hole like a dowel then just buy a gauge pin to fit and cut to length to use in the fixture.
Always nice videos. For the 'sandwhich' pieces, aren't there any 'points' to locate them together? (Other than the bolts)
can you provide details on the enclosure you built? looks pretty good and a lot smaller than tormachs one
Nice work! I’d probably rough the inside, then the outside. Then finish the inside then the outside. Not saying your process isn’t better: just tossing that out there.
Hey guys, great work your doing on this adventure. A quick question which may have been answered already but what was the total machining time on this part, both oops.
I do understand this is prototype and speeds and feeds are probably conservative.
I have a 1100m but am not at this level yet , thanks
Great job. However I feel that the outer layer was "damaged" with the lateral finishing cuts. I would like to make them along the length for better fatigue strength. But it's true, that I don't know, how the part is loaded. It probably doesn't make a difference.
Your fusion 360 kung fu is great! But the part looks so light!!! Will it keep the load?? Thank you guys for the video!
Great machining video, really loved how you designed the part and fixture and machined it. Being an CAD enthusiast myself, can you please share 3D file for the part and the fixture to me .
hello dark aero, I want to ask where you get all the materials and tools to make aircraft ?
Have you considered hard coat anodizing your fixtures? Reduces chances of wear and damage with use. Same question for finished parts.
Did y’all ever make a video on the enclosure you made for the tormach?
Do you intend to switch to a cast part for production. There is a lot of machining going on in the manufacture of the part.
Nice looking part! I take it that's 7075? Hard to make 6061 come out that pretty. Did you guys do FEA on the ears? I don't know what you're using for load assumptions but to my old engineer eyes those features don't look like they have enough safety factor.
Thanks for watching and for the comment! The landing gear was designed in accordance with the FAA’s Part 23 load guidelines for certified aircraft gear.
A shell/fly cutter might prove to be a wise investment to cut (haha, get it?) down a lot of time in the first step. Instead of using the 3/8 endmill to do all that work flattening the part out, a shell cutter could do it in a fraction of the time. This would also vastly extend the lifespan of said endmill since it's workload would be lightened quite significantly.
Thanks for watching! Definitely looking at a fly cutter as one of our next tools.
Using the small cutter for facing your fixture is good practice for reducing any tram error in your head.
@@jamescarter9147 This is exactly why I thought that they did it this way.
How long to machine the 2 mating halves?
Your first part is always the most expensive, as I watched you video I noted you were using small end mills to rough everything, but later you mentioned using larger tools for roughing.
You wat to use the largest tool you can, then use finish tools.
Use a face mill to surface your material, they take wide shallow cuts.
But EXCELLENT quality. Keep it up
Good idea on the face mill! That’s one of the next tools we would like to get!
@@DarkAeroInc I suggest a 2.00 diameter face mill with your current machine.
Where can I get the video design guide?
What clamps are you using for your first and second operations?
Will you guys be casting the part when going into production?
What software do you use to run FEA on such a part
Very nice.
How long was the total programming time?
What was your step over on the ball end mill parallel finish?
Bryce Workman 0.02” step over which puts the scallop height at around 0.0004”.
@@DarkAeroInc This is where I usually go wrong. I use to use a much smaller step over but a much faster feed per tooth. The cusp height would be good but part surface finish not so good. One question though. Did you not think about putting counter bore pockets through the other side of your fixture to bolt the part directly to the fixture then clamp the fixture to the machine? If there were large quantities you could have used a zero point clamping system for the fixture. Great work by the way. If you were based in the NE of England and looking for a job then this channel would certainly get my attention. well done!
Thanks for sharing this video , can you please tell me what are the type of servo motors and it is size used in this cnc ? Also what is the size of the guide rails ?? I very apprecieated that.
If you send me your email I can send you some information that goes into the details of how they decided on the stepper motors for the series 3 machine.
@@DarkAeroInc ameeneng12345@gmail.com
This my email.
Hello. Cool video. I just wanted to know how did you determine the total stress that will apply on this part. Is it well known that the pockets for removing materials must be triangular if yes why?
Also what softwares do you use for CAD and machining simulation.
Thanks.
Thanks for the comment! FAR Part 23 provides guidelines for landing load conditions based on the weight and performance of an aircraft. We used this guideline to understand the loads this component would see under worst case landing conditions. You can perform simple hand and spreadsheet calculations to determine stresses on landing gear parts and then further confirm part stresses using FEA. We also plan on doing drop tests to verify our analysis work. We use Onshape for CAD and Fusion for CAM.
Thanks
Impressive! About how much was the aluminium bullion by itself?
What are the little clamps you use on the side of the part?
AerialKoala Pitbull clamps made by Mitee Bite.
One thought. Rough out by Water jet 6 or more of those with all bolt holes, G54 offset, keep the tabs you have, make 6 at a time.
Thanks for watching! Yes, this is good idea! We had been discussing ways to cut down cycle time recently and the topic of water jet cutting out the rough shapes came up. It's a great way to save time and material!
Question: why was OP1's XY origin off of the center raw stock instead of the fixture? Did you have problems when going to OP2?
tony wilkinson great question. I wanted to create a feature on the fixture I could reference for my origin for OP1 but it was basically an oversight when I designed the fixture plate. Another issue was I was running up against the Y travel of the machine so I was limited on space for adding a spot I could pick up Y that was off the stock. I would like to have it off the stock for a future improvement. If I had lost power at any point during OP 1 I would have lost my XY origin and would have had no way to pick those up again. So def want to change that going forward.
@@DarkAeroInc that makes sense. The part is beautiful, and I can tell many hours went into it.
I stumbled upon your channel from your cad commercials comparing why you switched from fusion 360 to Onshape. I am curious to know how is it switch coming along? Are you guys college grads with engineering degrees? Or guys with a desire to create some thing viable.? How long did you guys use fusion 360 before switching to Onshape.?
Dark Knight thank you for checking out our videos! We were initially using SolidWorks but then switched over to Onshape. We’ve been using Onshape for a few years now and we really like it, still happy with our decision. :) We first started using SolidWorks back in college around 2007. We all have engineering degrees but in different fields: aerospace, mechanical, and electrical. Currently we use Onshape for CAD and Fusion360 for CAM.
looks nice guys. Jus Curious why do you use Auto Cad vs VisualCamc which is integrated with Onshape? I have never used it but someday i will need a Cam software would like to know your thoughts
Jordan Reimer thank you! We’ve played around a little bit with VisualCAM. It doesn’t feel as refined as Fusion. The user interface also feels a little dated. Fusion just has an all around more capable CAM package at a reasonable price in our opinion.
@@DarkAeroInc Thanks for your insight! I will see what options are available when it comes my time to get into CAM
Jordan Reimer no problem! Happy to give our input. If you have any other questions, feel free to reach out. 👍🏼