Not to say that there is not a skill for CNCing, yours is a brain and muscle skill. I would rather be a manual machinist in a job shop speaking for myself. Its an art form.
Nice to see the machine moving that much material, it is a hell of a lot of chips. Just out of curiosity, it would be interesting to see if @David Wilks could come up with a way to using a parting tool then trepan the material discarding the outer portion. Then come back and rough the blank to the size you ended up with.
I had the same thought. I wonder if there are any trepanning specialists here in the U.S. In this case, Peter got the job because he can knock 4 pieces out pretty quickly and the customer knows he's getting top quality work - quickly. Time is money, as they say.
This video shows exacly why i love watching you do stuff Peter.you always do it the correct way and never cut corners. Always indicate raw stock and milling the center for perfect center. Never in a hurry 😁👍
This part is very similar in size and shape to shafts I'm machining at the moment except we shrink fit and weld the flanges after rough turning and final machine it.I guess it comes down to what it's used for.
Thank you Peter for posting this interesting video on your work. I'm sorry there are so many trolls with the same endless repetitive comment. I appreciated you answering the question so many times with patience.
I understand people don’t have the time to read over 200 comments. So I don’t mind answering the same question. It at least shows they are interested. Thanks John.
Haha. And do you think that Felix would get a broom, sweep up and move the full drums without being told. He's too busy smoking cigarettes and looking at his phone.
Impressive material removal peter. I was thinking something along the lines of the guys with the trepanning idea, we used to have a work where we would face grove as deep as the face groove tool would go and then part it with a normal grooving tool, creating rings. We actually used the rings for the parts, would make 3 different diameter parts from the stock we had, were much smaller pieces of course :) and it was brass. Not sure you have face grooving tools that go deep enough to make it worth while in such massive stock. Here it would make the process much longer, you would have to remove the tailstock and hammer the ring off every time, probably the time waste not worth the material saving.
I couldn't help but imagine the finished product as a massive engine valve+stem, and got chills from the size of the resulting engine to go with them =D Very nice work. Thank you for the quality videos.
As a young Applications Engineer in Australia I once did some test cutting for a customer in the Japanese factory on one of these machines with a 6.0m (236") bed length. Incredibly powerful and versatile machines.
Just incredible work! I love your videos...even though I'll probably never have the opportunity to operate machines like yours, I very much appreciate the precision and beauty of the work you do! Thanks for posting your videos, I really enjoy watching them. All the best, Jon
Hello Peter. Right after working for centerline I worked at Watson grinding (Right around the corner. ) we used to made very similar parts like that. You brought memories back to me.
That is a baby chuck heck even my 36" 4 jaw is small compared to some out there but you certainly won't be dual key setting my chuck unless you have 8 foot arms. LOL
I wonder if an enormous core drill (a bit like the concrete ones) and a super-sketchy parting operation could let you keep most of that removed stock in one piece. Probably not worth it but would still be interesting.
We make a very similar shaft part like that in our shop. We get blanks with a large disk and shaft friction welded together. Thus we avoid machining all of that off of a solid billet.
This is an example of when forging could save a lot of machining time and stock. Of course, you'd need a large-enough run to justify the tooling for forging.
Exactly what I was thinking. How many parts would it take to justify having castings made for this job. 1,000lbs of chips is insane but if its only a small order, you have no choice
@@squeegied3rdeye713 Casting one-offs is a bit easier than forging, as nowadays you can actually produce your pattern with styrofoam or 3D printing rather than wood like the older way, but there's still the fact that casting isn't always foolproof. I worked few a few months for a company that machined iron castings for engine flywheels, and one part had a recurring issue with voids near the hub. Casting steel is more difficult than grey or ductile iron, from what I understand. But I've seen some neat videos of a company near me that forges similar parts for things like gear blanks, but those are done a few dozen at a time.
@@SuperAWaC Billet metal is a solid length (often in a square or circle profile) of material that has been extruded into shape, either by continuous casting or hot rolling. Billet material is often used in cnc machining.
@@darrennelson6803 I am a machinist. That is not a billet, it is a bar. Billets are what get made into bars. Using billet in the manner you are is a nonsensical marketing buzzword. The process for wrought metals is usually something like: Molten -> Bloom/Ingot -> Billet -> Bar (round/square/etc) or Molten -> Bloom/Ingot -> Slab -> Plate/Sheet What you're doing is the equivalent of calling a piece of metal sheet a "slab". Imagine tearing off a piece of aluminum foil and saying "here's a slab of aluminum" or "here's an ingot of aluminum". It's just the wrong word.
This is why I advocate machines having their own jib cranes instead of trying to save money with a communal lift or having just one bridge or gantry crane. Jib cranes save so much time and effort
If the machine can handle a part or fixture weighing more than say 60-100 pounds it should have a hoist. It is also a mistake to put a 1000 lb hoist in a machine that can handle 4000 lb. put the correct size or someone will overload it!
You can't always store the parts in close proximity to the machine. So, if you have to transfer the part one or more times in order to machine it you gain nothing. Normally a jib crane has a very short distance it can travel.
My grandpa use to co own a farm equipment dealership. There was a table there that I ended up with. It was made back in the 60s and the insurance made them get rid of it about 2015 so I got it. Its 2’ by 3’, 4” thick solid steel. An anvil table. I cant even imagine how much it weighs. It was sitting upside down on concrete blocks when I got it. I slid it and it destroyed those blocks.
Yes but this steel doesn't have a real high carbon content. OK for hammers and tools. But it should be higher for knifes. It would work maybe combined with something of higher carbon.
I am overwhelmed by your professionalism. I would be happy if you address the questions: what makes the Mazak so accurate? stepper? Linear encoder? Rotary? Routes on linear bearings? I would love a lesson on the subject.
This machine is just servos with encoders to ball screws. The ball screws have liquid cooling run thru them. And yes the axis run on linear bearings. To get a better idea I have a video that shows these things.
It's jobs like this where I love hogging with my big 6 series inserts! ~400sfm .5" DOC. It makes steamy potato chips and fast work of big shafts. Just gotta have the HP and rigidity to make it all happen.
That's insane! I've never machines anything in my life, I just stumbled upon this video and I was mind blown about the .25" DOC... .5" DOC!? what kind of machine and cutting tool can do that? I'm genuinely interested, I didn't know we could move metal like this lol
Working at NOSL Louisville, I machined parts like this back in the day on manual lathes. I used to see how much of a cut the machine could handle. ( I tripped the circuit breakers a few times.) The hot chips felt good on cold winter days.
Customer order do from one piece and noting else. A piece made from a solid block is always the strongest, but also the most expensive and especially for something like this since there was so much material to remove but the customer knew what he wanted no matter the cost.
@@dtiydr Yes the - customer is always right but is with over kill .A welding engineer might save him from over kill .Yes welding can be stronger than the parent metal i can tell you for sure it would work with a correct heat treating process. 🧐
@@curtisvonepp4335 That is what I said in another comment but probably after sending out for heat treatment after welding the additional cost would negate the material savings of doing it from billet instead of a 2 piece welding.
I very seldom get this circumstance. Most of the jobs I do take a lot of manual operation intervention. I did have to stop and index the insert quite a few time during this so there wasn’t a hour straight without doing anything.
This is the SMW hydraulic steady rest. Normally it opens up. But I’m right at the max capacity. 16.18” dia. Of the rough stock. So I have to manually shove the arms out a little.
I'm estimating that this is 14"-16" at the largest OD. Since the video is sped up so much, one gets the impression that the rpm is way high. If my assumption is correct, you would probably be running the spindle at 160 or 140 rpm. Am I close? It would be great if a part of the clip would show the real-time speed. The fast clip is also cool- 3 hours shown in 10 mins. Your videos are amazing and the attention to detail is outstanding. Thanks you for sharing your experience. Respect!
Слава Петров somehow came to my mind... ;-) Using forged pieces would make it faster and cheaper material-wise, but the cost of forging would be probably much higher than 400 kg of this material turned into shavings. With bigger batches, like, say 40 or 400 pcs - yes, it might be worthwhile to use forged "zagatovki", but not for a batch of just four pieces, I reckon. Also, as others pointed it out already, time is money, especially with those expensive machines, so any "economising" here would be like spending a dollar to save a dime. Split pieces design? Yes, unless specs called specifically for monolithic "dietal".
Why do they turn it all the way starting from the initial od? Like why couldnt they cut down the desired od (plus an inch or two) with a hollow core bit or some sort and then cut the stock into two main pieces? I feel like that couldn’t be that difficult and would increase the value of the scrap greatly
For this few parts the cost of doing that would exceed the value of the scrap. Also the time it would take to make or acquire the tooling to do it would be to long. One other and even more important issue is there is no way on this machine for me to even do that kind of machining operation. There is no way to properly mount and support the treepanning tool. So for this customer who was in need of the parts on a shorter time schedule. This is the most economical way to go. If there were more parts and time a open die forging would be the way. This would use less steel and also require less machining roughing time.
@@assassinlexx1993 I'm running an 18 core Intel36i processor with quantum bi-lateral fuel change/crossover mother board, and ceramic bearing motor. I think that is what helps the most with limiting the light dimming. My chuck run-out is now measured in feet, instead of 10-thousandths, but I think I can use Stephan's chuck tapping video to get it back into specs.
Watching that first lift reminded me of a co-worker that forgot to pull a fixture pin before lifting a tank laser sight off a test fixture. $40K damage.
I'm thinking if the stock was 3D printed, there will be less waste due to machining but I'm not sure if the strength is comparable but the price would be bit higher.
Non-cnc hobby machinist here. Whats the advantage of using a drill and endmill at an angle to cut a center vs just using a center drill in this instance?
Even conventional welding of a plate on the spindle would have saved a lot of material but maybe they can't find good enough welders to do a full penetration weld and then I reckon being 140 it would have to have a full heat treat done after welding so the cost of sending it out to get re heat treated is more than the material was so turn it off out of billet is the cheapest way to go.
Watching just a few of your videos I have learned a great deal! I am completely new to CNC machining, so please forgive my ignorance. Is there no way to use trepanning to remove the bulk of that material? I don't know how one would deal with the big "tube" of excess material coming off when parting it, maybe that's the reason it isn't done. It just seems like such a waste to create half a ton of chips when making a shaft. Thanks very much for your excellent videos and discussions.
Look at David Wilks latest video he is doing a similar thing. It is possible on the right machine. On my machine I don’t really have the proper way to mount a treepanning tool or the volume of coolant necessary to make it work. It would be nice to have the piece of hole bar that would come from it.
@@EdgePrecision I found your site after watching David Wilks. I understand about the tool and coolant. Trepanning sure takes a torrent of coolant to cool the tool and move the chips. I hadn't thought about that. I appreciate your taking the time to respond. Thanks a lot.
I've seen a few comments saying trepan it and part it off Peter. I have a piece of inconel 718 to do. If you get time look on my channel Wednesday. I do this a lot. It's only a small job but you'll get the drift. I made sunnppa channel to cut 95mm trepanning tool. What is the shank details of your collet. Can you use straight shank? I fancy making a smallish tool for you. This job would've been perfect to do... trepan to depth... part through. 🤔
Thanks David. It looks like I will be making some more of very similar parts for this customer. But unfortunately they all vary in size. These ones were the largest ones. All the rest will be smaller. Or so they say. I will keep a eye out for your video Wednesday.
I have a question please. What are the reason why you don’t prepare two smaller pieces, weld them together and finish them off? That would probably save you a ton of material, time, tooltip, and other... Must these pieces for some reason be made out of one solid piece? Please advise.
This is the way the original parts were made and failed. So this customer felt that in order to eliminate the possibility of that happening again, they wanted a part from solid. Also their machine was down and this was the fastest way to do it.
@@EdgePrecision thanks a lot for your swift response! Yes, I thought so myself, but a proper laid weld (x-rayed without voids) should in theory be just as strong as a solid piece. Perhaps the welding wasn’t up to the mark? Anyway, thanks for sharing your work👍😁
Haha! You got that right. Certainly not making the tool, we're lucky enough to have quite a few on hand but it's not very easy to find them here in the USA.
This is a ridiculous idea for this machine. How do you suppose I would mount the tool? Not to mention having to make it. Trepanning takes a high volume of coolant that the systems on this machine doesn’t supply.
@@EdgePrecisionTrying to be nice and offer a tip for future jobs is all I was doing. We rough an oil field job on our 17-in Clausing 10hp manual lathe, 12-in cast iron billets turned into flange connection for 4-in pipe. Very similar to what is being done in the video. No flood coolant, instead it's an air line about 10psi with coolant bled in the line. It's enough to blow the treppan clean of chips, and it never really gets hot because I'm just using a standard trigon insert at the tip. Tool on that job is made from standard DOM pipe with slots and insert pockets milled on a Bridgeport. It gets us within 0.1" of final, and then we put it in the Okuma and finish the job. Again, just trying to pass along a suggestion for a process that is pretty rarely used these days. Might help someone win a big on a job, helped us win a few oil jobs recently since our equipment is kinda outdated and we need all the help we can get.
Would it be possible to make the flange and the shaft seperate parts? Say you machine the shaft from some smaller od stock, then machine the flange and weld them together or thread them together somehow It would take more processes but would waste far less metal and money, possibly even time
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I have said it before but despite my 20+ years working in manual machine shops with a little CNC programming, these videos make me feel like a newbie.
Ive been machining for 15 years in a small shop and also feel like a newb watching these . Machines i run are much older snd smaller .
Not to say that there is not a skill for CNCing, yours is a brain and muscle skill. I would rather be a manual machinist in a job shop speaking for myself. Its an art form.
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Yes I agree with you with a CNC machine the programer makes the part, all the operator has to do is push the button. I could do that.
And that's why Peter's recycling bin weighs 10 tons...
And???
@@jansteiner2408 someone mentioned it in a earlier video, it is a longer story.
Pretty neat. One of those jobs where you are grateful for not needing to shovel out the chip pan.
Nice to see the machine moving that much material, it is a hell of a lot of chips. Just out of curiosity, it would be interesting to see if @David Wilks could come up with a way to using a parting tool then trepan the material discarding the outer portion. Then come back and rough the blank to the size you ended up with.
Don't give David any ideas 🤣
@@ChrisMaj haha what's the worst that can happen he tries it out of a piece of 718 Inco, he gets to work his trepanning muscle and we all get a video.
I had the same thought. I wonder if there are any trepanning specialists here in the U.S.
In this case, Peter got the job because he can knock 4 pieces out pretty quickly and the customer knows he's getting top quality work - quickly. Time is money, as they say.
Just thought about that when running thru comments, it could be done. And wasting all that material is such a shame ...
I’ve been reliably informed that Dave does not like parting
reminds me of those cartoons where they put a log on a lathe and turn it down to one toothpick...
Hand tool rescue did just that last xmas but with a hand plane!
⁷Utah 8 Z×9 to pi6
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LMAO!!!!
This video shows exacly why i love watching you do stuff Peter.you always do it the correct way and never cut corners. Always indicate raw stock and milling the center for perfect center. Never in a hurry 😁👍
This part is very similar in size and shape to shafts I'm machining at the moment except we shrink fit and weld the flanges after rough turning and final machine it.I guess it comes down to what it's used for.
Thank you Peter for posting this interesting video on your work. I'm sorry there are so many trolls with the same endless repetitive comment. I appreciated you answering the question so many times with patience.
I understand people don’t have the time to read over 200 comments. So I don’t mind answering the same question. It at least shows they are interested. Thanks John.
Three hours machining time is impressive. That would take my TL1 forever. Actually it wouldn’t even chuck up in the little lathe. Thanks for posting.
Bad day for the apprentice as he cleans out tons of chips.
At least the machine has a chip conveyor
😁😁😁😁
Haha. And do you think that Felix would get a broom, sweep up and move the full drums without being told. He's too busy smoking cigarettes and looking at his phone.
Impressive material removal peter.
I was thinking something along the lines of the guys with the trepanning idea, we used to have a work where we would face grove as deep as the face groove tool would go and then part it with a normal grooving tool, creating rings. We actually used the rings for the parts, would make 3 different diameter parts from the stock we had, were much smaller pieces of course :) and it was brass. Not sure you have face grooving tools that go deep enough to make it worth while in such massive stock.
Here it would make the process much longer, you would have to remove the tailstock and hammer the ring off every time, probably the time waste not worth the material saving.
You could mill two slots and get half-circles, although they wouldn't be useful for much.
I couldn't help but imagine the finished product as a massive engine valve+stem, and got chills from the size of the resulting engine to go with them =D
Very nice work. Thank you for the quality videos.
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As a young Applications Engineer in Australia I once did some test cutting for a customer in the Japanese factory on one of these machines with a 6.0m (236") bed length. Incredibly powerful and versatile machines.
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Those chips weight more than my entire machine.
LMAO
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Just incredible work! I love your videos...even though I'll probably never have the opportunity to operate machines like yours, I very much appreciate the precision and beauty of the work you do! Thanks for posting your videos, I really enjoy watching them.
All the best,
Jon
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man, this gopro enclosure is a true piece of art.
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Nice job Peter. It's good the customer let you film this job.
1 new blank, 1 new chips bin... Nifty! Thanks for the video.
I always learned something new from watching your videos.
Hello Peter.
Right after working for centerline I worked at Watson grinding (Right around the corner. ) we used to made very similar parts like that. You brought memories back to me.
Wasn’t Watson the place that blew up. That even shook the windows of my house four miles away.
@@antoniodejesuscontreras8544
en.wikipedia.org/wiki/2020_Houston_explosion
Huh! Lucky you weren't there, and I hope everybody here was all right.
Ok I’m super jealous of how you single point a 60deg tailstock center hahaha that’s awesome
You’re ready to enter the 4 jaw challenge, super heavyweight class. Keith Fenner and Adam Booth haven’t got a hope.
That is a baby chuck heck even my 36" 4 jaw is small compared to some out there but you certainly won't be dual key setting my chuck unless you have 8 foot arms. LOL
@@bcbloc02 just when you think you're king of the hill, Brian rolls in and pisses on your parade. 😉
interesting , particularly centre point milling
That was bizarre. Don't understand why that tailstock doesn't have a turret set up to centre drill.
@@millomweb probably doesn't have that future , and I think the centre point has specific angle into it
@@ParsMaker A turret lathe would do that, no problem.
Watched many of your videos, I live in Conroe , wish I could come by and watch what you do
You could trepan to the rough size of the largest diameter first: that would save a lot of time and save useful material
Forged a rough one
I do not miss working on CNCs. Love watching others do it though.
I wonder if an enormous core drill (a bit like the concrete ones) and a super-sketchy parting operation could let you keep most of that removed stock in one piece. Probably not worth it but would still be interesting.
The spindle can't take that kind of load. With the insert tooling that he had he could take much bigger cuts but the rigidity needed is ridiculous.
@@modris2980 I was thinking more like trepaning with single or maybe opposed cutters, not a full row of holesaw teeth.
Nice to get to see the heavy turning. :-)
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I like how you milled in the center instead of drilling. In thinking that is a better way considering the size of material.
I guess it gets the cutting speed up without spinning tons of metal at 2,000 rpm.
It's always better
We make a very similar shaft part like that in our shop. We get blanks with a large disk and shaft friction welded together. Thus we avoid machining all of that off of a solid billet.
This is an example of when forging could save a lot of machining time and stock. Of course, you'd need a large-enough run to justify the tooling for forging.
Exactly what I was thinking. How many parts would it take to justify having castings made for this job. 1,000lbs of chips is insane but if its only a small order, you have no choice
@@squeegied3rdeye713 Casting one-offs is a bit easier than forging, as nowadays you can actually produce your pattern with styrofoam or 3D printing rather than wood like the older way, but there's still the fact that casting isn't always foolproof. I worked few a few months for a company that machined iron castings for engine flywheels, and one part had a recurring issue with voids near the hub. Casting steel is more difficult than grey or ductile iron, from what I understand. But I've seen some neat videos of a company near me that forges similar parts for things like gear blanks, but those are done a few dozen at a time.
Wow I’ve never seen a center cut like that. Then again I’ve never been lucky enough to have live tooling. Great job!
When you mill it like that, you will always get it concentric to the rotation of the part.
You know you are worth your weight when they trust you to turn massive billets into toothpicks
this is not a billet it is a bar
@@SuperAWaC yes but please read the definition of billet
@@SuperAWaC Billet metal is a solid length (often in a square or circle profile) of material that has been extruded into shape, either by continuous casting or hot rolling. Billet material is often used in cnc machining.
@@darrennelson6803 I am a machinist. That is not a billet, it is a bar. Billets are what get made into bars. Using billet in the manner you are is a nonsensical marketing buzzword.
The process for wrought metals is usually something like:
Molten -> Bloom/Ingot -> Billet -> Bar (round/square/etc)
or
Molten -> Bloom/Ingot -> Slab -> Plate/Sheet
What you're doing is the equivalent of calling a piece of metal sheet a "slab". Imagine tearing off a piece of aluminum foil and saying "here's a slab of aluminum" or "here's an ingot of aluminum". It's just the wrong word.
@@SuperAWaC pin a rose on your nose nobody cares!! I was giving him a compliment. If you don't like it I don't care!!
This is why I advocate machines having their own jib cranes instead of trying to save money with a communal lift or having just one bridge or gantry crane. Jib cranes save so much time and effort
If the machine can handle a part or fixture weighing more than say 60-100 pounds it should have a hoist. It is also a mistake to put a 1000 lb hoist in a machine that can handle 4000 lb. put the correct size or someone will overload it!
@@EdgePrecision I visit lots of shops with a bunch of bent engine hoists sitting around
You can't always store the parts in close proximity to the machine. So, if you have to transfer the part one or more times in order to machine it you gain nothing. Normally a jib crane has a very short distance it can travel.
@@garys9694 that's why you put the parts on a pallet and then move them around with a pallet jack or forklift.
@@SuperAWaC Yeah, I know, that's what I said.
Man people should pay a lot of money to follow a master like this
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My grandpa use to co own a farm equipment dealership. There was a table there that I ended up with. It was made back in the 60s and the insurance made them get rid of it about 2015 so I got it. Its 2’ by 3’, 4” thick solid steel. An anvil table. I cant even imagine how much it weighs. It was sitting upside down on concrete blocks when I got it. I slid it and it destroyed those blocks.
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Very Nice INTEGREX.Congratulations
Damn those machines are a beast
Fantastic amazin.......
From Greece John Grizopoulos retired machinist
Such a cool video, and cool crane.
We respect our eternal teacher. skilled in processing
You know Peter, with your Forging Area you could take chips from some of these different projects and do a Damascus Knife.
Yes but this steel doesn't have a real high carbon content. OK for hammers and tools. But it should be higher for knifes. It would work maybe combined with something of higher carbon.
Great work. Thanks Peter.
I love that you can create your own center point rather than using a lathe center drill. Seems to be so much more satisfying.
I am overwhelmed by your professionalism. I would be happy if you address the questions: what makes the Mazak so accurate? stepper? Linear encoder? Rotary? Routes on linear bearings? I would love a lesson on the subject.
This machine is just servos with encoders to ball screws. The ball screws have liquid cooling run thru them. And yes the axis run on linear bearings. To get a better idea I have a video that shows these things.
Look at the video “Under the covers of the Mazak”.
Thanks !
Enjoyed Peter!
ATB, Robin
Thanks Robin!
It's jobs like this where I love hogging with my big 6 series inserts! ~400sfm .5" DOC. It makes steamy potato chips and fast work of big shafts. Just gotta have the HP and rigidity to make it all happen.
That's insane! I've never machines anything in my life, I just stumbled upon this video and I was mind blown about the .25" DOC... .5" DOC!? what kind of machine and cutting tool can do that? I'm genuinely interested, I didn't know we could move metal like this lol
Working at NOSL Louisville, I machined parts like this back in the day on manual lathes. I used to see how much of a cut the machine could handle. ( I tripped the circuit breakers a few times.) The hot chips felt good on cold winter days.
I love all the room in there...... Seems safe
That is one nice small crane you use there.
Wow that's a lot of chips . With welding technology today weld a shaft to a flange bullet and machine to specks.
Customer order do from one piece and noting else. A piece made from a solid block is always the strongest, but also the most expensive and especially for something like this since there was so much material to remove but the customer knew what he wanted no matter the cost.
@@dtiydr Yes the - customer is always right but is with over kill .A welding engineer might save him from over kill .Yes welding can be stronger than the parent metal i can tell you for sure it would work with a correct heat treating process. 🧐
@@curtisvonepp4335 That is what I said in another comment but probably after sending out for heat treatment after welding the additional cost would negate the material savings of doing it from billet instead of a 2 piece welding.
Nice video Peter, thanks!
Great work!
Nice lathe, it's bigger than my room.
Thank god you sped this up
Nice to have a job like this every day where you can sit back for an hour or two an let the machine work.
I very seldom get this circumstance. Most of the jobs I do take a lot of manual operation intervention. I did have to stop and index the insert quite a few time during this so there wasn’t a hour straight without doing anything.
Sandvik prime turning would have cut the cycle time on that quite a bit .
Yes you are right or else iscar cnmx
Now I need to go back and re-watch when you made steady rest because I didn't remember it having quick release to swing rollers out.
This is the SMW hydraulic steady rest. Normally it opens up. But I’m right at the max capacity. 16.18” dia. Of the rough stock. So I have to manually shove the arms out a little.
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I'm estimating that this is 14"-16" at the largest OD. Since the video is sped up so much, one gets the impression that the rpm is way high. If my assumption is correct, you would probably be running the spindle at 160 or 140 rpm. Am I close? It would be great if a part of the clip would show the real-time speed. The fast clip is also cool- 3 hours shown in 10 mins.
Your videos are amazing and the attention to detail is outstanding. Thanks you for sharing your experience. Respect!
I just read the description- it is 16.15" OD!
Also the clip in the video where I overlaid the machines screen. If you look it shows the rpm at the 600 sfm of the first pass.
@@EdgePrecision Absolutely! I see it now that you pointed it out. Thank you.
Scary big chunks spinning.
woooow..amazing video...i like it bro
Thanks for video. Have a nice day
side note what an incredible machine
Nice machine
for a while I thought you were going to sell us cutters and just showing off how damn fast that machine would make 800 lbs of chips.
В стружку ушло 2/3 массы заготовки, такие вещи или раздельно надо проектировать или поковку обробатывать
Слава Петров somehow came to my mind... ;-) Using forged pieces would make it faster and cheaper material-wise, but the cost of forging would be probably much higher than 400 kg of this material turned into shavings. With bigger batches, like, say 40 or 400 pcs - yes, it might be worthwhile to use forged "zagatovki", but not for a batch of just four pieces, I reckon. Also, as others pointed it out already, time is money, especially with those expensive machines, so any "economising" here would be like spending a dollar to save a dime. Split pieces design? Yes, unless specs called specifically for monolithic "dietal".
Great video, thanks!
Learned a lot from you. Thanks
tray using a thermal camera that will be interesting to see. i love u video
the chips coming off would be very hot. the cutting zone would be very hot. you wouldn't see much through the coolant. that's about it.
Hello. Make more videos with big parts like this plz.
Como siempre un video muy instructivo..gracias por tu tiempo..un saludo y mucha salud
Como siempre, gracias por sus amables comentarios.
th-cam.com/video/Ej6sLtDnY5s/w-d-xo.html
Your work is really amazing congratulation. I think that you can tray to show us one course of program piece on the PC.
GRAVY JOB!! LOVE THOSE
th-cam.com/video/Ej6sLtDnY5s/w-d-xo.html
what is the reason for cutting the center with an endmill vs just center drill it?
Yeah. Been thinking the same. Maybe he don't have center drill?
Doesn’t want to damage steady rest turning at high rpm on cold rolled steel because probably not perfectly concentric.
@@paolofracalanza6540 yeah. Make sense.
Better concentricity
Why did you not use a center drill at the beginning?
👍Lightened that dude up!
According to my cad software the part will weigh around 165 lbs when done.
Why do they turn it all the way starting from the initial od? Like why couldnt they cut down the desired od (plus an inch or two) with a hollow core bit or some sort and then cut the stock into two main pieces? I feel like that couldn’t be that difficult and would increase the value of the scrap greatly
For this few parts the cost of doing that would exceed the value of the scrap. Also the time it would take to make or acquire the tooling to do it would be to long. One other and even more important issue is there is no way on this machine for me to even do that kind of machining operation. There is no way to properly mount and support the treepanning tool. So for this customer who was in need of the parts on a shorter time schedule. This is the most economical way to go. If there were more parts and time a open die forging would be the way. This would use less steel and also require less machining roughing time.
@@EdgePrecision Awesome that makes sense, thanks for the reply. Cool video!
I was turning one of these down on my mini lathe today. Piece of cake....right? :-)
I was wondering why my lights dimmed.
I never seen a 50 hp. motor on a mini lathe .
@@assassinlexx1993 I'm running an 18 core Intel36i processor with quantum bi-lateral fuel change/crossover mother board, and ceramic bearing motor. I think that is what helps the most with limiting the light dimming. My chuck run-out is now measured in feet, instead of 10-thousandths, but I think I can use Stephan's chuck tapping video to get it back into specs.
@@number40Fan
🤣👍
Good to see you back again, yes quite a few bins of swarf, could the part not be a forging ??
It would be kind of expensive for only 4 pieces.
Watching that first lift reminded me of a co-worker that forgot to pull a fixture pin before lifting a tank laser sight off a test fixture.
$40K damage.
Thought the same. The lathe could get torn and bent by the lift in case any fixture element is forgotten to put off. 😫
That's awesome!
I'm thinking if the stock was 3D printed, there will be less waste due to machining but I'm not sure if the strength is comparable but the price would be bit higher.
Nothing but respect 👏🏽
Very cool!
Non-cnc hobby machinist here. Whats the advantage of using a drill and endmill at an angle to cut a center vs just using a center drill in this instance?
Doing it this way assures it runs concentric to the rotation. Also I don’t have a center drill in the tool changer.
@@EdgePrecision But if you are using steady rest for a raw stock isn't the center kind of out of shape?
@@ChrisMaj this material was already turned on the OD. If that wasn’t the case I would have used a center drill.
wonderful
I recommend friction welding.
Even conventional welding of a plate on the spindle would have saved a lot of material but maybe they can't find good enough welders to do a full penetration weld and then I reckon being 140 it would have to have a full heat treat done after welding so the cost of sending it out to get re heat treated is more than the material was so turn it off out of billet is the cheapest way to go.
Wow . We just did a part 10”dia x 10” long titanium
Watching just a few of your videos I have learned a great deal! I am completely new to CNC machining, so please forgive my ignorance. Is there no way to use trepanning to remove the bulk of that material? I don't know how one would deal with the big "tube" of excess material coming off when parting it, maybe that's the reason it isn't done. It just seems like such a waste to create half a ton of chips when making a shaft. Thanks very much for your excellent videos and discussions.
Look at David Wilks latest video he is doing a similar thing. It is possible on the right machine. On my machine I don’t really have the proper way to mount a treepanning tool or the volume of coolant necessary to make it work. It would be nice to have the piece of hole bar that would come from it.
@@EdgePrecision I found your site after watching David Wilks. I understand about the tool and coolant. Trepanning sure takes a torrent of coolant to cool the tool and move the chips. I hadn't thought about that. I appreciate your taking the time to respond. Thanks a lot.
It would be interesting to see the fit of the centre inside the machine centre hole. Cross section view.
th-cam.com/video/Ej6sLtDnY5s/w-d-xo.html
Seems an unusual way of preparing the centre to take the tail stock. We would just use a number 6 centre drill.
Yes it could be done that way. I didn’t have one so I did it this way.
А у нас в некоторых организациях такие ,,железяки,, на руках таскают.
Wish I was smart enough to be a machinist they make some damn good money
It's ok money. Like $60k a year
I've seen a few comments saying trepan it and part it off Peter. I have a piece of inconel 718 to do. If you get time look on my channel Wednesday. I do this a lot. It's only a small job but you'll get the drift. I made sunnppa channel to cut 95mm trepanning tool. What is the shank details of your collet. Can you use straight shank? I fancy making a smallish tool for you. This job would've been perfect to do... trepan to depth... part through. 🤔
Thanks David. It looks like I will be making some more of very similar parts for this customer. But unfortunately they all vary in size. These ones were the largest ones. All the rest will be smaller. Or so they say. I will keep a eye out for your video Wednesday.
I have a question please. What are the reason why you don’t prepare two smaller pieces, weld them together and finish them off? That would probably save you a ton of material, time, tooltip, and other... Must these pieces for some reason be made out of one solid piece? Please advise.
This is the way the original parts were made and failed. So this customer felt that in order to eliminate the possibility of that happening again, they wanted a part from solid. Also their machine was down and this was the fastest way to do it.
@@EdgePrecision thanks a lot for your swift response! Yes, I thought so myself, but a proper laid weld (x-rayed without voids) should in theory be just as strong as a solid piece. Perhaps the welding wasn’t up to the mark? Anyway, thanks for sharing your work👍😁
Intéressant
To tak jak by z jednego drzewa jedną wykałaczke zrobił😉😆 Tyle matwrjału?🤔
Czasem taniej i szybciej jest kupić cały surowy materiał jak czekać na odkuwke .
Using mazatrol? Gotta love it for these types of parts. Probobly only 3 units in the whole program
This was a Cam program but Mazatrol would have also worked as well.
just drop one of those rounds into a flat rate box and ship it to me.... That would be my perfect power hammer anvil
If you ever have to do this again, use a hollow trepanning drill and deep parting to cutoff. Would cut total job time down to maybe 20-25 minutes.
I'd like to see you trepanning this in 20-25 minutes including making the trepanning tool... :D
Haha! You got that right. Certainly not making the tool, we're lucky enough to have quite a few on hand but it's not very easy to find them here in the USA.
This is a ridiculous idea for this machine. How do you suppose I would mount the tool? Not to mention having to make it. Trepanning takes a high volume of coolant that the systems on this machine doesn’t supply.
@@EdgePrecisionTrying to be nice and offer a tip for future jobs is all I was doing. We rough an oil field job on our 17-in Clausing 10hp manual lathe, 12-in cast iron billets turned into flange connection for 4-in pipe. Very similar to what is being done in the video. No flood coolant, instead it's an air line about 10psi with coolant bled in the line. It's enough to blow the treppan clean of chips, and it never really gets hot because I'm just using a standard trigon insert at the tip. Tool on that job is made from standard DOM pipe with slots and insert pockets milled on a Bridgeport. It gets us within 0.1" of final, and then we put it in the Okuma and finish the job. Again, just trying to pass along a suggestion for a process that is pretty rarely used these days. Might help someone win a big on a job, helped us win a few oil jobs recently since our equipment is kinda outdated and we need all the help we can get.
Would it be possible to make the flange and the shaft seperate parts?
Say you machine the shaft from some smaller od stock, then machine the flange and weld them together or thread them together somehow
It would take more processes but would waste far less metal and money, possibly even time
They did do it that way. The part failed. So they are going with this.
@@EdgePrecision ok just was throwing out an idea