Love this guy, real machinist. "You have to become one with the B Axis grasshopper". Took me a minute to orient my brain on the camera mount. This is the guy who makes stuff other shops run from!!
After watching all of these videos, It gets boring telling you the same thing over and over, so most of the time I just click "The Like Button" and say nothing. Incredible job once again Peter !!
@@EdgePrecision Not having seen the Video for the fixture, how did you calculate the COG for the set up?, do you have a balancing machine?. I know that CAD will give you a mass figure for the part and the fixture, but in my experience, unless you get that correct, the imbalance can cause a huge issue, in fact it could shake your machine to bits. lol
1ginner1 I always run this setup in the machines low range. The max RPM in low is 460 rpm. At that speed there is not a balance issue. But most of the turning part is below that so vibration is not a problem. In fact even at the 460 RPM max I can’t feel any significant vibration. I did use the cad just kept trimming and adding material until I got the center of gravity at the center of rotation. I know that’s not perfect balance but it’s close enough for this.
@@EdgePrecision Yep, I have the fortune of having both manual and CNC experience and in the old days we just used to keep adding or subtracting washers or whatever was handy to enable the set-up to work. Really enjoying the Videos, keep up the good work.
You have always made such nice looking fixtures. And always well designed. Maybe you aren't a blacksmith after all. LMAO To those of you that don't know, Peter is one of the finest machinists out there. He has continually impressed me for the 35+ years I have known him. He is a true craftsman. The video proves it beyond all doubt. Nice job Pete!!!
Gilbert, Thanks! The reason for the fixture is because I don't own a 30" 4-Jaw chuck that would be required to run this. But more than that I don't like running this big a part this much off center (About 200 Lbs. off center weight according to my cad software). In the program I have limited the speed to 500 RPM. This fixture runs with no vibration at that speed (I think it could go higher but its not necessary). The part is also firmly bolted into the fixture and can't come out.
I think the way you are doing it is best. I wouldn't use a 4 jaw if I were doing it. I noticed the counter weight. And the adjustment screws. And the strap slot. And the capture bolts. And, and, and.... You always see the bigger picture and all the conflicts. A video about the design and the fixture build would have been interesting as well. Maybe even more so. See ya soon buddy!
One of the finest machinists out there is putting it mildly! If I had to use a label , I would say something like "Master Instrument Maker" but even that does not cover CAD/CAM/Designer. Best I've ever seen after being a prototyping machinist/ for 30+ years.
Peter, keep up the vids I appreciate all the good info. Honestly I think your vids have some of the best information, have learned a lot by watching how you work.
The fixture is more interesting than the part. I’d like to see the thought behind these complicated fixtures in future videos. Watching the machining is interesting but the real brain work is designing the fixture. Thanks for sharing.
omergnl Thanks glad you liked it! This machine is a e650 the numbers in the Integrex names usually refer to the Y axis travel. In my case 650MM. This part according to my cad software has about 200 lbs. of off center weight. The fixture balances that. In low range this machine runs up to 500 RPM. It does that with no noticeable vibration.
It would be possible, but much more difficult. There are angles and undercut areas all with 32 finishes and close tolerances. Plus a ID thread. It would take many tools. As I said it is possible but this worked better. Also I had many parts so it was worth the effort for the fixture.
Wow, this is incredible!! I didn't think you can put that much weight on the spindle without damaging it. Especially since its not round. I'd imagine a lot of vibration on the spindle. Incredible work! 👍🏼
Good video :) But why do you make this on a multi axis machine instead of a horizontal mill? Sandvik, Komet and a lot of other companies can make stepped insert drills so you can make the hole in one operation.
Thanks glad you liked it. The reasons are. The bore gets larger inside past the thread and all the surfaces have to have a minimum of a 32 finish. Some with +- .001 tolerance. (This would be difficult without a U axis boring head on the horizontal mill. A attachment I don't have). Also I could drill the 1.313 dia. hole that intersects the bore after the lathe work (To avoid the intermittent cut on the lathe tools) .
This shows really well the versatility of mill turn centres..what made you go with the Mazak ..I've noticed they seem to have more models to choose from, some with bigger Y axis travel than the DMG Mori and Okuma models.
I bought the machine used from a mining equipment company in Milwaukie and had it moved to Houston. I am more familiar with the Mazak than the other brands. It is very hard to find one of these used at a decent price. I wont deal with Mori Seki because of the way they screwed me out of a warranty on a some Hitachi Seki machines after they bought the company.
Two general questions about work on the Integrex: In many videos I see you milling holes instead of drilling and boring. I have live tooling on my lathe too, obviously not like on the Integrex, but I always drill and bore. Is there a general rule that one should use the milling head for milling if possible ? Or do you just like to do it that way? Sometimes it seems like boring with a big boring bar would have been faster. Next question: Do you run the rapids at 100% ? The head seems so slow when going to toolchange for example. You do amazing work - Those blocks are scary if you mess one up.
The thing with this model of Integrex (e650H) is you can only go to X-.0393 or X-10MM. What that does is limit how far down you can get with a larger boring bar(This is not a problem with some of the newer models). That limitation is not so bad for milling but for turning it makes things more difficult. For facing you can of course index a boring bar to face down but if you are in a bore with say a 3.15" or Capto 80 size bar you can only reach down to about 3.75 in diameter. Than you have to switch to a smaller bar and than a smaller bar. It is easer just to mill some features then to drill and bore especially if you have a flat bottom. It works good to bore jaws, mill out most of the material with a feed mill than to finish with a boring bar because of the intermittent cut. The milling spindle on this Integrex has good power (50 Hp.)and RPM (10,000). On a lathe with milling on the turret this might not be the best way to go because of the limitations of the milling spindles. As to the rapid feed rates yes I am running them a 50% in the videos when the machine is running at 100% rapid for a tool change all those back sheet metal way covers slam home and it make me worry about them. The machine does it OK but for the type of work I do there is not really much advantage to running at full rapid (1600 inches per minute). I do sometimes run a tool like a feedmill that's making a lot of rapid clearance moves at 100% because of the nature of the cut and that does save a lot of time.
Thank you for the great answer! I was not aware of that X-axis limitation on that Integrex, now I understand why you're doing it the way you are now. You also gave me a good idea: Next time I am boring soft jaws I will definitely mill them first, and then just skim the last 0,3mm with the boring bar. I run my rapids at 50% too. I don't like how I can feel the whole machine moving if I run 100%.
@@Panzax1 Extremely late to this party, but if you can feel the machine move when it does a rapid then maybe it is not leveled properly? Or your acceleration parameters are set too high.
Peter, awesome professional work! Out of what material did yo make the charming fixture? And how long did it take to make it? I understand that it already makes sense to make a safe, stable and balanced fixture for this 44 parts to run but is there a chance for more repeating series to come or just a one off event? Thank you for sharing!
I have modified my post to do it. If I set custom setting 2 on the tool to 1. The program will feed from the clearance plane to the R position of the drilling cycle. Than turn the coolant and spindle on there. Than execute the drilling cycle. Than when it finishes drilling turn off the spindle and coolant at the R plane. Rapid to the clearance plane. So you set the start level (R) in the start hole. This all is automatic in the post with the tools custom setting #2 set to 1.
Serious work, fixture with for clamping the parts you also did and designed? I wonder how the counterweight was calculated so that there would be no disbalance and what were the maximum turns when processing this part?
When I drew the fixture assembly in cad. I assigned a material to each part. Than I took the model of the part and placed it in the fixture an assigned the proper material type to it. The cad software has the ability to calculate the center of the mass of all the parts together. I just adjusted the size of the counter weight until the center of the mass coincided with the center of rotation as close as possible. Now in the machining process I never have the machine out of low range. The max RPM in low is 460 RPM. The program limits the speed to 500. At that speed everything runs smooth enough to cause no problem. It is close enough not perfect but good enough.
This probably sounds mundane to most, but I'd appreciate seeing a video of mill maintenance, what sort of things you have to do and the scheduling of those things.
I did have something in mind that has to do with machine maintenance. But it will have to wait till I have to do this particular thing for the machine. In this case I am not particularity looking forward to it.
Duly impressed with the thought that went into the fixturing. The thought of turning a 500+ block of material off center scares me. The damage that something like that can do, yikes! Perhaps with enough experience one can become more secure with the process. Just wondering if you proofed the part somehow or relied on the simulation. Anyhow, thanks for taking the time to make this video.
Mārtiņš Zinbergs thanks I'm glad you liked it. I thought I had sent a reply when you sent this but I guess it didn't take. I don't have a 4-jaw for this machine large enough for this part so I made the fixture. It holds the part more securely and doesn't leave chuck jaw marks in the part.
I'm not really sure what this part does. I think is some kind of high pressure manifold. Its called on the drawing "CROSS, 4-WAY, API 2-9/16". I bet that sheds a lot of light on its application. Go figure, one of them cross things. As a machinist you don't usually know what the parts you make do. You just get paid to machine not engineer.
Yes it does. I drew up the fixture in cad and placed the part model in position. On the cad software it shows the center of gravity. I kept adding and trimming the fixture until the center of gravity matched the spindle centerline. It runs smooth up to the maximum RPM I run of 500 RPM. thanks for the comment.
That setup is truly amazing. I have machined parts off center but the one on this video looks pretty heavy and I don't see any vibration on the machine itself, that tells me the kind of balancing job you did on your fixture. Congratulations.
@@EdgePrecision peter you are a hell of a machinist great content and I love the infos that are on this comment reply please make more videos about fixturing and share and all the infos that you have no one will ever refuse awesome stuff keep going
Is the CAD software you simulate the weight balancing Solidwork? And if it is, would the analysis feature be included in the basic package of the software as a standard?
Wing Wu The software I use is SpaceClaim. All I did was model the fixture and part. Than added or subtracted material to the fixture until I got the center of gravity as close to the center of the spindle centerline as possible. You could probably do this in any software. It's not really balanced but it's close enough for this purpose. I ran the whole program in low range. The maximum speed in low is 460 RPM. It ran smooth enough at that speed.
Man, talk about high pucker factor. When those tools go flying from the tool change position to the start of the operation my heart almost stops. Do you run the first part at a slower rapid rate?
Yes the machine was set at 50% because the camera stuck to the B axis with a Noga base would fall off. This machine will rapid at 1200" a minute. When you run a program for the first time you would never catch a mistake at that speed. Also it is a very powerful machine it can do a lot of damage. Turning spindle 60 hp milling spindle 50 hp 10,000 rpm.
EIA I very seldom run a Mazatrol program. For lathe I don't mind Mazatrol but for milling I prefer EIA. I can tell what I am doing better in the cam software.
Looks like your level was really close. I was going to ask about the holding fixture but I see from the comments that you made it, very cool. What kind of thread gauge is that? I noticed a calibration control sticker on it, is that a customer requirement or your own ? Are we seeing the ops after you have dialed them in, i.e. is this the first part ?
Bill, I would like to say I'm that good with the level but it was just luck. Did you notice how the part was .0005 low in the middle? I squared the blocks before drilling that big hole. People even experienced people don't take into account stress in material when machining. That was caused by drilling that hole even that far away from the edge. The gage is a customer gage. Now days in the machining business it's all about quality control. Every thing has to be calibrated and certified. If your not prepared to do that it will limit your customers ability to deal with you. I see people on TH-cam doing things and they say that's good enough. Some times I wish I could just say that but it very seldom works that way. I don't have that luxury things have to be in tolerance or you have to have a corrective action report and a engineering deviation request filled out. What a pain. So you learn check double check don't take anything for granted. Wow am I going on I need to shut up now.
+Peter, I noticed that when you were tramming the part. But, I mis-read the direction and thought it was high in the middle. I couldn't figure out why it would be high, I'm glad you clarified that. Although I would not have even thought on that scale you would have been able to measure anything. I hear you on the the specs, I used to work in aerospace, and was involved in testing. Fortunately for me, I was doing R&D which is a bit different than the production testing done on flight hardware. That is more like what you describe, and yes what a pain somteimes....
+Bill De La Vega that Interapid indicator reads .0005" per division. By the way I have tried many different test indicators and prefer the Interapid for its high sensitivity and low stylus pressure. They are a little costly though.
Is it possible that these parts are for cci / bopp&reuther ? I made similar parts for them this and last year, also same material. Thanks in advance :)
This bore detail has a angles and undercuts that blend to each other with radi all with 32 finishes and close tolerances. Also a thread at the front of the bore. Now this wouldn’t be impossible on a vertical mill it would be much more difficult than in the lathe. This part has features on every side and is first on the horizontal mill for two operations. Than on the Mazak for the last operation. I have run this job a number of times. It was well worth the trouble to make this fixture. Also there is absolutely no risk in thus operation. The part is held on the fixture with two 1” bolts and a 1.50” cross pin. It can’t come out of the fixture. Much more secure than a chuck.
The fixture is somewhat balanced. You see the mass opposite the part? I drew that in cad and keep trimming away until the center of gravity was on the center of rotation. Its not perfect but close enough.
WOW ---that was painful to watch ---a horizontal mill and a boring head could have saved a lot of labour ---especially when clocking it up (dialing it in )-----threading and taper work could be transferred after most of the meat is taken out----why is it a machined finish and not ground? -----just wondering----the block might be out of square
Amazing how can you turn something that weighs half a ton? A metric ton? And off centre! I know this is a old video. I've not seen before. Don't know if you're guna see this comment. M
Why wouldn't you just put this in a mill and us boring heads or even a good mill can interpolate the hole precise. I don't know what tolerances you have to hit. the fixturing for this part to go into this machine doesn't seem like you would get your money back.
Derrick Klossner You are right it is possible. But the bore has tapers leading into radi all with 32 finishes and +- .001. It would take many more tools and more time on the mill to do the same thing. It only takes 3 different boring bars and one threading bar on the lathe.
Edge Precision I think it is cool. I like opinions. I work at a shop just starting into aerospace. the challenge of our shop is finding the correct machine to run a part on. there is just so many ways to make the same part.
In this video I just check the face run out to see what it was. The fixture controls that, if the part is machined square (which they were) the run out will be minimal. Well within the drawings tolerance. I just check it as a force of habit, just to see. there is no adjustment for this in the fixture. I don't know if you noticed in the video. I squared up the blocks before I roughed drilled the hole on the mill. Than on the lathe. When I ran the indicator across the top of the part to set the C zero. Did you notice the deviation from stress relieved when drilling the large hole in the face of the block?
The part can't come out of the fixture. There are two 1"-8 bolts holding it and a pin clamping it to the face. You can see them as I put the part on it. I would worry more if I was doing this in a four jaw chuck.
Edge Precision i really admire your professional knowledge and confidence. i don't know how you calculated the centrefugal force ,wich can be enourmous. once, i forgot a dial indicator attached to the spindle (total stupidity) and ran the spindle, the indicator flew of as a bullet, shattering the machine window. also, can't you damage your machine by spinning a large, off cencter part? can't it damage spindle bearings and balance? thanks for your video and answer
Fischer977 thanks! Yes it can if you let it go for to long. Usually you would stop it before it damages the bearings. What will damage spindles more often is a instant shock like rapiding into something. I have also seen a high pressure coolant gland fail and flow coolant thru the spindle bearings ruining them. The way I determined balance was in the cad software I modeled the part and fixture. Than assigned their material properties. Than added or subtracted from the fixture till the center of gravity was as close to the spindles centerline as I could get it. I limited the program to a maximum of 500 RPM. At that speed there is very little vibration.
Actually I left the machine in low range for the program. The maximum rpm is 490 in low range. No software, I just tried it once it was in the machine. It ran smooth enough at the low ranges max rpm so that was good enough.
Otto I'm not quite sure what you mean? The reason I made this fixture was #1 I don't own a 4 jaw large enough for this part. #2 the first time I ran this job I did 44 parts and have run it two times more. With this fixture it takes very little time to indicate the parts in.#3 The fixture balances the parts. #4 With this fixture it is safer because it is impossible for the part to come out of it. There is also less overhang on the spindle with it. So yes it does seem a little more complicated but in this case it was worth it.
I’m not sure. I made this video a long time ago. I will have to go back and review it. It wouldn’t be the first or the last time I’ve run into a camera in a machine.
Je ne sais pas exactement à quoi vous faites référence dans cette vidéo. Voulez-vous connaître la quantité de liquide de refroidissement utilisée ? Si tel est le cas, lors de l'usinage de métaux, il est nécessaire d'utiliser du liquide de refroidissement pour éliminer les copeaux et garder l'outil au frais afin qu'il ne perde pas son tranchant. Pitulaire pour une perceuse à canon car c'est un outil à une seule flûte avec une flûte droite. Il faut donc beaucoup de liquide de refroidissement à haute pression pour forcer les copeaux à sortir du trou.
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Love this guy, real machinist. "You have to become one with the B Axis grasshopper". Took me a minute to orient my brain on the camera mount. This is the guy who makes stuff other shops run from!!
After watching all of these videos, It gets boring telling you the same thing over and over, so most of the time I just click "The Like Button" and say nothing. Incredible job once again Peter !!
Not gonna lie, I involuntarily gasped when the spindle first turned on lol. Amazing work as always, Peter. Thanks for sharing it with us.
A machinist may not be the component designer but knowing how to design good fixtures makes all the difference!
Yes there is a certain amount of design work in planning and fixturing for machine jobs. It can make all the difference in how the job runs.
@@EdgePrecision Not having seen the Video for the fixture, how did you calculate the COG for the set up?, do you have a balancing machine?. I know that CAD will give you a mass figure for the part and the fixture, but in my experience, unless you get that correct, the imbalance can cause a huge issue, in fact it could shake your machine to bits. lol
1ginner1 I always run this setup in the machines low range. The max RPM in low is 460 rpm. At that speed there is not a balance issue. But most of the turning part is below that so vibration is not a problem. In fact even at the 460 RPM max I can’t feel any significant vibration. I did use the cad just kept trimming and adding material until I got the center of gravity at the center of rotation. I know that’s not perfect balance but it’s close enough for this.
@@EdgePrecision Yep, I have the fortune of having both manual and CNC experience and in the old days we just used to keep adding or subtracting washers or whatever was handy to enable the set-up to work. Really enjoying the Videos, keep up the good work.
You have always made such nice looking fixtures. And always well designed. Maybe you aren't a blacksmith after all. LMAO To those of you that don't know, Peter is one of the finest machinists out there. He has continually impressed me for the 35+ years I have known him. He is a true craftsman. The video proves it beyond all doubt. Nice job Pete!!!
Gilbert, Thanks! The reason for the fixture is because I don't own a 30" 4-Jaw chuck that would be required to run this. But more than that I don't like running this big a part this much off center (About 200 Lbs. off center weight according to my cad software). In the program I have limited the speed to 500 RPM. This fixture runs with no vibration at that speed (I think it could go higher but its not necessary). The part is also firmly bolted into the fixture and can't come out.
I think the way you are doing it is best. I wouldn't use a 4 jaw if I were doing it. I noticed the counter weight. And the adjustment screws. And the strap slot. And the capture bolts. And, and, and.... You always see the bigger picture and all the conflicts. A video about the design and the fixture build would have been interesting as well. Maybe even more so. See ya soon buddy!
I agree. Going through the fixture and the design thinking would be very interesting.
@@TexasHunter59 I second that, this fixture is amazing, I've learned so much just by looking at it.
One of the finest machinists out there is putting it mildly! If I had to use a label , I would say something like "Master Instrument Maker" but even that does not cover CAD/CAM/Designer. Best I've ever seen after being a prototyping machinist/ for 30+ years.
As a Mazak programmer and a general machinist I really appreciate this video you took the time to put up. BTW, awesome footage!
Thank you sir!
CarltonDry.Please sorry I didn't reply earlier I like to reply to every positive comment if possible. So thanks I appreciate your kind remarks.
I have been watching this guy's video's and I am extremely impressed by his skills.
Your machines lights were a lot brighter seven years ago.
Peter, keep up the vids I appreciate all the good info. Honestly I think your vids have some of the best information, have learned a lot by watching how you work.
that fixture is insane!!!
The fixture is more interesting than the part. I’d like to see the thought behind these complicated fixtures in future videos. Watching the machining is interesting but the real brain work is designing the fixture. Thanks for sharing.
i was wondering if an integrex i200st can rotate 500+ lbs without throwing the pieces to our heads...
scary... and awesome video
omergnl Thanks glad you liked it! This machine is a e650 the numbers in the Integrex names usually refer to the Y axis travel. In my case 650MM. This part according to my cad software has about 200 lbs. of off center weight. The fixture balances that. In low range this machine runs up to 500 RPM. It does that with no noticeable vibration.
Just the fixture is a jewel. What will the world do when you retire ?
Awesome work Sir, I was wondering could you have done that job with you big horizontal machining center?
It would be possible, but much more difficult. There are angles and undercut areas all with 32 finishes and close tolerances. Plus a ID thread. It would take many tools. As I said it is possible but this worked better. Also I had many parts so it was worth the effort for the fixture.
@@EdgePrecision Again beautiful work! Thanks for your reply.
Can you program your mazak integrex with mazatrol for angled hole drilling and other multi axis toolpaths or it is just strictly some sort of cam.
Mazatrol is able to do that as well. That said though I don’t use it hardly at all. I prefer to use cam software.
Really good fixture you built for this job . Great job well thought out . Old Tool Maker
JT Hay Fort Worth Texas
Wow, this is incredible!! I didn't think you can put that much weight on the spindle without damaging it. Especially since its not round. I'd imagine a lot of vibration on the spindle. Incredible work! 👍🏼
Good video :)
But why do you make this on a multi axis machine instead of a horizontal mill?
Sandvik, Komet and a lot of other companies can make stepped insert drills so you can make the hole in one operation.
Thanks glad you liked it. The reasons are. The bore gets larger inside past the thread and all the surfaces have to have a minimum of a 32 finish. Some with +- .001 tolerance. (This would be difficult without a U axis boring head on the horizontal mill. A attachment I don't have). Also I could drill the 1.313 dia. hole that intersects the bore after the lathe work (To avoid the intermittent cut on the lathe tools) .
没有配重的话会不会损坏主轴
Do you mean a chamfer? Maybe I misspelled something.
Hey ?, really loved that Celtic Knot. Didn't realize how much work went into it, awesome job. This video is ok.
Thanks Dennis glad you liked it.
This shows really well the versatility of mill turn centres..what made you go with the Mazak ..I've noticed they seem to have more models to choose from, some with bigger Y axis travel than the DMG Mori and Okuma models.
I bought the machine used from a mining equipment company in Milwaukie and had it moved to Houston. I am more familiar with the Mazak than the other brands. It is very hard to find one of these used at a decent price. I wont deal with Mori Seki because of the way they screwed me out of a warranty on a some Hitachi Seki machines after they bought the company.
Two general questions about work on the Integrex: In many videos I see you milling holes instead of drilling and boring. I have live tooling on my lathe too, obviously not like on the Integrex, but I always drill and bore. Is there a general rule that one should use the milling head for milling if possible ? Or do you just like to do it that way? Sometimes it seems like boring with a big boring bar would have been faster. Next question: Do you run the rapids at 100% ? The head seems so slow when going to toolchange for example. You do amazing work - Those blocks are scary if you mess one up.
The thing with this model of Integrex (e650H) is you can only go to X-.0393 or X-10MM. What that does is limit how far down you can get with a larger boring bar(This is not a problem with some of the newer models). That limitation is not so bad for milling but for turning it makes things more difficult. For facing you can of course index a boring bar to face down but if you are in a bore with say a 3.15" or Capto 80 size bar you can only reach down to about 3.75 in diameter. Than you have to switch to a smaller bar and than a smaller bar. It is easer just to mill some features then to drill and bore especially if you have a flat bottom. It works good to bore jaws, mill out most of the material with a feed mill than to finish with a boring bar because of the intermittent cut. The milling spindle on this Integrex has good power (50 Hp.)and RPM (10,000). On a lathe with milling on the turret this might not be the best way to go because of the limitations of the milling spindles. As to the rapid feed rates yes I am running them a 50% in the videos when the machine is running at 100% rapid for a tool change all those back sheet metal way covers slam home and it make me worry about them. The machine does it OK but for the type of work I do there is not really much advantage to running at full rapid (1600 inches per minute). I do sometimes run a tool like a feedmill that's making a lot of rapid clearance moves at 100% because of the nature of the cut and that does save a lot of time.
Thank you for the great answer! I was not aware of that X-axis limitation on that Integrex, now I understand why you're doing it the way you are now. You also gave me a good idea: Next time I am boring soft jaws I will definitely mill them first, and then just skim the last 0,3mm with the boring bar. I run my rapids at 50% too. I don't like how I can feel the whole machine moving if I run 100%.
@@Panzax1 Extremely late to this party, but if you can feel the machine move when it does a rapid then maybe it is not leveled properly? Or your acceleration parameters are set too high.
Peter, awesome professional work! Out of what material did yo make the charming fixture? And how long did it take to make it? I understand that it already makes sense to make a safe, stable and balanced fixture for this 44 parts to run but is there a chance for more repeating series to come or just a one off event? Thank you for sharing!
Amazing job :) How many rews in turning with this big chunck, please? And how many pots in the ATC?
I had the speed limited to 500 Rpm max for this program on the turning spindle. The tool magazine on this machine holds 80 tools.
how you made the drill enter the hole without rotation in the esprit cam .you cant tell I have not used many gun drill would love to learn how
I have modified my post to do it. If I set custom setting 2 on the tool to 1. The program will feed from the clearance plane to the R position of the drilling cycle. Than turn the coolant and spindle on there. Than execute the drilling cycle. Than when it finishes drilling turn off the spindle and coolant at the R plane. Rapid to the clearance plane. So you set the start level (R) in the start hole. This all is automatic in the post with the tools custom setting #2 set to 1.
Very good video. And the best bit? No silly background 'music'...
Do you make the fixture in house? It looks incredible.
Ok read some more comments and you did. Am in awe.
Serious work, fixture with for clamping the parts you also did and designed? I wonder how the counterweight was calculated so that there would be no disbalance and what were the maximum turns when processing this part?
When I drew the fixture assembly in cad. I assigned a material to each part. Than I took the model of the part and placed it in the fixture an assigned the proper material type to it. The cad software has the ability to calculate the center of the mass of all the parts together. I just adjusted the size of the counter weight until the center of the mass coincided with the center of rotation as close as possible. Now in the machining process I never have the machine out of low range. The max RPM in low is 460 RPM. The program limits the speed to 500. At that speed everything runs smooth enough to cause no problem. It is close enough not perfect but good enough.
Cool! something like this I thought, and in what program did you calculate all this? Is the clamping device mounted directly on the spindle taper?
The software I used was SpaceClaim. There is a chuck adapter plate bolted to the A-11 spindle taper. Than the back plate of the spindle bolts to that.
This probably sounds mundane to most, but I'd appreciate seeing a video of mill maintenance, what sort of things you have to do and the scheduling of those things.
I did have something in mind that has to do with machine maintenance. But it will have to wait till I have to do this particular thing for the machine. In this case I am not particularity looking forward to it.
love the big stuff turning fast.
Distanf2, Awesome!! Thanks!
Duly impressed with the thought that went into the fixturing. The thought of turning a 500+ block of material off center scares me. The damage that something like that can do, yikes! Perhaps with enough experience one can become more secure with the process. Just wondering if you proofed the part somehow or relied on the simulation. Anyhow, thanks for taking the time to make this video.
Mārtiņš Zinbergs thanks I'm glad you liked it. I thought I had sent a reply when you sent this but I guess it didn't take. I don't have a 4-jaw for this machine large enough for this part so I made the fixture. It holds the part more securely and doesn't leave chuck jaw marks in the part.
Balls! (you got 'em) Nice job!
Dang, I watch so many of these videos and never really think how much the workpieces weigh. Any hints to the application for such a stout block?
I'm not really sure what this part does. I think is some kind of high pressure manifold. Its called on the drawing "CROSS, 4-WAY, API 2-9/16". I bet that sheds a lot of light on its application. Go figure, one of them cross things. As a machinist you don't usually know what the parts you make do. You just get paid to machine not engineer.
Cool! Google dug up some examples, seems like it's for wells (presumably oil). Very neat, thanks for the great vids!
Takes alot of balancing to keep it turning like that with no vibration of piece and machine.
Yes it does. I drew up the fixture in cad and placed the part model in position. On the cad software it shows the center of gravity. I kept adding and trimming the fixture until the center of gravity matched the spindle centerline. It runs smooth up to the maximum RPM I run of 500 RPM. thanks for the comment.
That setup is truly amazing. I have machined parts off center but the one on this video looks pretty heavy and I don't see any vibration on the machine itself, that tells me the kind of balancing job you did on your fixture. Congratulations.
@@EdgePrecision peter you are a hell of a machinist great content and I love the infos that are on this comment reply please make more videos about fixturing and share and all the infos that you have no one will ever refuse awesome stuff keep going
...tak tomu říkám precizní práce 👉 👍👍🙋
i learn something new on every video i watch.
Is the CAD software you simulate the weight balancing Solidwork? And if it is, would the analysis feature be included in the basic package of the software as a standard?
Wing Wu The software I use is SpaceClaim. All I did was model the fixture and part. Than added or subtracted material to the fixture until I got the center of gravity as close to the center of the spindle centerline as possible. You could probably do this in any software. It's not really balanced but it's close enough for this purpose. I ran the whole program in low range. The maximum speed in low is 460 RPM. It ran smooth enough at that speed.
Man, talk about high pucker factor. When those tools go flying from the tool change position to the start of the operation my heart almost stops. Do you run the first part at a slower rapid rate?
Yes the machine was set at 50% because the camera stuck to the B axis with a Noga base would fall off. This machine will rapid at 1200" a minute. When you run a program for the first time you would never catch a mistake at that speed. Also it is a very powerful machine it can do a lot of damage. Turning spindle 60 hp milling spindle 50 hp 10,000 rpm.
Great vid.
You running mazatrol or eia?
EIA I very seldom run a Mazatrol program. For lathe I don't mind Mazatrol but for milling I prefer EIA. I can tell what I am doing better in the cam software.
Edge Precision good i am more an eia person too.
Good video keep it up
We machinists love VT Gage!
Looks like your level was really close. I was going to ask about the holding fixture but I see from the comments that you made it, very cool. What kind of thread gauge is that? I noticed a calibration control sticker on it, is that a customer requirement or your own ? Are we seeing the ops after you have dialed them in, i.e. is this the first part ?
Bill, I would like to say I'm that good with the level but it was just luck. Did you notice how the part was .0005 low in the middle? I squared the blocks before drilling that big hole. People even experienced people don't take into account stress in material when machining. That was caused by drilling that hole even that far away from the edge. The gage is a customer gage. Now days in the machining business it's all about quality control. Every thing has to be calibrated and certified. If your not prepared to do that it will limit your customers ability to deal with you. I see people on TH-cam doing things and they say that's good enough. Some times I wish I could just say that but it very seldom works that way. I don't have that luxury things
have to be in tolerance or you have to have a corrective action report and a engineering deviation request filled out. What a pain. So you learn check double check don't take anything for granted. Wow am I going on I need to shut up now.
+Peter, I noticed that when you were tramming the part. But, I mis-read the direction and thought it was high in the middle. I couldn't figure out why it would be high, I'm glad you clarified that. Although I would not have even thought on that scale you would have been able to measure anything.
I hear you on the the specs, I used to work in aerospace, and was involved in testing. Fortunately for me, I was doing R&D which is a bit different than the production testing done on flight hardware. That is more like what you describe, and yes what a pain somteimes....
+Bill De La Vega that Interapid indicator reads .0005" per division. By the way I have tried many different test indicators and prefer the Interapid for its high sensitivity and low stylus pressure. They are a little costly though.
I love watching this sort of CNC machining. It's like ballet with the potential for a train wreck.
15:18 You could command a spindle start at say 500rpm to throw the chips away so it doesn't need operator intervention.
Is it possible that these parts are for cci / bopp&reuther ? I made similar parts for them this and last year, also same material.
Thanks in advance :)
No but it is a Oilfield part.
Looks like a lot of risky business when all that could have been done and I 3 axis vertical Mill
This bore detail has a angles and undercuts that blend to each other with radi all with 32 finishes and close tolerances. Also a thread at the front of the bore. Now this wouldn’t be impossible on a vertical mill it would be much more difficult than in the lathe. This part has features on every side and is first on the horizontal mill for two operations. Than on the Mazak for the last operation. I have run this job a number of times. It was well worth the trouble to make this fixture. Also there is absolutely no risk in thus operation. The part is held on the fixture with two 1” bolts and a 1.50” cross pin. It can’t come out of the fixture. Much more secure than a chuck.
Hi peter . How much does that integrex cost new?
The newer e670H Mazak would run about $950,000.00 to $1,200,00.00 depending on the options you get.
@@EdgePrecision thank you Master Jedi Peter
What's a "chanfer"?
Welldone
You make vedio more & more
Jedi master you are
Very good work. Maybe you could make weight balancing.
The fixture is somewhat balanced. You see the mass opposite the part? I drew that in cad and keep trimming away until the center of gravity was on the center of rotation. Its not perfect but close enough.
WOW ---that was painful to watch ---a horizontal mill and a boring head could have saved a lot of labour ---especially when clocking it up (dialing it in )-----threading and taper work could be transferred after most of the meat is taken out----why is it a machined finish and not ground? -----just wondering----the block might be out of square
That is crazy. Nice
its an Integrex J 200??
The machine is a E650H
this E650H is similar to a J 200?? same kind??
Yes we also have a I-400 here the number usually refers to the Y axis travel so in my case the Y travel is 650 MM.
Amazing how can you turn something that weighs half a ton? A metric ton? And off centre! I know this is a old video. I've not seen before. Don't know if you're guna see this comment. M
Yes I see all comments. Thanks!
Which Mazak is this?
A e650H model.
Thanks. As usual you have created an exceptional video. Thank you your willingness to take time to share this.
man that is one busy friggin hole
Why wouldn't you just put this in a mill and us boring heads or even a good mill can interpolate the hole precise. I don't know what tolerances you have to hit. the fixturing for this part to go into this machine doesn't seem like you would get your money back.
Derrick Klossner You are right it is possible. But the bore has tapers leading into radi all with 32 finishes and +- .001. It would take many more tools and more time on the mill to do the same thing. It only takes 3 different boring bars and one threading bar on the lathe.
Edge Precision I think it is cool. I like opinions. I work at a shop just starting into aerospace. the challenge of our shop is finding the correct machine to run a part on. there is just so many ways to make the same part.
Wow...no counter weight needed. Is this Integrex?
U also dont use the 3d to center pieces!
I don’t like using this indicator for checking things like runout. I prefer a dial indicator for that.
@@EdgePrecision
Making molds with 0.010 mm tolerance, we also use de indicator to center/straighten pieces and the 3d for Z only!
it's great
Please make a instruction video on fixture design..
Please please
If made already share me link..
I watch all your video.
I am a learner.
Strange.......Indicating the hole first and then the face? No offence btw, I love to see your vids!!
In this video I just check the face run out to see what it was. The fixture controls that, if the part is machined square (which they were) the run out will be minimal. Well within the drawings tolerance. I just check it as a force of habit, just to see. there is no adjustment for this in the fixture. I don't know if you noticed in the video. I squared up the blocks before I roughed drilled the hole on the mill. Than on the lathe. When I ran the indicator across the top of the part to set the C zero. Did you notice the deviation from stress relieved when drilling the large hole in the face of the block?
isn't it dangerous?
The part can't come out of the fixture. There are two 1"-8 bolts holding it and a pin clamping it to the face. You can see them as I put the part on it. I would worry more if I was doing this in a four jaw chuck.
Edge Precision i really admire your professional knowledge and confidence. i don't know how you calculated the centrefugal force ,wich can be enourmous. once, i forgot a dial indicator attached to the spindle (total stupidity) and ran the spindle, the indicator flew of as a bullet, shattering the machine window. also, can't you damage your machine by spinning a large, off cencter part? can't it damage spindle bearings and balance?
thanks for your video and answer
Fischer977 thanks! Yes it can if you let it go for to long. Usually you would stop it before it damages the bearings. What will damage spindles more often is a instant shock like rapiding into something. I have also seen a high pressure coolant gland fail and flow coolant thru the spindle bearings ruining them. The way I determined balance was in the cad software I modeled the part and fixture. Than assigned their material properties. Than added or subtracted from the fixture till the center of gravity was as close to the spindles centerline as I could get it. I limited the program to a maximum of 500 RPM. At that speed there is very little vibration.
Edge Precision did you use any analysis cad modules? how did you determine the number 500 rpm?
Actually I left the machine in low range for the program. The maximum rpm is 490 in low range. No software, I just tried it once it was in the machine. It ran smooth enough at the low ranges max rpm so that was good enough.
why make it simple when you can do it the hard way am I right?
Otto I'm not quite sure what you mean? The reason I made this fixture was #1 I don't own a 4 jaw large enough for this part. #2 the first time I ran this job I did 44 parts and have run it two times more. With this fixture it takes very little time to indicate the parts in.#3 The fixture balances the parts. #4 With this fixture it is safer because it is impossible for the part to come out of it. There is also less overhang on the spindle with it. So yes it does seem a little more complicated but in this case it was worth it.
That fixture tho..
🇧🇷Daniel Machado - Brazil🌎
I think peter crashed the camera at 1137 lol
I’m not sure. I made this video a long time ago. I will have to go back and review it. It wouldn’t be the first or the last time I’ve run into a camera in a machine.
French tool
Ça doit être un vrai bazar à nettoyer ce genre de machine
Je ne sais pas exactement à quoi vous faites référence dans cette vidéo. Voulez-vous connaître la quantité de liquide de refroidissement utilisée ? Si tel est le cas, lors de l'usinage de métaux, il est nécessaire d'utiliser du liquide de refroidissement pour éliminer les copeaux et garder l'outil au frais afin qu'il ne perde pas son tranchant. Pitulaire pour une perceuse à canon car c'est un outil à une seule flûte avec une flûte droite. Il faut donc beaucoup de liquide de refroidissement à haute pression pour forcer les copeaux à sortir du trou.