As a young machinist I find it amazing that a expert such as yourself is willing to break down these intricate and complicated jobs. Thank you greatly for every one of your vlogs. The lessons are worth more than their weight in gold.
Always impressed with the work produced and the lengths you go to get the job done. Making a milling spindle to machine the internals of a part that you otherwise couldn't reach, that's another level.
42:00 Peter says, “It’s a little confusing…” That means it is a LOT confusing for the rest of us! Thank goodness there are machinists like Peter who can reason their way thru very complex machine set-ups AND explain the process!
I've been working on Integrex machines for years, and I've never seen anything like this. It's very impressive. You are a well of inspiration. I hope to have your level of knowledge one day.
I’m the dial bore gage snob you were talking about haha. When I started working in a CNC QC department), I first started setting the bore gages like you were in this video. The QC department would set bore gages for the machinists to use so they save time getting the first part finished and we knew that the gauges would be set and labeled correctly. Well my first or second day on the job I set a bunch of bore gauges for a lathe machinist and left the cart by his machine. A few minutes later his lead came to me and asked for a bore gage. I set it up and handed it to him. He handed it back and said I put the gage on backwards and the anvil should be facing down. Just as he got finished explaining everything to me, the lathe machinist walked in with all the bore gauges I set , and said the gauges were on backwards haha. Ever since then I’ve always set them up with the anvil down. I’m not here to criticize anyone, but I can’t tell you how many times I’d use a bore gauge to measure something only to have a senior employee come up to me and say that bore gauges aren’t accurate or don’t repeat. “We don’t use those things here”. Really the gauge should be set in the same orientation it is to be used. I’ve always found them to be a little more sensitive with the anvil down especially when measuring a titanium or zirconium due to the sticky surface action. Anyway I love your videos. The thread milling was star of the show, super cool to watch.
Instead of tensioning the belt by moving the centre of the small spindle further and further away from the Integrex milling spindle as the belt heats up and ultimately wears, you could add a spring tensioner using one of the holes and/or features in the spare material in the big aluminium plate that you're using as the carrier for the sub-spindle. In other words, a bit like how they do on car engines for the cam belt. This would allow you to fix the vertical position of the sub-spindle and not have to apply continuously changing offsets in the vertical axis. PS - please keep it up, I absolutely love your videos, you are by far THE best machining channel on TH-cam.
Even as a viewer, my anxiety levels were off the scale as Peter cut the threads as a last operation on this part. Always a pleasure to watch, and learn from, an expert machinist.
Wow! This is crazy impressive. I absolutely love the vids Peter keep em coming! I have watched you on here for many years now. You have taught me so much! Thank you Peter☺️
Incredible... Really a great job. Congratulations... With so much inventiveness and experience you can do even the impossible... Mechanics is infinitely fascinating. In 32 years of turning I have never seen things like this. Congratulations again
i work with a integrex 300 lower turrent and a second a chuck - the whole set up the whole idea is so foking NUTS what how u make one mistake with tool change and u lose 100k ur a legend big respect cant wait for the finished part if we allowed to see it
You are really amazing.. You are so comfortable explaining what you are doing.. Just watching you put the gauge blocks together shows how much experience you have..
Very cool project. I was sorta surprised that you didn't leave some material to do a final skim with the spindle running in it's own bearings, but seeing your results I guess that wasn't needed. Hats off on getting that to program way outside the box. I've had to do some of that, and usually break down and write the gcode directly with no canned cycles so I know for sure what the machine will do. Of course, that was with a much more simple 4 axis VMC being pressed into service as a lathe. I'm sure that display jumping from radius to diameter reading came as a shock.
The thing is this machine has interlocks on it. They sort of try prevent you from running it the way I wanted in this case. But I was able to work around them in this way.
Hi Peter, another excellent video about outside the box thinking and the know how and patience to pull it off. The thread mill solution was cool, like patting your head and rubbing your belly while looking in a mirror. Well done sir. Be well to you and yours.
amazing! Just when I thought you couldn't possibly improve, you machine to a higher level. To make all of that spindle assembly to a TIR of a tenth seems an impossibility but I saw it with my own eyes. Thanks for sharing Peter!
Pretty amazing job. The fact you made that spindle and put keys slots in it, I'm impressed it's only 1 tenth. If you were going to chase that tenth, maybe make the spindle bore under size and bore it when it's running in it's bearings. Good job 👍
My question is how does this level of additional work get justified? I can imagine that the only way you could justify a few weeks or more of tangential design & fabrication of an entire extra spindle for your machine is if the job: -Paid a huge amount per part -There we’re going to be multiple parts, maybe a repeat job Thank you, Peter, for taking us along. I built many small production aids when I was job-shopping, but nothing to this scale. Truly impressive.
Right now we are making two assemblies but later there will be 10 more assemblies. Whet you are not seeing (because I can’t show it) is this part is but one part to a much larger job/assembly. Besides this will actually be a lower cost way to buying mutable 90 degree heads on the larga Okuma vertical mill. The way they originally were planning to go. I don’t know the total price of the job. But it wouldn’t surprise me if it wasn’t in the millions of dollars range.
@@EdgePrecision Ok, I understand. Thank you for your reply! I’m amazed at what you have been able to show in the first place with many of these jobs. Thanks again for the great content.
I love those Gage block accessories. I really could use a set of them. Outstanding things happening here Peter. Thanks for sharing it all with us. Edit: On dial bore gauges I like to use my 2-6" Sunnen dial bore gage an it's setting fixture when ever I can because of the way in which you can set it all up fairly easy. But it does not cover smaller ranges and I use one like you have there for the things under 2" or so. And use a micrometer to set them. I like your setting method better.
This is very amazing work as always. You are a inspiration for my carrier. I might be wrong, but it went into the hole so slowly becouse there was an air gap between the two bearing. And as you pushed the thong deeper and deeper the volume of the air gap decreased and pressurised. Looking that geometry there might be some high pressure if the air can't escape. I don't know the parameters but it might be about 140kpa.
What I really like about you is the way you think outside the box. I would also fire the guy who designed the part that this spindle is made for, and I am a design engineer.
I'm pretty sure there has to be a way to override those doors. You have often said that it bothers you. You did mention it in a other video it's not that easy because of the sensors in the door but still. Great video! Love the creativity and craftsmanship.
No there is no way without re-writing the ladder diagram on the machine. I have talked to people very knowledgeable on these machines and they say it isn’t really possible or advisable to do so. It’s not really a problem, I have gotten use to it. I only mention it in videos to show I can’t do certain things. Like you might do on other machines. Like spraying coolant from a squirt bottle or polishing on parts. I a way it makes me a better machinest. I don’t/can’t rely on those things. And it is safer.
Thread milling reminds me of my workflow: 1. I don't think that can be done 2. I think that can be done, but I don't know how to do it 3. I've worked out how to do it Obviously my problems are simpler than yours. It's quite brave to start cutting on a part you have so much work in with a process you haven't tested.
Do you build the entire cost of manufacture of this accessory into the part or to you absorb any of it due to the fact that youll have the attachment? My assumption from my (non metal) world is that I would burry the entire cost of this into the one job an if it gets used in the future it is what it is. Really impressive as always and your patience with all the comments never ceases to amaze me. Its a testament to someone who is always learning and enjoys sharing knowledge instead of being afraid of "giving away their secrets". Ive always been an open book and love to teach and share knowledge.
If you are referring to setting the bore gauges. We also have a GaugeMaker machine here to do this in inspection. But that would actually take longer. Also for the video I wanted to show how you would do such things if you don’t have expensive equipment.
@@EdgePrecision ok that makes sense with the low budget strategy to show it. Yea i mean the setting of the bore gauges. We use this digital setting bench that you can adjust to your exact measure needed for your measuring task and thats a lot faster. It can also compesate temperature deviation in the room where you have to measure. Greetings from germany, i really like your videos!
Great reverse set up. I think if I had that machine and wanted to do semi manual ops, I would determine what it would take to fool the machine into believing the doors were shut and build the device to do so. This op would have been much less stressful if you were able to add coolant and blow air on the delicate cuts. Cheers! Thanks for sharing ......
When you assemble it, maybe add a mark to both gear and the belt, just like timing chain marks on internal combustion engine. Also will you be using tensioning pulleys on this?
Once I tension the belt this belt should remain tight. It has Kevlar reinforcement. So all I have to do is unclamp the pulleys shank at the top to un mount the belt. To remount it just position the lower spindle in the correct orientation. Then orient the Mazaks spindle put the top pulley in the belt with the tool/pulleys shank in the same orientation and clamp the tool in the Mazaks spindle. Everything should still be tensioned and orientated properly. No tensioning pulley should be necessary.
Hola disculpa una pregunta conque regularidad le das mantenimiento preventivo a Tu maquinaria y a tu kit de medición y si se lleva un registro del trabajo gracias y asta luego.
I love your videos, but missed any explanation of what this is for. I saw the 2 prior videos. I finally figured it out, but a brief description would have been nice. Keep up the great work!
so good job Pete,what about putting a hex head screw at the middle of the bet to adjust tension an to assure it will mo loose tension belt,just an idea,
Now that I know there’s enough room there is. I was planning on doing that. But once this belt is tensioned I think it should retain it. It has Kevlar reinforcing so it shouldn’t stretch, hopefully?
Yeah I read all the compliments and comments he's working with what he has, it seems like he only has that one machine they can do the larger work. New shops today is a whole different story.
when you press down on the spindle and it deflects, did you check where the deflection is coming from? put the indicator on the spindle, the spindle housing, the big part it is connected to and so forth. I mean if you are going to fight the deflect with the pre-load, it might be good to know if it is the spindle that is deflecting or rest of the assembly.
If it doesn’t make much difference on the dial bore gage orientation, then why do it your way? Even a small influence from the weight is something. What advantage do you gain by having the moving anvil down?
Is it possible to block certain operations such as tool change to prevent catastrophic failures in a CNC machine? Anyways it so impressive what you are doing here!
What are you doing for coolant when you run this offset head on the actual part? In the last video it looks like you've got two o-rings in there to capture the coolant from the milling spindle's nozzles? Coolant will exit through two ports on either side of the belt cover with nozzles or loc lines? This build is really nice.
@@GRTLRS for this video I didn’t have the o-rings installed. But when there installed the flood coolant will flow out the pipe tapped holes thru lockline tubes to the tool.
Not sure if it's already been asked, or covered in another video, but is there any reason you didn't leave some meat on the bore of the new spindle so that you could give it a finish skim once all mounted in position on the machine (with a boring bar in the chuck)
@@Jelckeb Yes I made the inner spacer .001” shorter than the outer spacer. The original preload was light. This gave me a little more like a medium preload. That turned out to be good for the speed and application I planed to use. I have already done this job and it worked good.
You are a awesome machinist . I truly admire your attention to detail. However I must point out and ask, why aren't you using a coaxial indicator in the horizontal position? You always have some droop from gravity when using a regular indicator in this position. I learned that in my first 5 years of my 30years machining.
You do have to test your indicator and its arm in the horizontal position. I have tested this short arm and Interapid indicator and it has very little error. Not enough to worry about. But don’t kid yourself a coaxial indicator will also have errors. The only one I would use (if I owned one) is the Haimer Centro. But that’s a $800.00 indicator.
@@EdgePrecision fair enough you do admit there is some error , could be .0002 on top and bottom. But that's .0004 total. With that , the tru Blake indicators when new and never crashed , are very close to probes in my experience. Never seen the 800$ model your mentioning. Still, I stand by my statement you're an awesome Machinist and I could learn lots from you in design and manufacturing. 👍🏻
Old Skool Questions: 1) How much will the belt tension alter the C/L of Tool Rotation? 2) Have you considered Belt Idler Tensioning, as in Cam Timing Tensioning on Auto applications? That much RPM & Diameter will cause some Belt Flop coming off each pulley😊
In order to run this machines turning spindle it has to be in the turning mode. In the turning mode the display reads in diameter. But that’s only in the X axis. But really all programs really don’t run in diameter but in actual dimensions from the active fixture offset. But again in the lathe mode the display shows diameter mostly for the operators convenance when turning parts. So that’s why it was reading twice the dimensions in only the X axis. Even though running a milling type of program. After making the video I thought about this and I realized what was happening.
Are u worried about gravity when spinning the indicator upside down with the heavy noga arm? Ive been using a indicator with a .125" stem in the collect for doing horizontal indicating
Is this all to manufacture one part, or will you be making several of them? Can't imagine the cost of the single part (if it is only one) after taking into account the R&D of the custom tooling / fixturing... or whatever this is called... Sophisticated and out of the box thinking - very impressive.
One wonders if they couldn't have designed the part easier to machine in the first place. I guess it's how important the part is, if it's going to be manufactured, it has to be cheap to make, but some stuff is "cost no object" - or perhaps designed by someone who isn't very good at their job.
@@bhleblanc around this time last year I sold my machines to Centerline. So it will be theirs. Also there are more of these parts coming in the future. This part is only one of a larger assembly.
Would it not be possible to wire in a manual interlock switch for the doors so you can run the machine with the doors open? There must be a microswitch or light sensor that could be intercepted?
@@MJBEngineering The Mazak expert guy I have to work on my machine (not from Mazak). He says short of rewriting the machines ladder program it isn’t possible. They have tried on other machines in or area without success. Mazak really locked out these auto doors. If they were manual ones there would be no problem.
Peter, any reason you didn't use a spring loaded belt tensioner to maintain the belt tension? Would there be too much slack or potential to jump teeth during operation?
@@bigmike2232 This was the best belt length I could get. I have never seen a spring loaded belt tensioner on a spindle. Think of what would happen if you tried to do rigid tapping (I don’t intend to do this now. But who could say in the future) with such a system. This is more like a timing belt situation. Like a servo motor uses.
@TheMachinist-k9n This comment has a lot of assumptions going on. Suffice to say no one is an expert in everything and it was a general question to Peter. I'll just say you're a pot assuming I'm a kettle.
@@bigmike2232 Well he did say in the video he had enough slack in the spindle head to adjust the belt tension, and also stated there is not going to be a ton of load on the belt 🤔 But yeah, lets go ahead and add a belt tensioner that will counter-act what he stated in the video. 🙄
@@TheMachinist-k9n Again, it was simple question, and as he said "put them in the comments". I don't spend much time tearing open* mill spindles, so I don't know how they are set up. But from my limited experience, belts usually have a certain spec for tension. Either through some or tensioning device on the equipment or through deflection. I just didn't see a way to set it precisely other than the bolt and prybar. Maybe I missed it, so link a timestamp.
@@jlplumley2 yes I can, but I’m currently in Mexico till the 26th after that I will copy and past that part of the program in a comment for you. Thanks!
@@JosephColihan No I use my Esprit cam software for the basic program but it did require some manual edits. I programmed it as if the milling spindle in Cam. But manually edited the program to reverse the spindles.
From a programming perspective, is there a larger likelihood of a mistake tool change or spindle activation? I think with your tool defined as a turning tool you’re relatively safe from spindle activation but the consequences are so much greater than if it was an actual turning tool. Great work as always and thanks for sharing, looking forward to more.
@@ianbrown5314 On this machine if you define a tool as a lathe tool in the tool setup/offset window. The tool will be clamped by the spindle’s coupling at its turning orientation. Therefore you cannot turn on the milling spindle. It will give an alarm.
@@EdgePrecision Yep all from new. I wonder if it is because my sets are metric. I have 1 new set still in the cupboard I'll open it up on monday and properly check all the included paperwork in case I did miss it somehow.
I have a concern. I’ve watched you assemble gage blocks here and in the past. When we use gage blocks and we may also need to attain a 1st Article inspection we clean the gage blocks with alcohol and a lint free paper and maybe a slight air blast because inspectors will clean their gage block build up with alcohol and then clean the part with alcohol and a a tip. A truthfully almost cringe watching you assemble gages out of the box. However you get things to fit together better than most. And that’s all I’m going to say about that ;-)
@@JosephColihan I will comment on this by saying. If you are dealing with a master set of gauges in inspection. Yes clean them oil them before assembly to maintain them with the utmost care. Because they are your quantity standard. That said when you ring gauge blocks together properly you can feel if there is any thing between them when you start. If so you stop and remove any dirt. As I said in this video (or maybe the previous I can’t remember) these are shop grade B blocks and I have always treated them this way for years, without any problems. But everyone should do what they are most comfortable with, or what their quality procedure’s specify. So if that’s what you do there is nothing wrong with being more carful.
As a young machinist I find it amazing that a expert such as yourself is willing to break down these intricate and complicated jobs. Thank you greatly for every one of your vlogs. The lessons are worth more than their weight in gold.
Great result! The mental gymnastics around getting the machine to threadmill with the main spindle was mind breaking 😅 Thanks!
Always impressed with the work produced and the lengths you go to get the job done. Making a milling spindle to machine the internals of a part that you otherwise couldn't reach, that's another level.
42:00 Peter says, “It’s a little confusing…”
That means it is a LOT confusing for the rest of us!
Thank goodness there are machinists like Peter who can reason their way thru very complex machine set-ups AND explain the process!
I've been working on Integrex machines for years, and I've never seen anything like this. It's very impressive. You are a well of inspiration. I hope to have your level of knowledge one day.
I’m the dial bore gage snob you were talking about haha. When I started working in a CNC QC department), I first started setting the bore gages like you were in this video. The QC department would set bore gages for the machinists to use so they save time getting the first part finished and we knew that the gauges would be set and labeled correctly. Well my first or second day on the job I set a bunch of bore gauges for a lathe machinist and left the cart by his machine. A few minutes later his lead came to me and asked for a bore gage. I set it up and handed it to him. He handed it back and said I put the gage on backwards and the anvil should be facing down. Just as he got finished explaining everything to me, the lathe machinist walked in with all the bore gauges I set , and said the gauges were on backwards haha. Ever since then I’ve always set them up with the anvil down. I’m not here to criticize anyone, but I can’t tell you how many times I’d use a bore gauge to measure something only to have a senior employee come up to me and say that bore gauges aren’t accurate or don’t repeat. “We don’t use those things here”. Really the gauge should be set in the same orientation it is to be used. I’ve always found them to be a little more sensitive with the anvil down especially when measuring a titanium or zirconium due to the sticky surface action. Anyway I love your videos. The thread milling was star of the show, super cool to watch.
this is awesome haha
Peter you are a jedi machinest. I've machined for 46 years and I wouldn't want to have to do the amazing things you machine. You are my inspiration. 😊
Instead of tensioning the belt by moving the centre of the small spindle further and further away from the Integrex milling spindle as the belt heats up and ultimately wears, you could add a spring tensioner using one of the holes and/or features in the spare material in the big aluminium plate that you're using as the carrier for the sub-spindle. In other words, a bit like how they do on car engines for the cam belt. This would allow you to fix the vertical position of the sub-spindle and not have to apply continuously changing offsets in the vertical axis.
PS - please keep it up, I absolutely love your videos, you are by far THE best machining channel on TH-cam.
I spent 41 years as a machinist and I am pretty danged sure that anyone I ever worked with including myself could ever do this. This is genius.
You mean never?
Yes! Never! I realized what I said did not make sense afterwards. Thanks!
People accuse me of thinking upside down and backwards all the time...
Thread milling upside down and backwards. And holding grinding tolerances on a huge machine. Just another day at work for Peter. Love it!
Even as a viewer, my anxiety levels were off the scale as Peter cut the threads as a last operation on this part. Always a pleasure to watch, and learn from, an expert machinist.
Great watching your craftsmanship. The more I lean the more I realize I don't know. Thank you
Wow!
This is crazy impressive.
I absolutely love the vids Peter keep em coming!
I have watched you on here for many years now.
You have taught me so much!
Thank you Peter☺️
Great video 👍 I share with everyone watching the video you're palpable nervousness in cutting that thread 😮,we share your excitement and sweat 😊
Thank you for showing the whole systematic process that you went through to get this done. I learned a lot by watching the whole thing.
Thank you for sharing this *and* for your detailed descriptions!
Incredible... Really a great job. Congratulations... With so much inventiveness and experience you can do even the impossible... Mechanics is infinitely fascinating. In 32 years of turning I have never seen things like this. Congratulations again
Wow! That is probably the most impressive use of a machine I’ve ever seen. Truly inspiring.
Man that shot of the busy desk with the calculator and McMaster baggies ❤❤❤ a kindred spirit for sure.
You know you profession, you know your machine and your software. Expertise at its max. Thank for sharing.
Words cannot say just how brilliant you are. I just wish I had .00015 of your knowledge. Thanks for bringing us along with this video!!!
Expert work, and outstanding thinking. Thank you, Peter, for showing your work.
i work with a integrex 300 lower turrent and a second a chuck - the whole set up the whole idea is so foking NUTS what how u make one mistake with tool change and u lose 100k ur a legend big respect cant wait for the finished part if we allowed to see it
You are really amazing.. You are so comfortable explaining what you are doing.. Just watching you put the gauge blocks together shows how much experience you have..
Nice . You always do crazy stuff like this… I always like this type of millturns, it’s always seams limitless. nice job like always…
Very cool project. I was sorta surprised that you didn't leave some material to do a final skim with the spindle running in it's own bearings, but seeing your results I guess that wasn't needed. Hats off on getting that to program way outside the box. I've had to do some of that, and usually break down and write the gcode directly with no canned cycles so I know for sure what the machine will do. Of course, that was with a much more simple 4 axis VMC being pressed into service as a lathe. I'm sure that display jumping from radius to diameter reading came as a shock.
The thing is this machine has interlocks on it. They sort of try prevent you from running it the way I wanted in this case. But I was able to work around them in this way.
Peter, wonderful video! Learning from a real pro! Thank you Peter! Best, Job
Hi Peter, another excellent video about outside the box thinking and the know how and patience to pull it off. The thread mill solution was cool, like patting your head and rubbing your belly while looking in a mirror. Well done sir. Be well to you and yours.
Thank you for sharing. This work of art you created is so beautiful - I would be afraid to use it! Incredible work!! Great job!!
amazing! Just when I thought you couldn't possibly improve, you machine to a higher level. To make all of that spindle assembly to a TIR of a tenth seems an impossibility but I saw it with my own eyes. Thanks for sharing Peter!
Pretty amazing job. The fact you made that spindle and put keys slots in it, I'm impressed it's only 1 tenth.
If you were going to chase that tenth, maybe make the spindle bore under size and bore it when it's running in it's bearings.
Good job 👍
My question is how does this level of additional work get justified? I can imagine that the only way you could justify a few weeks or more of tangential design & fabrication of an entire extra spindle for your machine is if the job:
-Paid a huge amount per part
-There we’re going to be multiple parts, maybe a repeat job
Thank you, Peter, for taking us along. I built many small production aids when I was job-shopping, but nothing to this scale. Truly impressive.
Right now we are making two assemblies but later there will be 10 more assemblies. Whet you are not seeing (because I can’t show it) is this part is but one part to a much larger job/assembly. Besides this will actually be a lower cost way to buying mutable 90 degree heads on the larga Okuma vertical mill. The way they originally were planning to go. I don’t know the total price of the job. But it wouldn’t surprise me if it wasn’t in the millions of dollars range.
@@EdgePrecision Ok, I understand. Thank you for your reply! I’m amazed at what you have been able to show in the first place with many of these jobs. Thanks again for the great content.
This is a great project. Thanks for sharing!
I love those Gage block accessories. I really could use a set of them. Outstanding things happening here Peter. Thanks for sharing it all with us. Edit: On dial bore gauges I like to use my 2-6" Sunnen dial bore gage an it's setting fixture when ever I can because of the way in which you can set it all up fairly easy. But it does not cover smaller ranges and I use one like you have there for the things under 2" or so. And use a micrometer to set them. I like your setting method better.
Great work Sir, thanks for taking us along.
I can believe it made you nervous, did me as well just watching😄. Always a pleasure watching you.
I am a CNC operator on an integrex 200 , but the things you do on that machine blow my mind.😮
Thank you very much, it's very interesting! You are a very good craftsman!
Thanks for not waisting your skills running for office.
An enjoyable masterclass in precision.
Peter your work is amazing and explaining the process must take some patience
OUT OF THIS WORLD PETER. HAD TO USE CAPITAL LETTERS. ATB FROM THE UK
Wow! A true master of the craft. They say “form follows function “. If that’s true, I think it will function beautifully. 👍🇳🇱
Hi Peter, you are obviously a descendant of "Hephaestus" (the Greek God of Engineering) .......sensational work, Cheers, Davo from Aus.
Nice. You really have an open mind.
Excellent Peter, As always
Amazing job as always, you are a inspiration for my machine shop and my youtube chanel, thank you for share those ideas.
From Brazil! 👏
Awesome work Peter. Hope we get to see this thing milling the part out of some nasty unobtanium material, which I'm sure it is. :)
@@mrjacob8836 Titanium is the first job.
😅 Just following the thought process and calculations softened my brain
This is very amazing work as always. You are a inspiration for my carrier.
I might be wrong, but it went into the hole so slowly becouse there was an air gap between the two bearing. And as you pushed the thong deeper and deeper the volume of the air gap decreased and pressurised. Looking that geometry there might be some high pressure if the air can't escape. I don't know the parameters but it might be about 140kpa.
What I really like about you is the way you think outside the box. I would also fire the guy who designed the part that this spindle is made for, and I am a design engineer.
Great video I can’t wait to see it running!!
I'm pretty sure there has to be a way to override those doors. You have often said that it bothers you. You did mention it in a other video it's not that easy because of the sensors in the door but still. Great video! Love the creativity and craftsmanship.
No there is no way without re-writing the ladder diagram on the machine. I have talked to people very knowledgeable on these machines and they say it isn’t really possible or advisable to do so. It’s not really a problem, I have gotten use to it. I only mention it in videos to show I can’t do certain things. Like you might do on other machines. Like spraying coolant from a squirt bottle or polishing on parts. I a way it makes me a better machinest. I don’t/can’t rely on those things. And it is safer.
It's nice to see the whole process! Wow, 0.0001 runout. At 1:02:30, the runout looks like 0.00005.
Thread milling reminds me of my workflow:
1. I don't think that can be done
2. I think that can be done, but I don't know how to do it
3. I've worked out how to do it
Obviously my problems are simpler than yours. It's quite brave to start cutting on a part you have so much work in with a process you haven't tested.
very good video Peter
Do you build the entire cost of manufacture of this accessory into the part or to you absorb any of it due to the fact that youll have the attachment? My assumption from my (non metal) world is that I would burry the entire cost of this into the one job an if it gets used in the future it is what it is.
Really impressive as always and your patience with all the comments never ceases to amaze me. Its a testament to someone who is always learning and enjoys sharing knowledge instead of being afraid of "giving away their secrets". Ive always been an open book and love to teach and share knowledge.
This is a small part of a large job you’re not seeing. So this actually is a lower cost than other options we looked at.
The adjusting of your tools with the endblocks is very time cosuming, we use the "garant setting bench" for this in our company and its awesome!
If you are referring to setting the bore gauges. We also have a GaugeMaker machine here to do this in inspection. But that would actually take longer. Also for the video I wanted to show how you would do such things if you don’t have expensive equipment.
@@EdgePrecision ok that makes sense with the low budget strategy to show it. Yea i mean the setting of the bore gauges. We use this digital setting bench that you can adjust to your exact measure needed for your measuring task and thats a lot faster. It can also compesate temperature deviation in the room where you have to measure.
Greetings from germany, i really like your videos!
Great reverse set up. I think if I had that machine and wanted to do semi manual ops, I would determine what it would take to fool the machine into believing the doors were shut and build the device to do so. This op would have been much less stressful if you were able to add coolant and blow air on the delicate cuts. Cheers! Thanks for sharing ......
When you assemble it, maybe add a mark to both gear and the belt, just like timing chain marks on internal combustion engine.
Also will you be using tensioning pulleys on this?
Once I tension the belt this belt should remain tight. It has Kevlar reinforcement. So all I have to do is unclamp the pulleys shank at the top to un mount the belt. To remount it just position the lower spindle in the correct orientation. Then orient the Mazaks spindle put the top pulley in the belt with the tool/pulleys shank in the same orientation and clamp the tool in the Mazaks spindle. Everything should still be tensioned and orientated properly. No tensioning pulley should be necessary.
Hola disculpa una pregunta conque regularidad le das mantenimiento preventivo a Tu maquinaria y a tu kit de medición y si se lleva un registro del trabajo gracias y asta luego.
I love your videos, but missed any explanation of what this is for. I saw the 2 prior videos. I finally figured it out, but a brief description would have been nice. Keep up the great work!
so good job Pete,what about putting a hex head screw at the middle of the bet to adjust tension an to assure it will mo loose tension belt,just an idea,
Now that I know there’s enough room there is. I was planning on doing that. But once this belt is tensioned I think it should retain it. It has Kevlar reinforcing so it shouldn’t stretch, hopefully?
Yeah I read all the compliments and comments he's working with what he has, it seems like he only has that one machine they can do the larger work. New shops today is a whole different story.
when you press down on the spindle and it deflects, did you check where the deflection is coming from? put the indicator on the spindle, the spindle housing, the big part it is connected to and so forth. I mean if you are going to fight the deflect with the pre-load, it might be good to know if it is the spindle that is deflecting or rest of the assembly.
I truly love your videos. Why don't you machine the bore to the recommended ID per the bearing manufacturer's datasheet?
@@thomashoffmann4504 I’m kind of doing something a little different then they intend. Or at least I have my own ideas of what to do.
That is an impressive contraption ! I wonder if you will need a belt tensioner or idler (or two) somewhere on that belt ?
I should be able to tension the belt between the two pulleys with the adjustment I show in the video.
@@EdgePrecision Yes, that will be ok. I was worried that you might get resonance or vibration in the belt because of the long spans.
Thats absolutely crazy! But i can't imagine, what job will it be used for? Will it be used in B0 or B90 ?
will we get to see the spindle in action?
If it doesn’t make much difference on the dial bore gage orientation, then why do it your way? Even a small influence from the weight is something. What advantage do you gain by having the moving anvil down?
Is it possible to block certain operations such as tool change to prevent catastrophic failures in a CNC machine?
Anyways it so impressive what you are doing here!
Will that belt be enclosed, or will it be exposed to chips? Asking for a friend.
Actually reads lets write that down. Those are some awesome words to hear
What are you doing for coolant when you run this offset head on the actual part? In the last video it looks like you've got two o-rings in there to capture the coolant from the milling spindle's nozzles? Coolant will exit through two ports on either side of the belt cover with nozzles or loc lines? This build is really nice.
@@GRTLRS for this video I didn’t have the o-rings installed. But when there installed the flood coolant will flow out the pipe tapped holes thru lockline tubes to the tool.
Absolutely brilliant! Would scrubbing the threads with a craytex help?
It could. I just need to do a little more deburr. The fit is very close on the bearings. It could even be dirt in there.
Not sure if it's already been asked, or covered in another video, but is there any reason you didn't leave some meat on the bore of the new spindle so that you could give it a finish skim once all mounted in position on the machine (with a boring bar in the chuck)
Yes I did think about doing that. But I decided to go this way. Fortunately it all worked out.
You can use the ATC stop function to stop any tool change from getting past the rapid to tool change position.
I plan to just delete all M6 commands in the programs.
absolutely incredible... 😁
Hello, how did you determine the correct bearing preload / spacer size? Thanks!
@@Jelckeb Yes I made the inner spacer .001” shorter than the outer spacer. The original preload was light. This gave me a little more like a medium preload. That turned out to be good for the speed and application I planed to use. I have already done this job and it worked good.
nothing is impossible.....the impossible just takes a longer......my motto for 20 years
You are a awesome machinist . I truly admire your attention to detail. However I must point out and ask, why aren't you using a coaxial indicator in the horizontal position? You always have some droop from gravity when using a regular indicator in this position. I learned that in my first 5 years of my 30years machining.
You do have to test your indicator and its arm in the horizontal position. I have tested this short arm and Interapid indicator and it has very little error. Not enough to worry about. But don’t kid yourself a coaxial indicator will also have errors. The only one I would use (if I owned one) is the Haimer Centro. But that’s a $800.00 indicator.
@@EdgePrecision fair enough you do admit there is some error , could be .0002 on top and bottom. But that's .0004 total. With that , the tru Blake indicators when new and never crashed , are very close to probes in my experience. Never seen the 800$ model your mentioning. Still, I stand by my statement you're an awesome Machinist and I could learn lots from you in design and manufacturing. 👍🏻
Old Skool Questions:
1) How much will the belt tension alter the C/L of Tool Rotation?
2) Have you considered Belt Idler Tensioning, as in Cam Timing Tensioning on Auto applications?
That much RPM & Diameter will cause some Belt Flop coming off each pulley😊
@@alanmunroe8332 We will see. I haven’t tried it yet.
I like the herring bone belt,i dont think belt tension is going to be a problem.
Especially because it has Kevlar reinforcing.
I is interesting to see how gauge blocks are used.
Is the display differential due to half of the cut being below turning centre line and half of it above?
In order to run this machines turning spindle it has to be in the turning mode. In the turning mode the display reads in diameter. But that’s only in the X axis. But really all programs really don’t run in diameter but in actual dimensions from the active fixture offset. But again in the lathe mode the display shows diameter mostly for the operators convenance when turning parts. So that’s why it was reading twice the dimensions in only the X axis. Even though running a milling type of program. After making the video I thought about this and I realized what was happening.
Are u worried about gravity when spinning the indicator upside down with the heavy noga arm? Ive been using a indicator with a .125" stem in the collect for doing horizontal indicating
Is this all to manufacture one part, or will you be making several of them? Can't imagine the cost of the single part (if it is only one) after taking into account the R&D of the custom tooling / fixturing... or whatever this is called...
Sophisticated and out of the box thinking - very impressive.
One wonders if they couldn't have designed the part easier to machine in the first place. I guess it's how important the part is, if it's going to be manufactured, it has to be cheap to make, but some stuff is "cost no object" - or perhaps designed by someone who isn't very good at their job.
Do you or Centerline get to keep ownership of this tool once the parts are complete? Would you expect ever to use it again?
@@bhleblanc around this time last year I sold my machines to Centerline. So it will be theirs. Also there are more of these parts coming in the future. This part is only one of a larger assembly.
Would it not be possible to wire in a manual interlock switch for the doors so you can run the machine with the doors open? There must be a microswitch or light sensor that could be intercepted?
@@MJBEngineering The Mazak expert guy I have to work on my machine (not from Mazak). He says short of rewriting the machines ladder program it isn’t possible. They have tried on other machines in or area without success. Mazak really locked out these auto doors. If they were manual ones there would be no problem.
@@EdgePrecision Blimey that's madness. Enjoying your project, i look forward to seeing it finalised
Peter, any reason you didn't use a spring loaded belt tensioner to maintain the belt tension? Would there be too much slack or potential to jump teeth during operation?
@@bigmike2232 This was the best belt length I could get. I have never seen a spring loaded belt tensioner on a spindle. Think of what would happen if you tried to do rigid tapping (I don’t intend to do this now. But who could say in the future) with such a system. This is more like a timing belt situation. Like a servo motor uses.
It's always funny when the general public chimes in with absolutely no Idea what they are talking about. Or watching for that matter. 🤣
@TheMachinist-k9n This comment has a lot of assumptions going on. Suffice to say no one is an expert in everything and it was a general question to Peter. I'll just say you're a pot assuming I'm a kettle.
@@bigmike2232 Well he did say in the video he had enough slack in the spindle head to adjust the belt tension, and also stated there is not going to be a ton of load on the belt 🤔
But yeah, lets go ahead and add a belt tensioner that will counter-act what he stated in the video. 🙄
@@TheMachinist-k9n Again, it was simple question, and as he said "put them in the comments". I don't spend much time tearing open* mill spindles, so I don't know how they are set up. But from my limited experience, belts usually have a certain spec for tension. Either through some or tensioning device on the equipment or through deflection. I just didn't see a way to set it precisely other than the bolt and prybar. Maybe I missed it, so link a timestamp.
Can you show the written programming procedure for threading that piece? I'm interested in how you wrote the program.
@@jlplumley2 yes I can, but I’m currently in Mexico till the 26th after that I will copy and past that part of the program in a comment for you. Thanks!
Did you write the thread milling program by hand ? That’s probably the most intense work I’ve ever seen done.
@@JosephColihan No I use my Esprit cam software for the basic program but it did require some manual edits. I programmed it as if the milling spindle in Cam. But manually edited the program to reverse the spindles.
From a programming perspective, is there a larger likelihood of a mistake tool change or spindle activation? I think with your tool defined as a turning tool you’re relatively safe from spindle activation but the consequences are so much greater than if it was an actual turning tool.
Great work as always and thanks for sharing, looking forward to more.
@@ianbrown5314 On this machine if you define a tool as a lathe tool in the tool setup/offset window. The tool will be clamped by the spindle’s coupling at its turning orientation. Therefore you cannot turn on the milling spindle. It will give an alarm.
do you have a cover above the belt?
@@-rmcustoms3355 Yes the belt will be completely covered.
What grade are those gage blocks?
Class B.
Where did you get the chart for setting the bore gauge if you don't mind me asking. None of my mitutoyo bore gauges included that I'm pretty sure.
All sets I have bought new have had this chart. Did you buy new sets? I haven’t checked but I bet you could download one off their website.
@@EdgePrecision Yep all from new. I wonder if it is because my sets are metric. I have 1 new set still in the cupboard I'll open it up on monday and properly check all the included paperwork in case I did miss it somehow.
Hello Peter, I need a quote on a job, what's the best way to get in touch?
Peter,
Guess I missed the video where you explained what the purpose of this offset head was, do you mind filling us in?
@@lukegkohler Watch the video before this one. In that video I explain it.
I have a concern. I’ve watched you assemble gage blocks here and in the past. When we use gage blocks and we may also need to attain a 1st Article inspection we clean the gage blocks with alcohol and a lint free paper and maybe a slight air blast because inspectors will clean their gage block build up with alcohol and then clean the part with alcohol and a a tip. A truthfully almost cringe watching you assemble gages out of the box. However you get things to fit together better than most. And that’s all I’m going to say about that ;-)
@@JosephColihan I will comment on this by saying. If you are dealing with a master set of gauges in inspection. Yes clean them oil them before assembly to maintain them with the utmost care. Because they are your quantity standard. That said when you ring gauge blocks together properly you can feel if there is any thing between them when you start. If so you stop and remove any dirt. As I said in this video (or maybe the previous I can’t remember) these are shop grade B blocks and I have always treated them this way for years, without any problems. But everyone should do what they are most comfortable with, or what their quality procedure’s specify. So if that’s what you do there is nothing wrong with being more carful.
High class.Aliens do exist, my friends. No doubt.