I work for HiShear an aerospace fastener co. They do large lots for Boeing and Airbus. For big bolts like this one they would invest in tooling to Hot stamp the head, grind the shank, hot roll the thread after heat treating. Maybe also roll radius or Roll Burnishing the head/shank radius for higher strength. Then the part goes to plating for what ever is called out.
I have machined this material a few times before and the knowledge you gain on the manual machine really helps the speeds and feeds for when you need to program a CNC !
@@ZZZHarpy101the data sheets might contain very in depth data about the material properties (yield strength, hardenability, tempco. etc) but the machining data is more guidance to get you close as there are way too many other factors, such as tool type or machine rigidity and resonances, to give concise information.
I used to weld Waspalloy, Inconel, Monel, and a lot of other aircraft engine alloys. I worked for a company called Chromalloy which was an FAA lic. repair station. We reconditioned hot section parts and combustion chambers for a large variety of commercial aircraft engines. I worked mostly on JT-9D Pratt and Whitney parts, and GE LM-2500 parts.
Very interested to learn more about the ''manual'', or I guess ''mechanically automated control'' machining of this stuff! Were the tools you used similar to what the screw machine operators would use? i.e brazed carbide touched up on Agathon grinders type of thing?
Nickel based superalloy with, let's see, 18-21 % chromium, which is ok, 12-15 % cobalt, which is YIKES!, a significant 3.5-5 % molybdenum for increased corrosion resistance, around 3% titanium and about 1.5% aluminium, to form intermetallics (it is age-hardening), a few knife tips of carbon, boron and zircon, and the rest is incidental, so only a max. value, not a minimum required concentration. Yeah, I don't need to _see_ this alloy (congrats, you guys are the first to show it to me!) because the chemical composition tells it all. This is one nasty mother trucker!
wow this guys metallurgy is on another planet, verry cool and intresting, i am a blacksmith, so i understand, but not on the level you do =] , like i said, impressive, thanx for the comment sir, appreciate you, Kindest regards.
@@ctc2469 we make everything from the iron-bearing alloys to to the crazy expensive hafnium-bearing ones, quite the rainbow of alloys and compositions!
@@nielsoudegriep2900 Very likely, he needs to be more covert, We call it Plutonium nitrided Hornetalloy, but those in the know, know what we're talkin bout. lol
I'm literally VTL turning a Waspaloy turbine disk now... Using a 3/8 button since I don't have to get into any tight corners. The bigger radius will last waaaaay longer, for anyone that may need to know.. also a lesser depth of cut helps a ton too, but I'm using a totally different composition of insert, so I may have to order up a 433 like this guy is using. Good stuff!
lol, making a throttle shaft from Ti... the slot and the two M3 holes tested me. i quickly decided that sharpening the broken taps was the best approach... short and stumpy :) only got Ti as i couldnt find steel in ground 7mm dia... cheaply, anyway. "give it a go, huh"?
@@paradiselost9946people under estimate the power of just shortening tools all the way up. Did a bunch of 2d cut out work with 1.2mm aluminium sheet, ground my own bits to 1.3mm off the shank. Was able to drive it about 10x faster than the code that was handed to me…. People quickly stopped double guessing me “Removing 90% percent of the lifetime of the tool”….. who cares, you pay me 2 of those tools an hour, but i just created 10 machines worth of production. Who cares if I go through 1 a day.
I have heard stories from my coworkers about how some gas turbine blades we make sometimes for Siemens and they are made of that stuff. The machine that runs it shakes so much when it begins to mill that you can feel the vibrations in the floor on the other side of the factory floor. We haven’t made them while I have worked there though so i can’t say if it is true or not but maybe someday I’ll see it for myself
I used to be a metal spinner , not a cnc metal spinner!!!!i mean a manual hand spinner, in the aerospace industry. Ive spun waspalloy so many times a nd trimmed it by hand . As a sheet metal its pretty tough aswell to bend and spin
I am amazed that a part stick out thatvfar did not cause tool chatter. That wasp metal is tuff stuff. I expect the aluminum was more of a challenge in the prototyping and used for filming purposes. Thank you for the VIDEO.
Try stellite 31. I used to make the pins that pushed out the old glass headlights thats had the four protrusions on the backside. B4 heat treat they would eat an insert about every 3 parts. This was 1988-89. Then after heat treat they came back and centerless ground everything with tolerances like +.0000 -.0002 you dressed the wheel every pin.
First came across Waspalloy in Rolls-Royce back in the early 1990's. Machining ring sections for jet engines, took a lot of testing to get the operation sequence correct.
That is a thing of beauty, im the sort of person that could spend hours looking at a nicely machined part, than an real beautiful sculpture, well machined parts ARE sculptures anyway, this part gives me warm feelings, really love the surface finish, so pleasing, this video is prosented in such a detailed way, and VERRY good quality, it so sickening how good it is, i sit here like WOOOOOOOOOW, look at that, ooow, ahhhhhhhh, THANK you SO much for the satisfying factual video, 1000/10 for sure, Best wishes to you and family, and keep up this GREAT content, i want to see more, so ofcourse im subbing, thanx SO much for exsisting in this world good sir, you are a giant to me.
Good explanation, you do a good job explaining what each process does. Would this be a candidate for ceramic turning? Obviously this is for demonstration purposes, but I definitely see how having a (B?) head isn't a 'fixall' for all situations, turret tools can get much close and you can reduce hangouts a whole bunch.
When Smart Cam and Master Cam came on the scene I was able to ditch my tablet for jotting down code, calculator, trig book, speed / feed calculator and never had to proof read another tape or enter anymore data line after line by hand. Those platforms made life so much easier and opened up the machining world to the future and beyond...
If you think that's tough try nimonic PK33, I used to work in a superalloy production facility, it was hard to just cut the billets with an abrasive wheel
Water with high pressure trough the tool pointing directly on the tip of the insert can also reduce wear and you can increase speeds and feeds. 10% coolant solution is also an advantage in these difficult to cut materials.
Our company is dedicated to creating high level educational CNC machining content like this. Our goal is to bring awareness to the trade and educate people to help give them a skillset that will allow them feed their families. In addition, we will also take on unique projects for customers like machining Brandon Herrera's AK50 and making a custom billet front grille for Gas Monkey Garage. We are also continuously developing our free online CNC academy and CNCEXPERT which is a platform built specifically for CNC machinists!
Titans of CNC is basically a showroom for machine and tool manufacturers, every video you see is pretty much an ad for Machine/Tool/CAM solutions. You might also learn something in these videos. But don't go around thinking they make these videos purely for educational purposes.
Risk more than others think is safe. Care more than others think is wise. Dream more than others think is practical.Expect more than others think is possible.
Cool part, cool video. I've never used that material but you cut it well. Why do you use a tapered endmill to finish the star pattern instead of a straight endmill in an axial (horisontal) orientation to the part? Is the parts corner radius too small to allow a suitable endmill to generate the shape properly in that orientation?
I have never seen Waspalloy being machined. But I have seen a sheet metal item butt welded with TIG. A beautiful seam without filler metal. If I remember, it was also done without back-up gas. The part was likely a special nozzle, shaped as a partly flattened cone, i.e. an elliptical cross section. The welding required rather funny shape tooling.
This stuff would be a lot worse than monel. That stuff is just tough and a bit gummy, this stuff is like IRL adamantium with its chemical makeup, all it would need would be a few percent tungsten and it would be nearly impossible to machine with anything short of EDM.😮.
I would love to see you guys machine some bronze parts, specifically the type found on sea vessels. I currently work with that material as a new manual machinist, aspiring to be a CNC machinist some day.
In dental we use chrome cobalt alloys for dentures, its a total pain to finish by hand (wax up needs to be as close as possible, and sprue shouldn't be any bigger than need). However I consistently meet people who have had partials for 50+ years. Bego Wironit is Co 64.0 · Cr 28.5 · Mo 5.0 · Si 1.0 · Mn 1.0 · C
When you pushed the part into the chuck, the jaws had enough of a radius to let the bolt seat to the face of the jaws and not interfere with the radius on the inside corner of the bolt?
Hi i was wondering if the online cnc acadamy would help me working woth cnc's that work woth stone and like granite, quartzite etc. I have 7 years experience and can run some pretty advanced stuff, but i am always interested in learning everything about it. Working witg metals is fairly similar, just a little more percision but i was wondering if the academy would help me with that. Thanks
"Going a little light for the threading" sounded very uncharacteristic of both this channel and the alloy, but that chip tells me "a little light" was still pretty aggressive
“It’s really a headache finding your feeds and speeds” yeah, no kidding. This stuff is tougher than Scrooges heart at Christmas. Especially if it’s already been hardened. We’ve been gobbling up inserts like a fat kid with unfettered access to a candy bowl.
For cutting aluminum "dry" for camera purposes I would suggest giving the piece a little spray of WD-40 first. Will cut much better and still give you a great shot.
СОЖ льется везде, но не там где нужно. Для обработки труднообрабатываемый материалов это очень важный фактор, который влияет на стойкость инструмента. Не уже ли у kennametal нет державок с подводом СОЖ на режущую кромку. Если нет то купите у Sandvik, бонусом видео будет приятней смотреть.
I work for HiShear an aerospace fastener co. They do large lots for Boeing and Airbus. For big bolts like this one they would invest in tooling to Hot stamp the head, grind the shank, hot roll the thread after heat treating. Maybe also roll radius or Roll Burnishing the head/shank radius for higher strength. Then the part goes to plating for what ever is called out.
Fascinating
So mostly no "cutting"? I guess that makes sense.
If you don't need to, don't.
Какая твёрдость по Роквелу у этого материала, после закалки?
@@johnathanmandrake7240Rolled threads are stronger too.
25-30Hrc after age hardening @@ЖелезнаяЖизнь
I have machined this material a few times before and the knowledge you gain on the manual machine really helps the speeds and feeds for when you need to program a CNC !
Question🤔. Why do material engineers provide data sheets for Waspaloy if machinists prefer to guess speeds and feeds on trial and errors?
@@ZZZHarpy101the data sheets might contain very in depth data about the material properties (yield strength, hardenability, tempco. etc) but the machining data is more guidance to get you close as there are way too many other factors, such as tool type or machine rigidity and resonances, to give concise information.
What RPM is he getting at 100 SFM?
That is one really expensive bolt.
CNC machines always amaze me. And what is even more amazing are the machinists that program the setup of a part.
I used to weld Waspalloy, Inconel, Monel, and a lot of other aircraft engine alloys. I worked for a company called Chromalloy which was an FAA lic. repair station. We reconditioned hot section parts and combustion chambers for a large variety of commercial aircraft engines. I worked mostly on JT-9D Pratt and Whitney parts, and GE LM-2500 parts.
I used to run this stuff on a turret lathe many years ago. We used cutting oil, low rpm and heavy feeds. Sharp tools are a must.
Very interested to learn more about the ''manual'', or I guess ''mechanically automated control'' machining of this stuff! Were the tools you used similar to what the screw machine operators would use? i.e brazed carbide touched up on Agathon grinders type of thing?
Nickel based superalloy with, let's see, 18-21 % chromium, which is ok, 12-15 % cobalt, which is YIKES!, a significant 3.5-5 % molybdenum for increased corrosion resistance, around 3% titanium and about 1.5% aluminium, to form intermetallics (it is age-hardening), a few knife tips of carbon, boron and zircon, and the rest is incidental, so only a max. value, not a minimum required concentration.
Yeah, I don't need to _see_ this alloy (congrats, you guys are the first to show it to me!) because the chemical composition tells it all. This is one nasty mother trucker!
Sounds like the metallic equivalent of dragon scales. It would be both hard and tough. 😮
wow this guys metallurgy is on another planet, verry cool and intresting, i am a blacksmith, so i understand, but not on the level you do =] , like i said, impressive, thanx for the comment sir, appreciate you, Kindest regards.
Working in a foundry that makes this stuff, don't worry, melting and alloying it is just as much of a pain as machining it is!
@@gibbygaming792 yes it is worked as an operator making these superalloys for 15 yrs (portland,or)
@@ctc2469 we make everything from the iron-bearing alloys to to the crazy expensive hafnium-bearing ones, quite the rainbow of alloys and compositions!
I used to turn Waspaloy to make high performance bolts for F1.
Is it like the headbolts?
@@nielsoudegriep2900 Likely that and Conrod bolts, Im curious as well
@@drd1924 i think hes being held hostage by his f1 team already for spreading the secret weapon is waspaloy🤫🤣
@@nielsoudegriep2900 Very likely, he needs to be more covert, We call it Plutonium nitrided Hornetalloy, but those in the know, know what we're talkin bout. lol
I had the pleasure of turning this on a big DSG lathe. A special "one off "for an oil company. It certainly was a massive learning curve for me!!
Nice work Tyson! Thanks for taking us through the entire process!
Why doesn’t he show what the actual RPM was he was turning that at?
Great video. Mechanical work of art. Love your programming explanations.
I'm literally VTL turning a Waspaloy turbine disk now... Using a 3/8 button since I don't have to get into any tight corners. The bigger radius will last waaaaay longer, for anyone that may need to know.. also a lesser depth of cut helps a ton too, but I'm using a totally different composition of insert, so I may have to order up a 433 like this guy is using. Good stuff!
The pain shows up when attempting to bore and thread smaller diameter features on super alloys.
lol, making a throttle shaft from Ti... the slot and the two M3 holes tested me.
i quickly decided that sharpening the broken taps was the best approach... short and stumpy :)
only got Ti as i couldnt find steel in ground 7mm dia... cheaply, anyway. "give it a go, huh"?
@@paradiselost9946people under estimate the power of just shortening tools all the way up. Did a bunch of 2d cut out work with 1.2mm aluminium sheet, ground my own bits to 1.3mm off the shank. Was able to drive it about 10x faster than the code that was handed to me…. People quickly stopped double guessing me “Removing 90% percent of the lifetime of the tool”….. who cares, you pay me 2 of those tools an hour, but i just created 10 machines worth of production. Who cares if I go through 1 a day.
Machined this decades ago, at Boeings real machine shop, for the space shuttle engines.
I have heard stories from my coworkers about how some gas turbine blades we make sometimes for Siemens and they are made of that stuff. The machine that runs it shakes so much when it begins to mill that you can feel the vibrations in the floor on the other side of the factory floor. We haven’t made them while I have worked there though so i can’t say if it is true or not but maybe someday I’ll see it for myself
It is true.
YES MORE TYSON! THE RETURN OF THE KING!
I learned about this stuff from my parents on an awesome take your kid to work day. Turbo machinery is very interesting
I don't think I've ever subscribed so fast to someone's channel.
Very thorough presentation , thank-you ,,, !
As someone who knows nothing about machining and manufacturing, I found this completely entrancing.❤
Great work Tyson! Speeds and feeds are KING!
Another great video Tyson. Always sooo easy to follow. 💪
Its cool to see things being made with this alloy i worked at a foundry making these types of alloy (wasp,hastelloy x,718 etc) for 15yrs
I used to be a metal spinner , not a cnc metal spinner!!!!i mean a manual hand spinner, in the aerospace industry. Ive spun waspalloy so many times a nd trimmed it by hand . As a sheet metal its pretty tough aswell to bend and spin
I am amazed that a part stick out thatvfar did not cause tool chatter. That wasp metal is tuff stuff. I expect the aluminum was more of a challenge in the prototyping and used for filming purposes.
Thank you for the VIDEO.
There was fine chatter during roughing which was removed by the finishing tool.Chatter was loud and clear during roughing.
I know a thing or two about what you're saying but I mostly love watching the machine put in some work
Excellent job Tyson.
Where the heck do you get your music? It's absolutely incredible! If I can find a playlist that I can listen to for hours I would be so happy.
Try stellite 31. I used to make the pins that pushed out the old glass headlights thats had the four protrusions on the backside. B4 heat treat they would eat an insert about every 3 parts. This was 1988-89. Then after heat treat they came back and centerless ground everything with tolerances like +.0000 -.0002 you dressed the wheel every pin.
Good work Tyson👏
I work on this everyday! Parts for the F22 🔥🔥🔥
Wonderful material! I've welded quite a bit of it over the years for turbo machinery shops.
Lots of information, thanks
First came across Waspalloy in Rolls-Royce back in the early 1990's. Machining ring sections for jet engines, took a lot of testing to get the operation sequence correct.
This is over my head, but damn I love veiwing. Carry on.
Awesome Content As Always Tyson 👍
That is a thing of beauty, im the sort of person that could spend hours looking at a nicely machined part, than an real beautiful sculpture, well machined parts ARE sculptures anyway, this part gives me warm feelings, really love the surface finish, so pleasing, this video is prosented in such a detailed way, and VERRY good quality, it so sickening how good it is, i sit here like WOOOOOOOOOW, look at that, ooow, ahhhhhhhh, THANK you SO much for the satisfying factual video, 1000/10 for sure, Best wishes to you and family, and keep up this GREAT content, i want to see more, so ofcourse im subbing, thanx SO much for exsisting in this world good sir, you are a giant to me.
Very Informative. Great.
This is something I'd love to get into for a living. Basic Machinist Here. (No CNC Exp, all manual)
Tyson is such a wizard
Good explanation, you do a good job explaining what each process does. Would this be a candidate for ceramic turning? Obviously this is for demonstration purposes, but I definitely see how having a (B?) head isn't a 'fixall' for all situations, turret tools can get much close and you can reduce hangouts a whole bunch.
Mastercam sure seems a lot easier than writing the code by hand
I mean that is kinda it's whole point lol
It definitely is.
When Smart Cam and Master Cam came on the scene I was able to ditch my tablet for jotting down code, calculator, trig book, speed / feed calculator and never had to proof read another tape or enter anymore data line after line by hand. Those platforms made life so much easier and opened up the machining world to the future and beyond...
15:04 The sound of the wasp ! 😄
Happiness mainly comes from our own attitude, rather than from external factors.
If you think that's tough try nimonic PK33, I used to work in a superalloy production facility, it was hard to just cut the billets with an abrasive wheel
Nothing diminishes anxiety faster than action.
Sounds like some seriously tough material! :D
Water with high pressure trough the tool pointing directly on the tip of the insert can also reduce wear and you can increase speeds and feeds.
10% coolant solution is also an advantage in these difficult to cut materials.
I just started a set up on some MP35N material. This stuff is hard!! I started at 100 SFM right from the gate. So far so good.
What do you people do now? Are you a shop....making parts for customers? Are you a school? What exactly are you all into?
Our company is dedicated to creating high level educational CNC machining content like this. Our goal is to bring awareness to the trade and educate people to help give them a skillset that will allow them feed their families. In addition, we will also take on unique projects for customers like machining Brandon Herrera's AK50 and making a custom billet front grille for Gas Monkey Garage. We are also continuously developing our free online CNC academy and CNCEXPERT which is a platform built specifically for CNC machinists!
Making money I would suggest.
Titans of CNC is basically a showroom for machine and tool manufacturers, every video you see is pretty much an ad for Machine/Tool/CAM solutions. You might also learn something in these videos. But don't go around thinking they make these videos purely for educational purposes.
Everything fun and profitable
@@emilkofod Thanks....how do you all make money??
Everyone can taste success when the going is easy, but few know how to taste victory when times get tough.
Some gnarly stuff for sure! If you know you know!
This is so damn cool in 1000 different ways! I would pay for a guided tour and even to do some work 😁
Risk more than others think is safe. Care more than others think is wise. Dream more than others think is practical.Expect more than others think is possible.
Cool part, cool video. I've never used that material but you cut it well. Why do you use a tapered endmill to finish the star pattern instead of a straight endmill in an axial (horisontal) orientation to the part? Is the parts corner radius too small to allow a suitable endmill to generate the shape properly in that orientation?
Miracles come in moments. Be ready and willing.
I have never seen Waspalloy being machined. But I have seen a sheet metal item butt welded with TIG. A beautiful seam without filler metal. If I remember, it was also done without back-up gas. The part was likely a special nozzle, shaped as a partly flattened cone, i.e. an elliptical cross section. The welding required rather funny shape tooling.
I work in a machine shop in Vegas and all we turn is monel inconel and waspaloy
They have conventional or CNC machines
I feel sorry for you bro, no aluminium butter...
This stuff would be a lot worse than monel. That stuff is just tough and a bit gummy, this stuff is like IRL adamantium with its chemical makeup, all it would need would be a few percent tungsten and it would be nearly impossible to machine with anything short of EDM.😮.
You ever turned MP35N?
It must be squeaky in there
I would love to see you guys machine some bronze parts, specifically the type found on sea vessels. I currently work with that material as a new manual machinist, aspiring to be a CNC machinist some day.
Haha here is the secret to machining bronze, let it cool before you take your measurments.
The Sketchy King meme is so good hahahaha
Chef's kiss, it's a beautiful 😚🤌
Nice video Tyson! Waspolloy can be AWFUL to machine.
Awesome video. Perfect style and great information. Love the lack of macho b.s..
In dental we use chrome cobalt alloys for dentures, its a total pain to finish by hand (wax up needs to be as close as possible, and sprue shouldn't be any bigger than need). However I consistently meet people who have had partials for 50+ years. Bego Wironit is Co 64.0 · Cr 28.5 · Mo 5.0 · Si 1.0 · Mn 1.0 · C
When you pushed the part into the chuck, the jaws had enough of a radius to let the bolt seat to the face of the jaws and not interfere with the radius on the inside corner of the bolt?
It doesn't sound like that will ever be on my travel list.
Hi i was wondering if the online cnc acadamy would help me working woth cnc's that work woth stone and like granite, quartzite etc. I have 7 years experience and can run some pretty advanced stuff, but i am always interested in learning everything about it. Working witg metals is fairly similar, just a little more percision but i was wondering if the academy would help me with that. Thanks
Amazing 🤩❤️
Imagination is not a talent of some men but is the health of every man.
Wish there was on-screen translations for imperial to metric 8) E: Well well well, found the conversions! Now I'm a happy clam
"Going a little light for the threading" sounded very uncharacteristic of both this channel and the alloy, but that chip tells me "a little light" was still pretty aggressive
You are always free to change your mind and choose a different future, or a different past.
“It’s really a headache finding your feeds and speeds” yeah, no kidding. This stuff is tougher than Scrooges heart at Christmas. Especially if it’s already been hardened. We’ve been gobbling up inserts like a fat kid with unfettered access to a candy bowl.
Roll threads on this stuff all the time, definitely prefer it over multiphase
For cutting aluminum "dry" for camera purposes I would suggest giving the piece a little spray of WD-40 first. Will cut much better and still give you a great shot.
Well after the first pass there is nothing left on the surface so no point besides making smoke.
Isopropyl 99%, no smoke
solid gold
Great job Tyson lets keep up the Lathe content.
Face your deficiencies and acknowledge them; but do not let them master you. Let them teach you patience, sweetness, insight.
Wow this is NUTS,
*bolt
Hi I really enjoyed this video👍
Is there a reason why you didn't use a continuous spiral path for the finishing pass of the star?
A life spent making mistakes is not only more honourable but more useful than a life spent in doing nothing.
I cant believe it the first video Ive seen from you guys where the rpm isnt 20k or 20 inches
If we learn to open our hearts, anyone, including the people who drive us crazy, can be our teacher.
It is better to take many small steps in the right direction than to make a great leap forward only to stumble backward.
So it that a $5000 bolt? Cause that seems like a lot of work to make a damn bolt. Holy moly!
A man who doesn't trust himself can never really trust anyone else.
I thought red would have felt warmer in summer but I didn't think about the equator.
I’m just a packaging service tech, holy shit this is super cool!
I want to see machining Hafnium!
Why are airplanes so expensive? This is why. One freaking bolt took that long. Truly amazing
Jinxed yourself when you said " Tool Life"
I’ve seen the same bolt on Alibaba for .39 cent
Nice part, I'd love to be able to program the star pattern
What make this material superior to others in application? BOOM
Heat resistance. And hardness.
Do ES-1 or Aermet next if you haven't already.
is waspaloy easier or harder to machine than inconel? In my shop we never run inconel above 90 SF/M. These speeds and feeds seem high.
The cobalt added to the alloy likely makes it more difficult than most of the Inconel family.
What rpm is he using? What does 100 SFM calculate to for a piece that diameter?
Very interesting…..approximately what would a bolt like this cost to fabricate ?
Rolled threads and forged heads are substantially stronger. Just look at how bicycle spokes are made. High tension fine threads.
The best thing about the future is that it only comes one day at a time.
Now that's one expensive bolt that I couldn't afford
While we try to teach our children all about life, our children teach us what life is all about.
СОЖ льется везде, но не там где нужно. Для обработки труднообрабатываемый материалов это очень важный фактор, который влияет на стойкость инструмента. Не уже ли у kennametal нет державок с подводом СОЖ на режущую кромку. Если нет то купите у Sandvik, бонусом видео будет приятней смотреть.