Probably the smartest man of my lifetime. The stuff you think of and how you do things is incredible. You make everything look easy. Glad you are teaching all of us. You are an artist of the trade.
Air cuts (29:00) are way better than crashes! When my company got its first CNC mill back around 1968, we crashed so many tools learning to program it to machine cylinder heads, we finally got big blocks of styrofoam to perfect the tool paths on. Way cheaper than busted castings, cutting tools & spindles.
I just started running a BIG mazak smoothG lathe last week after a year of a qt300 on production. Finally got into a shop not unlike the work you do here, and finally getting some worthwhile experience. Love the content man.
Hey Peter that was an epic part, the thought and time spent doing it right is amazing. hats off to you sir the only channel on youtube that can get me to watch cnc ops continuously. your a master at what you do!
Thanks so much for your time, and your fantastic attention to the details your tell us in your videos. You sir are an inspiration and a fantastic teacher. Thanks so much 👍
Wow! I am in awe of your machining and programming skills. And I'm a retired tool and model maker with many years of CAD/CAM/CNC machining. I thoroughly enjoyed this series and all of your videos. Thank you very much for making my day Peter
I have to ask, how does this job rank among the average jobs you do. Is it a heightened challenge? Is it something not many can do? Is it lucrative because it is exclusive, or is it not that lucrative because it is complicated... really interesting process, video, and part. Long time subscriber here, so thanks for the amazing content.
Thanks Boss for the work put into making and sharing these two videos! As a pilot and a 'for fun' machinist, I now more fully understand why airplane parts are so expensive😁 That angle drilling was wild. Regards/greg
Currently in a collegiate motorsports club and we are very lucky to have access to some haas cnc mills and lathes to machine our gearbox and other parts. Wanted to say your videos are like mind-candy and its awesome to be able to watch someone with so much knowledge go through in so much detail. Thank you for your in-depth explanations of it all, I enjoy watching and learning!
Incredible! What a programming job not much cutting a lot of programming. I thought I did difficult parts with machining Wing ribs for commercial Boeing aircraft from solid block. I did those for about 7 years using Catia, and 3 axis vertical Mills. Lot of contouring minimum six operations. I thought I did a long programming job wow great job Peter thanks for the videos!
Well Peter, amazing job you did there, hats off for you, ...... better than all those blaa blaa blaa pro's out there. 😉 More than 7 videos with over 4 hours of awesome craftsmanship, you handled some serious stuff. Thank you sir for the great content. 👍👍
Abso-freakin-loutely cool videos for this project as always. I'll say it again your air knife shows the best views even when flooded coolant. Curious if you had to replace any of the coolant driven right angle head bearings during the course of the run or did they hold up? Totally impressed with the planning and execution. Thanx for sharing.
Hey Peter, thats really great work. I like the steady rest design and your coolant powered tooling holders. These are really tight tolerances for a part of this size, obviously you aren't heating the part up with the machining you are doing, but I wonder how many degrees of ambient temperature would make the parts out of spec ! I am very surprised that the designers chose to reference a forging surface for (what looks to me like) mounting holes. I would bet that in the final assembly, all the other parts would be attached to the machined surfaces. I suppose that it could be for clearance for a yoke that has to go around the part. Anyway really good content, I always enjoy watching your videos.
BTW, you can hold the camera in hand with a cheap tool called a "gimble", and it will steady the horizon on your camera, no matter what position you put your hands in while carrying it. It's not really needed for what you're doing here-- but if you ever were to give a shop tour or anything like that where you needed to carry the camera, a gimble makes a huge difference. They make them for phones and go-pro's, ect.. many different types to choose from.
I actually have a gimble. But its to large to fit in the areas I'm showing. Also it takes to much time to get ready for this kind of thing. If I was doing a lot of walking shots and had the time to get it ready. Then maybe.
I'm assuming your using GD&T per ASME Y-14.5. You mentioned you have a .005 true position Q: does the feature control on the drawing allow for a modifier? Like MMC (maximum material condition) Cool part
Hi Peter, Ide be interested to know how many programmes it took to produce these parts and how many tools it took. Amazing work as always. Best wishes, Mal.
I always use a crappy mill and an ok lathe to invent new machines for work. When I include a grinder, a cut off wheel, welder, and a sander, It just seems to work. I get by, but I always have to massage most of the pieces. I have a new project for another company that I am tasked with. Could you recommend a new inexpensive CNC mill for me? I have no digital readout on either the lather or this crummy manual mill. Would you recommend a small Haas and Mastercam? I am familiar with Mastercam .
If you're familiar with MasterCam, AND, it can program 99% of the features, go with familiarity. The tolerances of the part dictate the machine. If they are open(+/-.001 to 0.005), then an inexpensive Haas will work. If you're trying to hold less than 0.001 all day on many parts, make sure the machine can perform this requirement by insisting on a runoff of components, 30 piece runoff is normal. Any good machine manufacturer will welcome the opportunity to showcase their machines capability. Hope it all works out, Jay.
Not really because the tailstock has to be engaged. It cant be somewhere in the middle of its travel. It has to be in or out. For the machine to run. I guess maybe something could be attached to the center that's there. If it could be adjusted into the part with the tialstock fully retracted. Maybe that could work. The tail center is really a dead center with a #6 morse taper. The bearings are in the quill. It can be taken out and replaced with a different one.
I do not understand why you are correcting for the 0.021" offset in the middle section because the bore ID of the overall part is aligned with the ends. Did the client instruct you to maintain uniform wall thickness in that section?
If I didn't run that milling off center (The .750 Ball mill you saw in the video) it would dig in on one side and be away of the other. Because the raw forging is not centered in that area in relation to the finished turning.
@@slavepetrich just the milling on the top of the ears adjacent to the raw forged sides. (With the .750 ball mill in the video). Was done on G57. All the holes and all other milling were on G54 offset. In this final setup.
They are video cameras. This machine was originally equipped with two of them. The one you see and one where the tool changer arm picks up the tool from the carrier coming from the tool magazine. The machine also had what they refereed to as a tower. This tower sat where I have the tool box in front of the machine now. It just got in the way of the access between the crane's column and the machine and could not really be moved like the toolbox. So I eliminated it. It had the computer that was connected to these cameras. All this doesn't really help with running the machine so it no longer works. Except for maybe the camera at the tool changer position. But now I can just remove the panel in front. This couldn't be done if the tower was blocking it's access. I think all this was for some kind of selling point to be able to connect this to a network so some office person could look at the machine. As I said it serves no machining purpose so I disconnected all of it.
@@EdgePrecision That makes sense! Thanks for answering so fully. If it's in the way, off it goes if it no longer serves a purpose. Relating to the tool changing of your machine, I've noticed that the 'park' position of the spindle awaiting to go through the magazine door is very far away in the Z axis. I understand the Integrex machines can be equipped with monster length tools and this is necessary for those, and I've seen you use decent length gun drills on the channel. Have you considered changing the machine parameters for the spindle to be closer to the door during toolchanging to save on time for shorter tools, or do you subscribe to the 'If it aint broke don't fix it' philosophy?
On the horizontal centerline parallel to the Z axis? Yes it is. This is pretty much controlled by the height of the tail stock center and the chuck. One thing I didn't show in the video. It is necessary for the part to be running true in the chuck at that end. Witch I did check before running the part. But for some reason I forgot to show in the video.
@@EdgePrecision oke. I mean the height on your cnc readout should be identical: it more of a double double check. Cheers. Very nice series on this very complicated part which you can't to affort to screw up. Forging a new one probably means you will lose money. So each one has to be right on the money. The hardest part is getting the first one as perfect. The second one is a lot easier etc etc. Much respect on the detail that goes in into each step. Cheers!
Yeah, but it's easy to see why. One mistake and he has to start all over on the entire thing; so there's a lot of risk happening as a constant. So there needs to be plenty of profit margin there to ensure that the job can even get finished in the first place. With great risk comes great reward.
I was surprised that you indicated on the forging, rather than the machined surface. 19:50 ... Why not use the machined surface on either side of the forging surface to do your indicating? How can you trust the forged surface to be precise? 19:50 (right click this number and "open in new tab", and it will take you right to that point in the video)
The purpose of indicating the raw forging in that area was for the milling on the ears next to it. Because it isn't in the center the milling would cut more into one side than the other. so those cuts have to be centered on the rough forging. I did mention this in the video.
@@EdgePrecision I know you did.. But I still didn't understand; I assumed you established those center holes on the ears by measuring from the the main center axis that you machined. I'll go back and watch it again-- because I'm still thrown off by how precise the hole has to be, but the ear around it is centered on the forging. idk? I must have missed something
@@EdgePrecision Oh, I see now. I watched it again-- I get it now. So out near the holes on the ears, you're still measured off of the main center axis-- but towards the base of the ears-- you change to the forging axis again so that it will transition nice. That's a nice catch, did you notice that when running a pre-simulation-- or did you catch that intuitively? I would have likely gouged the first one before I realized such a subtle detail. lol
I do need a new pare! I haven’t got around to getting new ones. A while back I set them on my stool. Than I sat on them and broke the frame at the hinge. Now they are held together with tape and superglue.
Probably the smartest man of my lifetime. The stuff you think of and how you do things is incredible. You make everything look easy. Glad you are teaching all of us. You are an artist of the trade.
contingency
i am pretty sure he's married you can slow your roll
There are a lot of expensive choices in the design of that component. Beautiful to see it being machined. Thank you for the video.
Air cuts (29:00) are way better than crashes!
When my company got its first CNC mill back around 1968, we crashed so many tools learning to program it to machine cylinder heads, we finally got big blocks of styrofoam to perfect the tool paths on. Way cheaper than busted castings, cutting tools & spindles.
I just started running a BIG mazak smoothG lathe last week after a year of a qt300 on production. Finally got into a shop not unlike the work you do here, and finally getting some worthwhile experience. Love the content man.
Hey Peter that was an epic part, the thought and time spent doing it right is amazing. hats off to you sir the only channel on youtube that can get me to watch cnc ops continuously. your a master at what you do!
Amazing ! Thanks Peter. It is always a pleasure to watch your videos. An Oscar for the Mazak in a starring role, and you for directing ! Cheers
Thanks so much for your time, and your fantastic attention to the details your tell us in your videos. You sir are an inspiration and a fantastic teacher. Thanks so much 👍
Wow! I am in awe of your machining and programming skills. And I'm a retired tool and model maker with many years of CAD/CAM/CNC machining. I thoroughly enjoyed this series and all of your videos. Thank you very much for making my day Peter
You do nice work! love watching your content and the way you walk the process through with the viewer. Thanks for sharing.
Great series. Thanks for taking the time to make these videos. Always such high quality and informative.
Awesome as usual. Enjoyed seeing the angle tools. Good stuff Peter! 👍🏽👍🏽
3D surface blend lines looked good 👍 nice strategy in those.
Thanks again from time that you gave us 😊
I have to ask, how does this job rank among the average jobs you do. Is it a heightened challenge? Is it something not many can do? Is it lucrative because it is exclusive, or is it not that lucrative because it is complicated... really interesting process, video, and part. Long time subscriber here, so thanks for the amazing content.
Thanks Boss for the work put into making and sharing these two videos! As a pilot and a 'for fun' machinist, I now more fully understand why airplane parts are so expensive😁 That angle drilling was wild. Regards/greg
We could save some money and just order it from China... what could possibly go wrong?
Awesome video as always Peter. Totally enjoyed it!!!
Super Cool montage! And also veeery infirmative! Nice!) Look forward to see next videos!))
Currently in a collegiate motorsports club and we are very lucky to have access to some haas cnc mills and lathes to machine our gearbox and other parts. Wanted to say your videos are like mind-candy and its awesome to be able to watch someone with so much knowledge go through in so much detail. Thank you for your in-depth explanations of it all, I enjoy watching and learning!
also I gotta say how musical the cuts around the 36 minute mark are
Incredible! What a programming job not much cutting a lot of programming. I thought I did difficult parts with machining Wing ribs for commercial Boeing aircraft from solid block. I did those for about 7 years using Catia, and 3 axis vertical Mills. Lot of contouring minimum six operations. I thought I did a long programming job wow great job Peter thanks for the videos!
Amazing work Peter, like usual 👍👍
Quite a piece of work. I tip my hat to you man!!
Well Peter, amazing job you did there, hats off for you, ...... better than all those blaa blaa blaa pro's out there. 😉
More than 7 videos with over 4 hours of awesome craftsmanship, you handled some serious stuff.
Thank you sir for the great content. 👍👍
Love to see how everything blended with lathe work!
you are de best cnc..thanks for your time peter
I literally felt like clapping at the end of this video :) Well done Peter!
Awesome work as always.
Abso-freakin-loutely cool videos for this project as always. I'll say it again your air knife shows the best views even when flooded coolant. Curious if you had to replace any of the coolant driven right angle head bearings during the course of the run or did they hold up? Totally impressed with the planning and execution. Thanx for sharing.
Thanks for another great video.
This is an amazing machine and an amazing brain running it
You're inspiring! ! ! ! ! Thank you.
Hey Peter, thats really great work. I like the steady rest design and your coolant powered tooling holders. These are really tight tolerances for a part of this size, obviously you aren't heating the part up with the machining you are doing, but I wonder how many degrees of ambient temperature would make the parts out of spec ! I am very surprised that the designers chose to reference a forging surface for (what looks to me like) mounting holes. I would bet that in the final assembly, all the other parts would be attached to the machined surfaces. I suppose that it could be for clearance for a yoke that has to go around the part. Anyway really good content, I always enjoy watching your videos.
Amazing work!
just wonderful!
Lots of details to absorb.
Beautiful!
Cool! Thanks for the video.
Peter great videos! Have you seen any Changes with the counter bores after removing the excess material on the bosses? Thanks again for the content.
Great video thank you
Awesome!
I like it Peter. More please!
Imagine if the engineer would have engineered just simply 2 parallel flats instead of that difficult back spot face / boss feature .
It seems like that would have worked.
AMAZING!
Great integrex video. You got some miles on these things. Takes a while to learn all this stuff
Raise in z.. or x in this case.. integrex life summed up
BTW, you can hold the camera in hand with a cheap tool called a "gimble", and it will steady the horizon on your camera, no matter what position you put your hands in while carrying it. It's not really needed for what you're doing here-- but if you ever were to give a shop tour or anything like that where you needed to carry the camera, a gimble makes a huge difference. They make them for phones and go-pro's, ect.. many different types to choose from.
I actually have a gimble. But its to large to fit in the areas I'm showing. Also it takes to much time to get ready for this kind of thing. If I was doing a lot of walking shots and had the time to get it ready. Then maybe.
Very very nice and 0 dislikes 👏🏻
perfect!!
LOL! I'M STILL IN THE "STONE AGE" of MACHINING!
Great Job Peter.
I assume you turned the OD where the Steady was to final size before taking out the part?
No I’m not doing that. They are.
I'm assuming your using GD&T per ASME Y-14.5. You mentioned you have a .005 true position Q: does the feature control on the drawing allow for a modifier? Like MMC (maximum material condition)
Cool part
I LOVE your video's! My question - how in the world did you quote these parts?
In the case of this job. I was given a price and agreed to do it for that.
He also needed an $8000 tool, so he just made his own. lol..
Only experience guy like you can do this type of job unless they got trained by you this good 👍 👌 😌 😏.
When the start button becomes the pucker button.
Hi Peter, Ide be interested to know how many programmes it took to produce these parts and how many tools it took. Amazing work as always. Best wishes, Mal.
I always use a crappy mill and an ok lathe to invent new machines for work. When I include a grinder, a cut off wheel, welder, and a sander, It just seems to work. I get by, but I always have to massage most of the pieces. I have a new project for another company that I am tasked with. Could you recommend a new inexpensive CNC mill for me? I have no digital readout on either the lather or this crummy manual mill. Would you recommend a small Haas and Mastercam? I am familiar with Mastercam .
If you're familiar with MasterCam, AND, it can program 99% of the features, go with familiarity. The tolerances of the part dictate the machine. If they are open(+/-.001 to 0.005), then an inexpensive Haas will work. If you're trying to hold less than 0.001 all day on many parts, make sure the machine can perform this requirement by insisting on a runoff of components, 30 piece runoff is normal. Any good machine manufacturer will welcome the opportunity to showcase their machines capability. Hope it all works out, Jay.
@@jaycrook1076 Thank you Jay, a 30 piece run off will very much influence my decision. +/- .001or smaller is a must.
Nice! I guess the cuts in the large threads are for a locking device of some kind? God Bless.
I'm not sure but that would make sense.
amazingg
nice
WoW
Can you make an manually adjusted tail center adapter .extend the tail stock all the way out then be able to adjust tension manually?
Not really because the tailstock has to be engaged. It cant be somewhere in the middle of its travel. It has to be in or out. For the machine to run. I guess maybe something could be attached to the center that's there. If it could be adjusted into the part with the tialstock fully retracted. Maybe that could work. The tail center is really a dead center with a #6 morse taper. The bearings are in the quill. It can be taken out and replaced with a different one.
I do not understand why you are correcting for the 0.021" offset in the middle section because the bore ID of the overall part is aligned with the ends.
Did the client instruct you to maintain uniform wall thickness in that section?
If I didn't run that milling off center (The .750 Ball mill you saw in the video) it would dig in on one side and be away of the other. Because the raw forging is not centered in that area in relation to the finished turning.
@@EdgePrecision Holes you drilled there after milling , did you drill them in g57 forge center or g54 turn center?
@@slavepetrich just the milling on the top of the ears adjacent to the raw forged sides. (With the .750 ball mill in the video). Was done on G57. All the holes and all other milling were on G54 offset. In this final setup.
WOW
Peter, what is the purpose of the camera looking thing in the box at the right hand end of the machine? Does it still work?
They are video cameras. This machine was originally equipped with two of them. The one you see and one where the tool changer arm picks up the tool from the carrier coming from the tool magazine. The machine also had what they refereed to as a tower. This tower sat where I have the tool box in front of the machine now. It just got in the way of the access between the crane's column and the machine and could not really be moved like the toolbox. So I eliminated it. It had the computer that was connected to these cameras. All this doesn't really help with running the machine so it no longer works. Except for maybe the camera at the tool changer position. But now I can just remove the panel in front. This couldn't be done if the tower was blocking it's access. I think all this was for some kind of selling point to be able to connect this to a network so some office person could look at the machine. As I said it serves no machining purpose so I disconnected all of it.
@@EdgePrecision That makes sense! Thanks for answering so fully. If it's in the way, off it goes if it no longer serves a purpose.
Relating to the tool changing of your machine, I've noticed that the 'park' position of the spindle awaiting to go through the magazine door is very far away in the Z axis. I understand the Integrex machines can be equipped with monster length tools and this is necessary for those, and I've seen you use decent length gun drills on the channel. Have you considered changing the machine parameters for the spindle to be closer to the door during toolchanging to save on time for shorter tools, or do you subscribe to the 'If it aint broke don't fix it' philosophy?
The height when indicating should be the identical on both sides, right?
On the horizontal centerline parallel to the Z axis? Yes it is. This is pretty much controlled by the height of the tail stock center and the chuck. One thing I didn't show in the video. It is necessary for the part to be running true in the chuck at that end. Witch I did check before running the part. But for some reason I forgot to show in the video.
@@EdgePrecision oke. I mean the height on your cnc readout should be identical: it more of a double double check. Cheers. Very nice series on this very complicated part which you can't to affort to screw up. Forging a new one probably means you will lose money. So each one has to be right on the money. The hardest part is getting the first one as perfect. The second one is a lot easier etc etc. Much respect on the detail that goes in into each step. Cheers!
It's scary to think how much something like this costs.
Yeah, but it's easy to see why. One mistake and he has to start all over on the entire thing; so there's a lot of risk happening as a constant. So there needs to be plenty of profit margin there to ensure that the job can even get finished in the first place. With great risk comes great reward.
I was surprised that you indicated on the forging, rather than the machined surface. 19:50 ... Why not use the machined surface on either side of the forging surface to do your indicating? How can you trust the forged surface to be precise? 19:50 (right click this number and "open in new tab", and it will take you right to that point in the video)
The purpose of indicating the raw forging in that area was for the milling on the ears next to it. Because it isn't in the center the milling would cut more into one side than the other. so those cuts have to be centered on the rough forging. I did mention this in the video.
@@EdgePrecision I know you did.. But I still didn't understand; I assumed you established those center holes on the ears by measuring from the the main center axis that you machined. I'll go back and watch it again-- because I'm still thrown off by how precise the hole has to be, but the ear around it is centered on the forging. idk? I must have missed something
@@calholli The other side with the holes and boss are not on this offset. just the milling on the top of the ears next to the sides.
@@EdgePrecision Oh, I see now. I watched it again-- I get it now. So out near the holes on the ears, you're still measured off of the main center axis-- but towards the base of the ears-- you change to the forging axis again so that it will transition nice. That's a nice catch, did you notice that when running a pre-simulation-- or did you catch that intuitively? I would have likely gouged the first one before I realized such a subtle detail. lol
@@calholli No my simulation stock model doesn't take this into account. I noticed this running the setup part.
Hiya Peter
6:36 That's what she said.
Peter i started a gofundme for a new pair of glasses for you...... maybe a 5 axis pair on the mazak.
I do need a new pare! I haven’t got around to getting new ones. A while back I set them on my stool. Than I sat on them and broke the frame at the hinge. Now they are held together with tape and superglue.
@@EdgePrecision i know lol. Well get to walmart and get a new one..
better cutting some air instead of slamming in the part :D
What do you call this style of machine?
It’s what’s known as a mill turn machine. In this case a Mazak Integrex e650H.
@@EdgePrecision Thanks! It looks like a very versatile machine. Would you recommend that style for a first CNC machine (or machine in general)?
@@MetrologyEngineer If you can afford it. Than you can also afford to repair it.
landing gear ? :)
Part of one. This company makes sort of aftermarket parts for older aircraft. That the parts are no longer manufactured.
@@EdgePrecision maybe this will be a higher quality part than the OEM one was...
Maybe. I just do the machine work.