Machining Our Own Brake Rotor on SMX 3100ST 9 Axis | DN Solutions
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- Опубліковано 25 тра 2022
- Tyson Makes a Brake Rotor on our SMX 3100ST from DN Solutions. We use our Schunk claw jaws to hold a 100 Lb piece of Cast Iron Material, and Kennametal Tooling to make this amazing part.
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#CNC #Machining #Machinist - Наука та технологія
I love how Tyson explains things in simple terms, with no excess drama, and is honest about his fears running things too. This shows people the true side of machining, things get scary at times but it is about managing risk.
Yes! I hope he leads the other to less shouting and atempted drama. I dont wanna watch orange county choppers
I turn brake rotors & drums for a living. Our speeds are very docile compared to what you are using but one thing remains. The shape of the part is a BELL. It generates harmonics which effects the surface finish. We always use an elastic strap and wrap the rotor or drum to help absorb the harmonics. Without it you get fish tails in the finish. You also have an interrupted cut which has to be murder on the tooling as well. You might consider hole ops on the rotor face last. As a last op a non directional finish with a flex hone type tool is advised.
How many machines do you have at your shop?
Do you make your rotors and drums from solid stock like Tyson is doing or do you get them preformed and then finish machine the parts?
Order of operations, drilling and chamfering last could leave burrs on an otherwise smooth face. These machines are way more ridged than the average Ammco lathe, making interrupted cuts on these machines is child's play. Not all manufacturers recommend non-directional finishes. The OEM of these rotors only provide coated rotors. Most European OEM's use coated rotors. Now in the aftermarket world, you do what you have to do.
I also make rotors for a living and agree with you. Drilling should always be last and you would want to balance it before using. Also to save alot of time, kennametal has drill that would do your top and bottom chamfers as it drills each hole.
@@cryptoldya6229 oh yeah ! totally forgot about balance !!
You guys broke a record! The worlds most expensive brake rotor. Well done video Tyson!
*most expensive cast iron rotor
@@BigWill3855 all drums and rotors are cast iron.
@@Jon-O. ever heard of carbon ceramic?
@@BigWill3855 brake pads yeah
@@BigWill3855 or even carbon carbon bec if you watch F1 you will know how much they cost 🤣
First the holes are to help with heat yes but actually it's more to release the gasses that attribute to brake fade that build up between the rotor and pad. The gasses literally create a barrier from the metals touching eachother. Also those rotors are useless without veins which are actually the major cooling component of the rotor.
Also without the vanes gases cannot escape correctly.
@2:01 - The face of your boss when he catches you working on personal projects on company time.
Tyson is my most favorite guy at this shop. Humble, calm, knowledgeable.
Can't stand the 'in your face'-attitude of Titan and some of the others...
We have a popular saying in my country when we see a son following in his father’s footsteps and almost outpacing him, then we say..... This cub is the son of that lion..... Certainly you are Tyson Girloy, the son of the lion Titan Girloy 🦁 boom 🔥🔥♥
I always enjoy Tyson videos they are always a complete project. this is something I would do if I had a machine large enough I'm always making custom car parts for our builds. Keep up the great content.
Always super chill too, very relaxing imo
FYI, my customer owns the machine schedule. I could make anything I want. At the end of the day they call the shots. I wish I had the time to make all this stuff.
What all do you make?
love the "boom" when titan shows up (the machine is so cool. so versatile with the amount of axes ... compaired to a machine with a revolver you probably save hours every week)
As always top notch. That finish though... true master of your craft Tyson. Much love and gratitude
Besides the chattering while turning over the holes …
I've never really enjoyed machining cast iron. The surfaces are fine and it's fairly easy to deal with for tolerances and heat, but that's where the good bits end.
The smell is the least weird thing about it.
The chips are more like granulate that gets everywhere - the bottom of my coolant reservoir was covered in a black sludge which was due to the composition of the metal.
My small drills started breaking because the particles clogged the pumps for the through-spindle cooling 👀
Exactly lol, but what about those fine ass brass chips that find a way into every corner of the machine
yea, piece is a beaut, but we have turned down jobs simply by the fact that Cast Iron sucks when you machine it.
cast iron lends it self to good old fashion open lathes without coolant. I can totally concur on the mess with castiron, I cut brake rotors a lot on my brake lathe and turn mill rolls for a living and the mess is indeed terrible
Better than the splinters I get from grinding super alloys
@@AlChemicalLife PPE anyone??
NICE work Tyson! Good looking part!
"Oh, you said it was a hundred pounds?"
*Literally nopes out of there*
I know, I wouldn't be anywhere near the door.
@@MarcoRodriguez-ci3pg you need to come stand by the lathe i run with a 20,000 lb cast iron part spinning at 125rpm hogging off a 1 inch doc :-)
YOUR REALEY COMEING ON . WELL DONE LAD .
Love this kinda of video showing every step of the way. Keep you engaged. Awesome content.
I just love machining cast iron, love the smell, love the cleanness of the coolant, love cleanness of tools and machine, just love it.
Lol
I can just smell the burning paint from the ends from here...
Tysons of CNC
Exceptional video! You know it's a good sign when I can't help but watch these complete project runs just because it's fascinating. Makes me glad to be getting into the industry despite what a few manual machinists have been saying about CNC. Keep killing it ya'll. Would love to come for a tour in a few years!
Great video Tyson. Those ceramic inserts are a beast!
Tysons videos are always the most informative and we really get to see what’s going on.
I've always wanted to do this but I always thought "oh but how are you going to do the cooling vanes?" so it's really cool that you guys tried it out.
Always wondered this too, that’s why they are generally cast and then skimmed. I wonder how much the veins matter🤔
@@AlphaEngineer2022 They do matter, a lot. You have around 2 times more surface for cooling so brake disc takes longer to overheat and loses heat way faster.
Without the venting the rotors are also heavier than they need to be.
@@Stasiek_Zabojca perplexed as to why they showed a race car. Without venting, this disc is just plain bad
Exactly. I think they only made a rotor for the "show" because those rotor will be horrible. They are heavy, will over heat very fast, take for ever to cold down and high performance rotor use a specific alloy to match the pad.
You’re a beast Tyson, beautiful part man!
Since you guys have the best machines in the business it would be really neat to see what you can do when machining custom wheels
for motorcycles, cars and trucks, be it, 1 piece, 2 piece, 3 piece or 3d custom aluminum billet styles.
The most suited for stuff like titan alloy yes, maybe not the best. But some 5 axis machining of a rim would be fun
@@kleini3 They could make the most amazing looking billet wheels with their new multi-axis machines. Hopefully Titan thinks about
making a video one of these days.
Love Tysons videos! He’s so easy to follow.
Ex mechanic here, I know this is demo purposes only, but id have loved to see the vents that are mandatory for proper cooling.
Also my old boss used to make/modify his own by buying blanks and machining his own on his heavily modified (I think home made) brake resurfacing machine. That thing always scared tf out of me as it was more inline with a wood working lath that you had to use hand tools with...that all looked home made.
That said that guy could work wonders on it. Seen him even make a diff crown gear, all I made was a broken finger when the stupid tool bit in hard when I first tried using it. Did learn how to reface on it. Then next workshop had a real one....well imagine my new bosses face when he saw me attempting to do it by hand tools (old boss had gifted me a set, wish I still had them and my old tools, but that's what happens when you get injured majorly on the job under bosses orders, all your tools, your project cars, racing cars and all go "missing").
I’ve seen this video a couple of times now and Tyson killed this part! I bet it was very intimidating standing next to that piece of cast iron with only the large door between them. 👍🔥
I'm really confused, where is venting channels on this disc? without good air flow it is suitable only for low perfomance applications.
I thought something was missing. While the veins could technically still be added it just proves why parts like rotors are something better when cast then just surfaced
@@kingofkings600 They aren't mandatory, but if you're spending what I'm sure this cost to manufacture, they're definitely expected.
This is just an educational exercise. Without internal venting this part is not performance-oriented
"Solid brake rotors are usually machined from a single piece of raw material, like cast iron. Although more exotic materials are available particularly when it involves racing or street performance requirements.
Solid discs usually appear at the rear of the vehicle."
@@gt40f bro they literally showed the car they were going to put it on and it sure wasn't my grandpa's Corolla.
OSHA must freak out at 0:41.
Also good to know you can trust your life to something you made.
Nice work! What a beautiful part!
That machine is insane. Must be fun being able to use it everyday!
Tyson is a BEAST!!! Freaking awesome job, dude!
love the content from the lathe side we need more!
Keep these videos this length. 15 minutes is perfect
Can’t wait to start working! Going to school for this and can’t wait to learn more and better yet can’t wait to start doing projects (my own) like this myself !!!
Would love to see you guys machining a pair of 50lb, old school deep dish weight plates.
Rogue made a beautiful set out of billets of stainless steel for the Arnold Strongman classic.
Always good movie with Tyson ! Realy interesting !
Another awesome and inspiring video, well done.
That was awesome Tyson!
Great work as always! :D
Awesome Content As Always Tyson 👍
My job is cutting full length material to deliver cut to length pieces just like that cast iron piece you started with. Always fun to see what people do with this stuff
Love the idea of lights out, it's machining at a master's level. Would lie to see this after the automation is installed and tuned.
Better than those psychological crap videos . Tyson u are killing it !
Good content, thanks for sharing!
Boom from Brazil 🇧🇷👊🏼🇺🇲
Drilled or slotted rotors are for venting gases created by the pads, cleaning of the pads and additional cooling. The issue with drilling is they are prone to cracking. With that small chamfer I would guess those wont last long if its in a high heat application.
We need more videos like this for this channel.
Now I want this channel to make a YoYo thats perfect
Like that Doosan. Impressive machine.
beautiful part!
its so mesmerizing watching materials getting remove
I know this might not be a production part, but why drill before finish? Intermittent cuts degrade tools faster than consistent cuts, especially with carbide. I also noticed your chamfer interpolation is conventional (unless you're using a left-hand cutter) Lastly, why interpolate when the feature can be created with a dwell canned cycle?
Too many holes, heat n stress could affect the surface flatness which is likely very important on this part. My theory at least.
in cast iron these Drills basicly dont care. it just wont be as precice as it culd be from a positioning standpoint. In the other hand the drills are very short.
Every time the show of somthing they just "show of" the American way ;D In fact the flatness of the finished part is horrible cors he finished over the drilled holes, so if you would messure the surface there it will be around 10µm +- after every hole dou to the vibrations of the part end the tool.
And the last BIG BIG ooooooffff in Machining break discs is that you have to machine both front and back surface in one Operation (Workholding). So this Rotor will not peforme on a real car.
@@savioer I agree with this
I'm guessing he didn't want to scratch the finished faces with drill chips.
@@fordhoarder if you look closely, there's a witness mark behind each hole from the intermittent cut.
Very satisfying and amazing job, but can you machine a vented rotor just to see what sort of challenges part like this makes?
Your kid is amazing!!
8:20 this here folks is called experience!!! great job dude...
It's sensible machining, with large parts like this anything you can do to reduce the OD radically reduces the load on the spindle
He still could plunge cut the face if that operation had to happen first. Kind of the same as OD cutting.
Experience? lol Its just common sense. They teach you this in school.
MMPR 0.08 is always the best for finishing a "rough" piece ^^
I'm an auto detailer. Not sure how I even got here. But this is f-ing awesome
Those rapids first at X and then at Z are spookyyy
I was really hoping for you to try it out on a car, but still a nice video
Great video but just curious, why do you drill your holes before finishing turning and risk chipping a ceramic insert?
[05/27/22] Very well done, excellent work. What grade of cast iron was this, and how much cooling time between the various ops, if any?
What is the purpose of the coolant, pouring out from the corner? Flushing away the chips? Also, isn't it easier to buy a multi-axis turning tool with 45 degree insert placement, which you can just rotate 45 degrees on a B-Axis, so there's no any interference between workpiece and the head?
i guess, your nc-control or at least your cam-soft could handle it: for facing give your boring bar a 45° rake angel, than you can face your parts at first op. and as a bonus you can raise/double your feeds too!💪
awesome
The first one here .... like usual 🔥🔥 boom
This is so cool
Tyson the Lathe-Guy show how its made. Awesome. But why the big drill oriented like this, the hot chips lay on the top side of the drill, heating the drill asymetric up, With coolant no issue, but like this? Does the Drill get warm?
Tyson, you are awesome!!! Booooommmm
Is there any specific reason why the holes were drilled before the finish pass over the diameters, was the intermittent cut a preferred option over any potential swarf marks from the drilling op. or is this just down to personal preference
How did you deburr the backside of the holes? Do Cogsdill spring loaded chamfer bits work?
you could add some venting by drilling holes from top to the center. next project?
Great video! No chamfer on the inside?
Longer videos 😍finally
Nice, but standard rotors are hollow for ventilation and less weight. Unsprung mass is relevant. 3D metal printing would have been my choice. Bugatti made the calipers of the Chiron that way.
amazing
14:46 - Talk to us about them jaws and by the jaws I don't mean their serrations but the stick out from the chucks OD what's behind them that allows such rigidity and extension?
Now I wanna see the run-out on the face from the first operation after roughing the other side.
Yea id like to see this on a brake lathe checking the hub mounting face to the brake surface runout. The fact they didnt hold it by the mounting hub (like a brake lathe) makes me think their would be some runout.
I used to trepan the centres out of big stainless blanks to 15 inch diameter which was interesting.
Then I threaded them and checked the thread size using three bits of 1/16 wire.
По больше бы таких видео.
when cutting cast it rings without a damper and the ring can transfer into marks on the cut
So, how do you deburr the back side of the holes? Also the back side of the ID finish pass?
That's a badass music and sfx used in this video. Can i please ask add links to them, so I can listen it in full versions?
Wondering if you chamfered the thru holes back side of that rotor?
Please Some Videos for A2 Tools Steel and SS420
We use a lot of this material on our shop for plastic Injection Molds
Thanks!!
Nice video!
BEAAAUUUUTIFUUUUL
kirksite the rooster tail is like sand blasting the machine had fibrous chips on the iron ceiling rafters forty feet up. On a sixty foot five axis gantry mill running 1200 inches per minute at .030 per tooth at 10000 rpm .125 depth of cut with a four tooth 2 inch indexable shell mill It was insane. That was the fastest that machine was Ever run basically maxed it out.
Most cars these days have an internally ventilated brake disc. Are you going to put it on like that or are you going to put some internal ventilation in there too?
Can you finish the rotor and machine out the vented slots between the braking surfaces? This was some pretty simple machining otherwise
barry what did you do to the drill?!
Hahahha that was the one I ran dry in the horizontal 😂
I don't think I have ever seen a solid brake rotor that was drilled before, normally that is only done on vented brake rotors. Perhaps adding some custom designed "slots" to aid in brake pad cleaning would have been a better choice on a solid brake rotor.
so what happens when you resurface them? the holes are there.
@@nieljones6181 you dont typically resurface drilled rotors, they are crack prone and usually 1 time use with any abuse. slotted can be resurface but you loose the slots performance so its basically pointless too.
@@MrChevelle83 ah. I see. Didn’t know that
Question, how would you vent these rotors ?
Uuuuhm as nice as it is,love your vids, ain't it easier and cheaper to buy these from manufacturers specifically dedicated for making these?
Cool! 130 lbs. starting weight. What is the finished weight? Thank You.
It's amazing how you can name the actual exact names of the tools, insert
No te falta la ventilacion interior del disco?
In general if you had a water jet could you / would you core out the center to cut down on the weight?
Doubtful with cast due to porosity and fast rusting
I was once standing by a lathe with a 4 ton (around 8800pounds) part, which was spinning at around 700rpm, and i was scared in the beginning. i instantly took a few steps back as the spindle accelerated.
I work around 15 ton parts spinning 125rpm and its still intimidating standing there even after years of doing it! I always think (what if the quill cone failed and this thing came sailing out of the lathe)
@@MrChevelle83 I kind of think anything that a lathe throws while spinning at 2700 SFM is going be terrifying regardless of how big it is.
Why did you transfer the part by hand to the sub chuck?
I love working wiithh cast iron (said noone ever)
Horrible stuff, makes a right mess of machine and operator. Always rough out on old machine then finish on newer lathe.
Next time make this with milling machine!
Machined our own universe