Cutting Metal inside an Electron Microscope
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- Опубліковано 30 тра 2023
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Today we are machining some metal inside the scanning electron microscope! By creating a custom fixture, we can manually advance a carbide cutter and cut metal inside the vacuum chamber of my SEM. Then we can construct a timelapse of those images to see what metal looks like under extreme magnification when being cut!
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Wow. It's much less crystalline than I imagined. More like moving that clay you demonstrated on. Interesting how it pushes until the stress builds and then separates.
Well aluminum and it alloys are known too be very ductile aka "gummy" steel would be a way better demonstrate for the cristals and well there size depends on the heat treatment and alloy
Yeah that's exactly what I was thinking!
ye it reminded me of this video about a certain geotechnical foundation failure ua-cam.com/video/KgKW10iA_4w/v-deo.html
@@TheLtVoss Isn't mild steel more ductile than 6061? If I'm remembering the young's modulus graph I think mild steel goes from elastic to plastic later than 6061. But, I'd have to look to be sure.
Copper is, counterintuitively, stronger than steel or AL. When we talk about material properties, we sometimes mix up the nomenclature in regular conversation.
That's just what I was gonna comment! I was amazed by how similar it looked to the clay!
I gotta give a fat thumbs up just for the fact that you cut to the chase and showed us the actual footage within the first 30 seconds. Great content.
This is honestly why I watched the whole thing. I got to see it right away and then wanted to know how he did it instead of skipping all the way to the end
Got me to sub. Just for that fact!
That's the only reason I stuck around on this randomly recommended video. The footage hooked me and was immediately interesting. Turns out after seeing that I'd want to know more :shrug:
Yup. The whole reason I watched the vid was once I saw the result I wanted to see how hard it was for him. Honest fucking shit. That’s what I want. You can tease me if you’re slowly introducing some theory, but if it’s a project I want a demo up front.
Really nice work! Every time someone wonders why the machined surface can't have a better finish, I'll refer them to this video. The process looks surgical from afar, but the tool is just ripping chunks off. I also really want stepper motors in my SEM!
How about a collaboration between you two guys? You have two of the most unique channels on YT.
This is not cutting at the intended speed either, that has a bug influence
@@christiancina5875 That's a great point. Every material has an optimum cutting speed.
Between the two of you, it'd be awesome to polish and etch a sample and see the cutter move through grains and boundaries. And definitely agree that steppers in the chamber would be a great time investment and open up a whole lot of ideas into the realm of practicality.
при реальном резании в зоне деформации материала происходит сильное нагревание, которое радикально меняет картину. Чистота обработанной поверхности очень сильно зависит от режима резания. Чуть ли не больше чем от всего остального.
It’s wild how a video that cost you a month or two will be in the minds of thousands of machinist for the rest of our careers. I know you didn’t have time to get into the variety of material/rake but that gave a lot of perspective on what I’ve only been able to learn through experience
any verbage you can share by making a video would be a good thiing. Ignore wanting to be fancy else you will leave us ignorant. :)
Sometimes, a picture is worth a thousand hours... of professional experience.
This channel is so underrated it's sad. Absolutely amazing footage and something every machinist should watch.
I agree. I'm not a machinist but this channel has some of the most interesting topics
🥰🥰🥰
Criminally underrated I would say . The topics and well as the actual videos are masterfully crafted . It is hands down one of my most favorite channels on this platform.
I totally agree! I am doing a phd in materials engineering (Fatigue life prediction) and I still learn so much here!
@Breaking Taps obsession level resonates with mine, and my colleagues too. We sometimes discuss the latest BT video over lunch 😃😃😃
You could install your own electrical feed through on your SEM chamber. What would be really cool is if you could cut some steel that you first etch to display the grains and then show how the grains under the cut are modified by the cutting process.
I think there are crystallographic techniques that let an SEM directly see the grain structure too.
I am glad mr breaking taps decided to give the ol' elbow grease method a shot before drilling holes in his shiny new electron microscope.
There is also the method of placing some mechanism between the limit switches and the carriage that gets crashed into when zeroing out the carriage, and using the compressing force to do an iterative action (like rotating a knob 1 degree or w/e)
My first thought was to use extremely high gearing and magnets on either side of the glass. Though maybe that would affect the beam...
I have also operated battery powered devices in vacuum... Best to seal the battery in its own "chamber" but some lithium batteries handle the vacuum ok, solid state batteries are best.
I've thought about it, but my machine (a little desktop SEM) does some internal gymnastics to move the chamber into position. So it'd be a bit more complicated than repurposing a flanged port or something 😢 Definitely agree about cutting some steel that has been pre-etched! Would love to see the grain boundaries moving around!
I love how you showed the footage first, instead of trying to build "excitement". Just in case someone actually just wants to see what's stated in the video title, that is fantastic. Brief summary and right in. Love it!
Hi! Thermo employee here, actually working in the TEM department :) this channel is actually one of my inspirations of working where I do! Thank you for the effort you put into this channel, I always enjoy the videos
Unfortunately I don't think I'll get permission to send you a sample holder haha
Maybe just a loan? See if the marketing department would sponsor it... where else are you going to get this high production value and targeted advertising? $4k seems like a steal, especially since that's list price. Are there any factory seconds with only a few working pins? I bet your coworkers would be as interested in this video as you are.
Show this to your bosses!
Please QWERTY, appeal to the boss! Must have motorized cutter action. Excellent marketing material for the company!
If the platform included this automation, Breaking Taps could maybe look at lots of materials, from ceramics and glasses through foams and... idk, but this could get interesting, maybe compression load tests and who knows what all?
Permission granted.
In the first minute of the vid, I expected a vaccum actuator or some spring wound actuator, but never expected you to do it manually ! Thank you man!
Hehe why do something efficiently when you can toil at it for hours by hand! 😂I only realized my mistake after an hour or two and saw how little the timelapse moved from the images I had collected. Whoops! :)
you could build a self contained electrical system. A sort of "anti-vacuum" chamber, where you could put a couple of batteries and an Arduino Nano, inside a sealed box entirely within the vacuum chamber. It could either have a bluetooth/wifi to let you advance it on command, or just be pre-programmed to move it once every 30 seconds or something.
Does it even necessarily have to be sealed? It shouldn’t really matter at low voltages right? Or it more outgassing from the PCB? If so, are there coatings which could be applied?
@@mduckernz batteries in a vacuum chamber is not a good idea. the best methode would be a vacuum power passthrough port
@@gerbil.It might be viable to create a small vacuum tight battery box though, just passing 2 pins out... Easier than modifying the SEM or buying it...
You might be able to transfer power in inductively with a couple of coils. It won't be efficient, but it doesn't need to be.
@@mduckernz I'd be primarily worried about the vapor pressure of the electrolyte bursting the cells open, or any capacitors, especially since batteries will warm up in use without any air cooling. Outgassing from the cells, or any capacitors, or the PCB itself potentially poisoning the vacuum would be a concern as well. I'm not sure how hard of a vacuum you need for electron microscopy. If it's able to pull down to pressure in just 5 minutes, about his time per frame, it can't be that hard of a vacuum (can take hours for super deep vacuum levels).
I love how you quickly set up the premise and immediately afterwards show the actual footage you captured. Super efficient
The cutting performance of the insert when running at speed is quite a lot different to the low speed shearing action you show in the stop action SEM sequence especially with negative inserts,they develop a stagnation zone with very high localized temps .
Yes indeed normally at speed there's a sort of small liquid ball that forms just as the tip. There's this just right little window for cutting speed, too slow it cracks and ploughs like this video too fast and the liquid ball just melts the rest and sticks to the carbide tip
What does "stagnation zone" mean? Like where does the term come from? Is it a place where the blade essentially stops for a microsecond until the bit of metal in front of it melts and moves out of the way?
@@joshyoung1440 The blade. Never stops ,the material must flow over the raked cutting edge and become the chip or forced under the cutting edge and become the machined surface .the temperature at the stagnation point is 1200 deg C or higher depending on speeds,feed and materials, hope that helps
If you haven’t done it already, would love to see a metal surface change as it’s polished from 80 grit up to mirror polish. It would be awesome to see the microscopic changes on the metal surface. And what a mirror polish looks like under SEM. Btw this is an awesome video! Never though it would look like mud being scraped off
That's a good idea! I've looked at surface-ground finishes on the AFM before, but never a comprehensive comparison between different levels of grit. Would be neat to see!
@@BreakingTaps hopefully it'll be worth the time like this video was 👍 seeing this was insane!
@@BreakingTaps You might be able to buy a surface finish gauge which is just a bunch of mounted samples.
Yeah, the material being cut looks more like clay being pushed off. Never thought a cut wasnt really a cut before i saw this.
@@BreakingTapspolished and etched please
Also, thorlabs has a number of vacuum compatible linear actuators like the 13 mm PIA13VF piezo inertial or 25mm Z825BV DC servo actuators
This has to be the coolest animated micrography since Ben Krasnow did those wonderful videos with with the vinil record. I hope you can get one of those expansions for your machine, because the possibilities are just astounding!
I really loved that video! He's done so many cool projects, but that's definitely high on my list of favorites!
Came to say the same thing. Also, best use of googly eyes since Grady's tuned mass damper. Your channel is amazing.
Just took a course in "production technology" for 10 weeks (basicly a course about this).
You explained it way better in just 13 min. So interesting and pedagogical!
Thank you!
Technically pedagogy is one-on-one instruction and this is more didactic.
Great video.
My brain is having a hard time comparing how rough that cut looked to how smooth of a cut my lathe can make.
Realizing the scale is vastly different but still that is eye opening.
Tbf, the images concentrate more on the swarf coming off the material than the finished piece left behind. Perhaps that's why it's hard to visualise the finished smoothness?
Cutting edge stuff! Watching this raises so many material questions. Fascinating moving work. Cheers for sharing!
...oh u
Great work on this. A saying I've heard a few times over the years is "A great machinist makes chips. A good part is just the by-product." Seeing that happen from a new perspective was really exciting for me. Only thing I think is missing from your explanation is that getting the heat out of the cut is almost as important is getting the material itself out of the way.
Also. One of the cleanest transitions to an ad-read I've seen.
As a physicist working and modifying SEMs, I really like what you have done. I congratulate you for your patience in making this video.
I have made my living as a machinist, 40 years now. Ive known about the importance of tool geometry but never seen it demonstrated like this. Excellent work, new subscriber, great video.
Oh man all those hours for a 15 second clip. But what a BANGER of a clip. Love this channel.
You have no idea how excited I was when I saw this video come up. I'm a hobbyists machinist and I always wanted to see this action in detail. Ama amazing job.
It is absolutely amazing to me how you were able to manually advance the cutter and get everything back into a position close enough to make the photos into a video. Very impressive and definitely a ton of work.
I never comment on youtube videos but this one was amazing!! One month before you upload this video I presented my undergraduate monograph, regarding exactly this theme, the orthogonal cutting, but with a macro looking to the process, measuring the forces involved to cut materials with different rake angles. I'm very glad to found a video spreading this theme in a very didactic way! Once again, congrats for the content!
Small investment towards a bespoke vacuum-compatible remote-controlled 3-axis stage so you can do this kind of thing over and over. It's amazing. Who's doing this and sharing it with the public? Nobody.
Thanks! 🥰🥰🥰 I'm chatting with the folks at Thermo, don't think I'll be able to get a free chamber but think I might be able to wrangle a discount. Appreciate the support!
This channel is some of the best science and engineering content on the web. Absolutely phenomenal.
This is awesome! I would love to see this again with other metals. I really appreciate the time you put into this project! Very neat. Thank you!
Thank you for showing thr footage right at the beginning! Now I can watch the rest of the video with a sense of appreciation.
That's amazing photography! And being an old mechanical engineer who does a little machining work at home, I really appreciate seeing the details of the cutting.
Amazing footage! Thank you for spending all those hours capturing it. It's so mesmerizing and interesting and it triggers many questions for further tests.
This electron microscopy video of cutting metal is high quality. I hope many students in Engineering, material science,fabrication,etc. get to see this.
The plasticity of the Aluminium is amazing to see (especially after the modeling clay in the intro) as well as the sharing of the Aluminium...
This is absolutely entrancing! I've seen metal shear clips similar to this but never at such high quality! And excellent explanation with the clay model, I've thought the same thing about metal plasticity at small scales.
Your content is amazing! I really enjoy the side of youtube that does research to an academia standard, really inspires me to join and do a bit of research in my own field and post it on youtube. Keep up the great work!
Showing the importance of depth of cut was excellent. Ya gotta bite the material to actually get it to move and fold over itself. Great video. Been cutting chips for over 30 years now. 18 yrs with my own business. And always wanted to see the cutting action this way. Thank you, greatly appreciated
Wow, it really is like clay! I've seen a blacksmith demonstrate techniques on some stiff clay, but this really drove home how it's the flexibility of metal that makes it metal.
without thinking about what it is that you are cutting it looks alot like what clay looks like when you run a scoop through it. its interesting that a metal acts like that
Agreed! I really wasn't expecting it to end up looking so similar to the clay
Scooping ice cream is a machining operation, change my mind
Not going to lie, that was one of the most impressive videos I've watched on UA-cam. Would never have guessed that's how aluminum would look while being cut. Was only my first video of yours I've seen, but subscribing so I can see more!
I wanted something to show non-machinists how cutters work and the effects of rake angle. This video is great and simplifies it in a way anyone can understand. Great job! Thank you!
When you zoomed out a little it made the carbide cutter look massive.... That's crazy and I really like the perspective of it.
This fundamentally changes how I think about cutting metal! Thanks for your labours, hope you had a good podcast.
Awesome content, everything was so clear and well produced, subjects you cover are fascinating.
You are giving a lot of people the chance to experience things that in most likelihood they would generally never get the chance to see.
Thank you for the effort you put in, it is appreciated by many :)
How interesting! Being able to see a cut at this depth makes it clear why cutter geometry and depth of cut are so important, as well as what the curl is showing us as the cut is made. I could see this video being used in trade school for introductory machinist classes.
Excellent, lot of research and work well rewarded.
Thanks for sharing.
As a materials scientist and engineneer, I absolutely love the close-up cutting action you've managed to capture!
One word of caution though! And that word is "galling" or, if I use two words, "cold welding". Your stop-motion capture allowed oxygen to get in contact with all metal surfaces in between each capture. This has an unseen benefit of letting the newly created aluminium (aluminum) surface react with air to self-seal itself with a natural oxide layer. This alumina layer will act as a barrier between direct metal-to-metal unlubricated sliding contact and prevent galling.
Once you do the cutting and image capturing in an _uninterrupted_ hard vacuum you'll have a much higher chance of two metal surfaces cold-welding to each other because no protective oxide layer can be formed that would reduce the chance of galling to occur.
Love the fact that someone else says alumina instead of aluminum oxide lol.
@@joshyoung1440 I think I'm missing your point.
Aluminum oxide = alumina = Al2O3 = aluminium oxide = Aluminium(III) oxide. There are a few more names/designations, but they all refer to the same stuff.
I agree, this is some of the coolest footage I have seen in some time. Considering some of the footage I have seen using detcord over the last couple of weeks, this is saying something.
Also immensely satisfying. As it made me smile simply by watching it. I really love these videos you have been doing with the electron microscope.
edit: I just realized that I need to add this to my list of awesome animation I have seen. As it is a really nice example of stop motion animation, done in way (inside the electron microscope) that you just don't really see. I am a giant fan of animation of all sorts, so I love seeing things like this.
As of late I've become somewhat jaded with YOU TUBE due to my watching it A LOT.
This video is without a doubt the coolest thing I've seen in some time.
i did not know i needed to see this, i have done a whole lot of metalwork over the years and the ruggedness of chips from milling and lathe turning always made me think of what happened on a microscopic level.
Long time follower and your stuff is always great, but this one hits! I have been wanting to do this for a long time! My day job as a machinist, I machine a lot or really crazy pure elemental metals and have always wanted to see the cutting action like this. Super good! Thank you for doin what you do!
🥰 thanks!
Fascinating! I found the flaking on the top surface as it curls interesting. Is that a more brittle oxide layer? Also, +1 for the cell bio to software track 😄
Incredible. I hope you take this further, I would love to see higher strength steels being cut and using the footage to explain why certain steels are tougher/harder to cut.
I love this video. I am a Manufacturing Engineer and have used just about every carbide insert out there. The geometry and coating can make 100x difference in life. Its pretty wild
Holly damn this is awesome...
PS. "HSS is not use anymore" me that just bought few hss bits... So... I need to return them now? XD
I'll take them off you if I must.
Haha yeahhhh I knew that would probably draw some comments 😂 "Very broad generalization" he says, as he hides the recently-used HSS taps and drills 😇
Because of the greyscale image it definitely looks like you're just cutting clay in the SEM.
This is So great! I am a self taught machinist, with a background in woodworking and I've found it hard to build a mental model of what goes on at the tool edge cutting metal - thinking of the metal as fluid, being pushed is really helpful as a way to get away from my mental model (and physical experience) of wood machining.
I love you can see faint fault lines that crack apart when the cut pushes againt it getting those longer fractures
Could you make a battery powered feed device?
There's got to be a variety of batteries which wouldn't be a problem in a vacuum. Right?
You could replace any oil in an appropriate motor with some of your vacuum grease (if it is even needed).
You should be able to control the device wirelessly. I assume the vacuum chamber would allow enough RF to allow radio control.
Thanks for another interesting video.
Maybe this is a dumb question, but couldn't you just put a remote controlled motor in the chamber with a battery and advance the cut with that? Sounds kinda easier than a mechanical wind up drive
Not dumb at all! Definitely considering it, although it's a little tricky since most batteries won't like the vacuum chamber either. So I'd probably need to make some kind of air-tight enclosure for the battery so it stays pressurized. Doable but there is relatively limited space, and I'm a bit concerned if my engineering wasn't good enough. I'm not sure what happens when batteries depressurize inside a vacuum chamber 😬
There are some design details that could make it a little more complicated but yes I think that's a great thought and it may be easier than spring drive.
@@BreakingTaps make a power passthrough ring that can act as a gasket on the lid? embed/glue in banana plug connectors(or any kind of connector you want) and you have an easy way to pass power through from the outside.
@@BreakingTaps What sort of batteries do cubesats use? I wonder how difficult space-rated batteries are to get ones hands on.
Dang man. You put the point of the video right at the beginning and THEN going into detail? Instant like from me. Thanks!
Thank you for doing this. Really Fun to see it.
I'm watching this video again and again.... thanks so much for spending all that time making it... your efforts are certainly appreciated here.
So cool thank you, very interesting how the surface looks like it becomes fibrous when it curls on itself
I sorta knew the mechanics from observing (larger) chips, but watching it in (kinda) real time was really cool.
Nice footage!! Thanks for all the work!
Ive been a machinist for 40 years. That was so cool to see on that level. I have imagined what is happening at the shear point.
So much labor to get this image! Thank you!
Wow, props for showing the focus of the video right away!
Wow. seeing things this up close really changes your view on things. I had no clue aluminum would behave like this when cut 🤯 Please make more of this kind of video.
I'm glad I wasn't the only one making the connection to the appearance of moving clay... It really is great to see it at that scale.
love this one! I had a master's degree in metal cutting theory and made some stationary ESM photos myself almost 40 years ago.
Thank you for showing it right away
That is brilliant. Extremely insightful. Congratulations!
The amount of dedication and perseverance is wow.
It is great work man. Thank you so much for your work. It is a great video and I like it a lot. I think that you came out with great outcome with reasonable resources.
Very impressive footage. I'll share this with my colleagues at ASML. Thank you for putting in the effort.
Thanks for this amazing details of cutting tool !!!
total art! heroic effort!! Thank you for this amazing content!
The metal looks like clay at that magnification. Excellent results. Thanks for taking the time to do this - it helps my brain😀
Thx so much for taking the time to create this, it is really interesting, a new experience
It's cool they represented carving so well in surf's up, they used seashells and the shavings curled up the shell before rolling over exactly like it did in this footage, good video man. Also a great movie
So amazing! I’d love to see different types of materials and different rake angles! It’s wild how much the aluminum looks like clay, I thought it would be more crystalline.
This is amazing, thank you for doing this.
This is one of the best videos that I’ve seen on UA-cam. Smart, well organized, and interesting.
There’s one detail you should add on your next video about chip formation: temperature.
Cold metal responds to milling differently than room temperature metal, although not necessarily in an advantageous way.
In fact, they make a vortex air separator which provides cold air for machining small parts. A nitrogen tank can also be used.
Respect for this man and his patience
Fascinating to see the crack propagate in front of the cutting edge!
I had a similar time consuming task for my masters thesis, a 15 h fatigue experiment with SEM images captured every 20 minutes. I ended up automating the entire process, took me a couple of months though!
I've taken several undergrad materials science classes and spent hundreds of hours in the machine shop, and I never felt like I had as intuitive an understanding of cutting action as I do now after seeing a 30 second video clip. Absolutely wild, very very cool, thanks!
Thanks for sharing the wonders of this world through your painstaking work
Dude, this video was awesome! Also you've improved a LOT from the first videos,, much more confortable in camera, and also the presentation was superb, as also the editing! Congrats!
So cool. Thanks for creating and sharing.
I will definitely watch additional videos comparing cutter geometry and types of materials.
Fantastic and invaluable scientific data. Kudos to you sir.
Fascinating to see it so close up.
it blows my mind how much detail exists on such a small scale.
Love the SEM content-keep it coming!
Thank you for putting the footage first thing in the video rather than the last thing!
I wish i had videos like this one when i was learning about the mechanics of materials, this video just made me understand things that i learned much better
I tell my machining students to think of metal as "enthusiastic clay" because of the way metal smudges around when making chips. This is a lovely demonstration.
Oh wow. Well worth the effort. Very cool results.
This was so interesting!
Really looking forward to seeing some harder materials being cut under the electron microscope!!
This was very cool. I recently saw a Japanese video from the 50's and 60's showing cutting tools in action that was done with optical microscopy.