From California USA; unfortunately I knew it would warp from the welding. It is amazing how much the welding will pull and warp that thick of steel. That stress is still in the steel; but with that light of cuts the warping after the cutting “ I am hoping is not excessive”. Remember that episode at CEE where Curtis had that improperly heat treated steel that kept warping after every cut because of the internal stresses! I would recommend be careful and Do not cut the O-ring groves too deep. Leave enough rubber standing proud of the face so that the O-rings can compress down and seal. With the amount of torque that thing is going to have on it might cause it to start walking around on those bolts and possibly even loosen the bolts. This is so interesting. I am definitely not going to miss this.
What watwsplace8614 said! Nice work. Carbide, CBN etc are awesome, but never overlook the humble HSS, it can shine where the others chip and fail, and can be ground into form tools limited only by your imagination. Great video Matt, keep it up! Can't wait to see that big bastard moving some dirt.
Brilliant video and solution to a problem. It always amazes me the range of tools and machines that are out there. Have a brilliant Christmas and a Happy New Year
Chater the bane of any machinist. Interested to see how you will recut the six o-ring grooves. Absolutely love how you show the struggles and how you overcome them keep it up!!
Always ...always ...always plan for warp when building weldments. If you get lucky and the warp is within spec, run with it. When the plates get thicker the weld gets larger, the contraction forces during cooling increase immensely. If you can't take the part to the precision, take the precision to the part. This type of flange work is critical in some pipe work when high pressures are involved. Always great to see someone learn a new process and put that skill in their toolbox.
Good morning Matt, I'm sat in me long johns, cold af here in merry old England 😂, and up you pop, like a warm ray of sunshine, I'll make a hot brew, and settle in Love the work you guys do. Have an absolutely wonderful day, my mate, and a wonderful Christmas, too 🎉 Edit: Flange facer eh? Who'd have thunk it lol, crazy bit of kit, hope you rented it?
Do a post weld heat treatment of the welded areas on the flange at about 580 to 600 Deg C for an hour per inch and cool in still air, that should do two things; temper the hard areas around the weld, and relieve stress so that after machining the flange remains dimensionally stable er.
I have done a little bit of machining in class and out. This machine reminds me of a portable cylinder borer and a portable valve face restoring machine for steam locomotives. Those are two different machines but are set up on the cylinder saddle for boring the cylinders of the piston and piston valve for the borer and a machine that mounts above the valve face of a slide valve-equipped locomotive to reface the slide valve surface to restore the surface for the slide valve to ride on. Both machines are used instead of removing the cylinder saddle to set up on a horizontal or vertical boring machine or mill to do the job, particularly when the machines are not available where the work needs to be done. I thought that adding a bar and support through the hole to the other side of the head would add some rigidity to the machine and set-up if it could be done. This would add a longer shaft for the machine to rotate around and be steadier than just the clamps used gave, I could be wrong because of inexperience. Arp, Texas. In the northeastern part of the state.
Always loved engineering, especially cnc but get a buzz out of watching you tackle these big projects. Yet to see Cyclops make an appearance on the Hulk! Christmas greetings from the UK. Steve
Back when I was going through my meshiest apprenticeship, Whish I completed in 1971, we sometimes used tool bits called stellite, not sure I am spelling this correctly, but it was extremely tough and durable. Much harder than normal tool steel. Might want to try it sometime if you can even find it, if available.
Dude… that was an education if ever I’ve had one. Never even knew such a bit of kit existed until now. After seeing what was going on with the inserts my brain went to good old hi speed or tungsten. The cutters I learnt on & you went there too so I was a little chuffed over that, & it worked which was wicked cool. As for an easier way??? Sent it to Kurtis 😂 he probably won’t speak to ya ever again but it’s still easier.😂😂😂 My very best wishes to you guys. Hope you all have a very merry Christmas & safe & happy new year. Thanks so much for pitting this channel together. It’s helped me more than you know. Cheers everyone Patch
might be a good idea to talk to someone in the gold mining industry. they use those flange facing machines on the autoclave flange faces. the face is overlaid with titanium then machined to achieve a "gramophone" finish so that the chevron spiral wound gaskets willl seat properly. never actually done the job myself, had others who did the machining for us, but it is a very interesting process on a flange that is approx 1500mm diameter.
Hi Matt. We used to have to, occasionally, machine the “ tires” on our asphalt plants. These are large steel rings, about 3.5m in diameter, that are placed around the mixing drum and run on trunions to stay true. These things are very hard and the only way to cut them is to grind them. The company we used also had flange grinders for the same reasons as you’re running into. I’m in Alberta, Canada by the way. I’m sure there would be something available in Australia. I enjoy your content very much. Have a great Christmas and Happy New Year!
YoooMate HSS is the way and yes it takes forever. Very nice to watch. Your videos are always interesting and educational sort of. and always good material. congrats.
The flange facer was a clever machine, and you gotta love it, seeing good old HSS cutters to the rescue! Happy Holidays, and hope you folks have a great 2025!
I might have tried a brazed carbide tool. Tougher than an insert, stays sharp longer than HSS. Or even a solid carbide tool for the same reasons. Of course the heat affected zone could be avoided or minimized by welding in smaller sections or heating the whole thing before welding. But that may just make it worse. May want to consider your order of operations, weld then heat the flange up and allow it to normalize, then weld to the larger part. At least then there would be consistency even if that means consistently wrong. Can see Curtis now furiously planning out a shop built flange facer.
That's pretty wild to see how the welds have pulled in the flange face on the early cuts. It will be interesting to see the design changes (for welding up the flange ribs) for future monster tool. Thanks man. Merry Christmas ... (tuning in from San Diego, CA, USA). Good to see little Teddy playing peek-a-boo.....
It don't matter what situation you find yourself in, odds on someone somewhere has been there before you. That means that there is a good chance the right tool already exists to fix your situation, you just need to find it. Thanks to Phil, it would appear you found the right tool for this particular job.
Hi Matt I suspect a mill would work better for facing the interrupted cut, not sure whats out there these days. There are contractors in the area that do nothing but machine stuff in place for paper mills etc. If you get bored troll the Climax machine too website. HSS has saved many projects for me this summer facing big flanges full of holes. I would go with a cobalt HSS or even Stellite tools because they will last longer. Funny there is nothing like a Frenna or wobbly crane in here in the US. We just use forklifts of all sizes. Hope you have a wonderful Christmas! Ross
A perfect excuse to go buy a huge HBM! I had to machine some crappy welded steel on a clapped out, floppy lathe once. A HSS bit ground with a large radius, almost like a button, and low rake did surprisingly well at avoiding chatter and surviving the cuts. It's a geometry that will flex out of a cut instead of pulling into it, so it tends to settle on a comfy middle ground. You might want to experiment with that sometime and see if it works well with the flange cutter. If all else fails, zip tie a die grinder on your flange cutter and let 'er rip.
I had suspected that kind of sorcery existed, so it was very interesting to see the flange facer in action but aslo wondering if the stroke length of a shaper would be enough to do that job (with the shaper supported on a giant riser base). Everything here in the land of banana units as Kurtis calls them is beginning to shut down for the holiday season also. Cheers to you and HAL team.
Heat affected zone at the extreme OD is a bit of a trifecta. Not only does the surface hardness increase, your rigidity decreases, while your surface speed increases for a fixed RPM. The last one often gets over looked. That's a significant delta from your ID to your OD. HSS is probably where I would have started. You have full control. Just playing with the tooling relief can drastically change harmonics. Difference between having a sled at the back to resist diving or having a guillotine that dives straight in as soon as the surface hardness subsides. Moving everything around the yard probably would have tripped me up more than dialing the cut in. Love those yard cranes. I've only seen one at a scrap yard in the USA. For the longest time I assumed it was a home made contraption.
Hi guys. Just a theory, but to finish off you could fabricate a device that would hold a grinding wheel that would fit on the unit to give a lovely finish.
what a great show case to show your skills,, ,getting Teddy's hands dirty ha ha ha looks great :) looking forward to the next vid Merry Christmas and happy new year :)
That is certainly an interesting tool I have never heard or seen of them in the 5 years that I have been watching machining content on youtube, both your channel and Kurtis's are my favorite Australian channels. Wishing you and your whole crew a very Merry Christmas and a Happy New Year, from Burpengary QLD
Watching from the UK. I used to work in a naval dockyard. They had equipment like that to machine mountings for weapon and radar systems. Also had an 80 foot long lathe for machining propellor shafts off ships before they had on site machining gear. It sat unused for a long time, no one wanted to buy it, so I think it was scrapped eventually.
This is coming from a Field Machinist running the same types of equipment almost everyday. In this instance I would have gone for an OD mounted machine just for the sake of rigidity and faster material removal. ID Mounted machines are great for certain things but in this case with the heat affected area and many interrupted cuts it wasn’t the best machine to use.
Wow Just how big can you go? Amazing repair and using old school tools hand ground is terrific. Great job and as I am 95 I really liked watching. Could another flange be made up and added to the existing one? Maybe just a thought. Carl. My first lathe was flat belt drived from an overhead line..
Wonder if a grinder attachment could be designed for this type of facer? It would need brushes and slip rings for an electric grinder motor, but that's a pretty common application. Also you would need some type of spring tensioner and gauge to keep a constant grinder wheel pressure against the face as the grinding wheel wears down.
No problem for you guys, slight adjustments here an there, bobs your uncle, another job done boys, and quality work done as usual 👍😊. One of your best ones yet, Have a great Christmas and holiday, regards to you all and your families 👍
Sharpsburg, Georgia USA Great video, I've never seen that machine before, very interesting to watch. My first thought when i saw it operate at that slow speed was its like my shaper. I wonder if a bull nose shaped HSS cutter would handle those heat affected areas, ive had good luck but i don't think I've had to deal with steel that had 10 heavy passes of heat put into it, 2 or 3 maybe. Just an idea, i think its the problem solving part of the job that keeps us coming back.
Very interesting bit of kit. Off the cuff, if the cutting bit was rotary (endmill) with greater step-over and depth, it might be quicker, idk. Or, you could map how much these warp and keep a log of them. Then mill the opposite expected feature in it so it pulls straight when welded...if you could pull that off you've be revered forever as a wizzard. Have the beard to boot :)
Fortunately, someone else had that same problem in the past, so they invented a flange miller. I cannot even imagine any other practical way to tackle that problem, short of having a milling machine that stood like 20M tall! Happy holidays to you all at the shops.
Big fan of Curtis, now big fan of your channel. Both of you do some Big Machine work. Quite fascinating.
Merry Christmas 🎄
I chime in!
the level of precission you and CEE achieve with imprecise tools is truly astounding, very nice work, oh and season greetings from the UK
Retired Aussie engineer/tool and die maker in Butuan City, Philipines. Enjoy the break and I'm looking forward to watching in the new year.
From California USA; unfortunately I knew it would warp from the welding. It is amazing how much the welding will pull and warp that thick of steel. That stress is still in the steel; but with that light of cuts the warping after the cutting “ I am hoping is not excessive”. Remember that episode at CEE where Curtis had that improperly heat treated steel that kept warping after every cut because of the internal stresses! I would recommend be careful and Do not cut the O-ring groves too deep. Leave enough rubber standing proud of the face so that the O-rings can compress down and seal. With the amount of torque that thing is going to have on it might cause it to start walking around on those bolts and possibly even loosen the bolts.
This is so interesting. I am definitely not going to miss this.
Phil to the rescue. Great to have someone with decades of experience you can call upon for help. Merry Christmas, and enjoy your time off.
You have cool toys! Even the worst grump won't say: "too small"! :))))
New to the channel from Oregon, USA and CEE channel…great narration and just incredible work
What watwsplace8614 said! Nice work. Carbide, CBN etc are awesome, but never overlook the humble HSS, it can shine where the others chip and fail, and can be ground into form tools limited only by your imagination. Great video Matt, keep it up! Can't wait to see that big bastard moving some dirt.
Brilliant video and solution to a problem. It always amazes me the range of tools and machines that are out there. Have a brilliant Christmas and a Happy New Year
I am not mechanically trained but enjoy your content. Retired military from Pretoria South Africa. Thanks for the channel. Gerard
Merry Christmas from Sunny Rockhampton!
Chater the bane of any machinist. Interested to see how you will recut the six o-ring grooves. Absolutely love how you show the struggles and how you overcome them keep it up!!
Always ...always ...always plan for warp when building weldments. If you get lucky and the warp is within spec, run with it. When the plates get thicker the weld gets larger, the contraction forces during cooling increase immensely.
If you can't take the part to the precision, take the precision to the part. This type of flange work is critical in some pipe work when high pressures are involved.
Always great to see someone learn a new process and put that skill in their toolbox.
Good morning Matt, I'm sat in me long johns, cold af here in merry old England 😂, and up you pop, like a warm ray of sunshine, I'll make a hot brew, and settle in
Love the work you guys do. Have an absolutely wonderful day, my mate, and a wonderful Christmas, too 🎉
Edit: Flange facer eh? Who'd have thunk it lol, crazy bit of kit, hope you rented it?
Do a post weld heat treatment of the welded areas on the flange at about 580 to 600 Deg C for an hour per inch and cool in still air, that should do two things; temper the hard areas around the weld, and relieve stress so that after machining the flange remains dimensionally stable er.
Great video, great explanation, and amazing work.
Merry Christmas to all you lovely people! Greetings from Latvia!
Hi Matt loving the videos, watching in sunny Cape Town
I have done a little bit of machining in class and out. This machine reminds me of a portable cylinder borer and a portable valve face restoring machine for steam locomotives. Those are two different machines but are set up on the cylinder saddle for boring the cylinders of the piston and piston valve for the borer and a machine that mounts above the valve face of a slide valve-equipped locomotive to reface the slide valve surface to restore the surface for the slide valve to ride on. Both machines are used instead of removing the cylinder saddle to set up on a horizontal or vertical boring machine or mill to do the job, particularly when the machines are not available where the work needs to be done.
I thought that adding a bar and support through the hole to the other side of the head would add some rigidity to the machine and set-up if it could be done. This would add a longer shaft for the machine to rotate around and be steadier than just the clamps used gave, I could be wrong because of inexperience.
Arp, Texas. In the northeastern part of the state.
Great video keep it up, tuning in from California.
Well done! Some interesting comments below. Merry Christmas!
New to the Chanel from Germany. Merry Christmas
Merry Christmas
Greetings from the UK
Adelaide buddy! You channel was a UA-cam push and one that I appreciated
Great job... unbelievable job... I wish you and your family happy holiday's... I turn in from the Netherlands!
Well done! Hey from Arizona, USA
Happy Holidays great content from New Brunswisk Canada have a great holiday season
Always loved engineering, especially cnc but get a buzz out of watching you tackle these big projects. Yet to see Cyclops make an appearance on the Hulk! Christmas greetings from the UK. Steve
Merry Christmas from Baltimore Maryland. Good show, man!
"Nothing is impossible,
Its just
Miracles take a little longer"
DG Fry
Managing Director
NQEA Australia
1982
Best advice i was ever given.
Hi Matt! Greetings from Harrison Arkansas - USA. Subscribed a few weeks ago after Curtis told us about your channel. Merry Christmas!
Back when I was going through my meshiest apprenticeship, Whish I completed in 1971, we sometimes used tool bits called stellite, not sure I am spelling this correctly, but it was extremely tough and durable. Much harder than normal tool steel. Might want to try it sometime if you can even find it, if available.
Happy Christmas and Happy New year 🎉
Hej ,Jens from Danmark. Glædelig jul og godt nytår.
I machined bulkhead seals on navy ships with something similar during my apprenticeship. Was really interesting!
Dude… that was an education if ever I’ve had one. Never even knew such a bit of kit existed until now.
After seeing what was going on with the inserts my brain went to good old hi speed or tungsten. The cutters I learnt on & you went there too so I was a little chuffed over that, & it worked which was wicked cool.
As for an easier way??? Sent it to Kurtis 😂 he probably won’t speak to ya ever again but it’s still easier.😂😂😂
My very best wishes to you guys. Hope you all have a very merry Christmas & safe & happy new year.
Thanks so much for pitting this channel together. It’s helped me more than you know. Cheers everyone
Patch
might be a good idea to talk to someone in the gold mining industry. they use those flange facing machines on the autoclave flange faces. the face is overlaid with titanium then machined to achieve a "gramophone" finish so that the chevron spiral wound gaskets willl seat properly. never actually done the job myself, had others who did the machining for us, but it is a very interesting process on a flange that is approx 1500mm diameter.
Happy Christmas 🎄 From County Armagh Northern Ireland 🇮🇪 🇬🇧
Wowzers, hi from NZ,
Just found your channel, very cool.
Happy days.
Hi Matt. We used to have to, occasionally, machine the “ tires” on our asphalt plants. These are large steel rings, about 3.5m in diameter, that are placed around the mixing drum and run on trunions to stay true. These things are very hard and the only way to cut them is to grind them. The company we used also had flange grinders for the same reasons as you’re running into. I’m in Alberta, Canada by the way. I’m sure there would be something available in Australia. I enjoy your content very much. Have a great Christmas and Happy New Year!
Mississauga, Ontario, Canada here, just west of Toronto! Loads of fun!
YoooMate HSS is the way and yes it takes forever. Very nice to watch. Your videos are always interesting and educational sort of. and always good material. congrats.
Why put a piece on the lathe when you can put a lathe on the piece.
Nice, Love this stuff.
Hi Matt from Merimbula NSW Australia.
Happy Holidays🎉 from North Carolina usa❗
Lying here bored waiting while the COVID antivirals do their magic when up pops the latest gem from Matt. Perfect antidote.. Cheers!
The flange facer was a clever machine, and you gotta love it, seeing good old HSS cutters to the rescue! Happy Holidays, and hope you folks have a great 2025!
I might have tried a brazed carbide tool. Tougher than an insert, stays sharp longer than HSS. Or even a solid carbide tool for the same reasons. Of course the heat affected zone could be avoided or minimized by welding in smaller sections or heating the whole thing before welding. But that may just make it worse. May want to consider your order of operations, weld then heat the flange up and allow it to normalize, then weld to the larger part. At least then there would be consistency even if that means consistently wrong.
Can see Curtis now furiously planning out a shop built flange facer.
Merry Christmas Matt and crew.
Looking forward to next weeks episode.
That's pretty wild to see how the welds have pulled in the flange face on the early cuts. It will be interesting to see the design changes (for welding up the flange ribs) for future monster tool. Thanks man. Merry Christmas ... (tuning in from San Diego, CA, USA). Good to see little Teddy playing peek-a-boo.....
Nice work and an interesting bit of kit.
Enjoy the break!
Matt,
Wishing the entire HAL team and their families a very Merry Christmas!!!
Very clever machine, have a good break over Christmas and new year
It don't matter what situation you find yourself in, odds on someone somewhere has been there before you.
That means that there is a good chance the right tool already exists to fix your situation, you just need to find it.
Thanks to Phil, it would appear you found the right tool for this particular job.
Hi Matt
I suspect a mill would work better for facing the interrupted cut, not sure whats out there these days.
There are contractors in the area that do nothing but machine stuff in place for paper mills etc.
If you get bored troll the Climax machine too website.
HSS has saved many projects for me this summer facing big flanges full of holes.
I would go with a cobalt HSS or even Stellite tools because they will last longer.
Funny there is nothing like a Frenna or wobbly crane in here in the US.
We just use forklifts of all sizes.
Hope you have a wonderful Christmas!
Ross
A perfect excuse to go buy a huge HBM!
I had to machine some crappy welded steel on a clapped out, floppy lathe once. A HSS bit ground with a large radius, almost like a button, and low rake did surprisingly well at avoiding chatter and surviving the cuts. It's a geometry that will flex out of a cut instead of pulling into it, so it tends to settle on a comfy middle ground. You might want to experiment with that sometime and see if it works well with the flange cutter.
If all else fails, zip tie a die grinder on your flange cutter and let 'er rip.
Thanks for the video Matt. Merry Christmas to you and the rest of the HAL team.
Cool stuff, thank you!
I had suspected that kind of sorcery existed, so it was very interesting to see the flange facer in action but aslo wondering if the stroke length of a shaper would be enough to do that job (with the shaper supported on a giant riser base). Everything here in the land of banana units as Kurtis calls them is beginning to shut down for the holiday season also. Cheers to you and HAL team.
Hi from sunny South Africa. We also now shut down for hloiday. Also a bit of rain. Happy Holidays !
Best vid yet! Super interesting and entertaining!
Watching from northern Alberta, Canada. Enjoying the content!
Great stuff, merry xmas to all.
Interesting job and video. Thanks and have a Merry Christmas!
best darn hole diggin project on youtube!
Heat affected zone at the extreme OD is a bit of a trifecta. Not only does the surface hardness increase, your rigidity decreases, while your surface speed increases for a fixed RPM. The last one often gets over looked. That's a significant delta from your ID to your OD. HSS is probably where I would have started. You have full control. Just playing with the tooling relief can drastically change harmonics. Difference between having a sled at the back to resist diving or having a guillotine that dives straight in as soon as the surface hardness subsides.
Moving everything around the yard probably would have tripped me up more than dialing the cut in. Love those yard cranes. I've only seen one at a scrap yard in the USA. For the longest time I assumed it was a home made contraption.
Very cool! Merry Christmas 🎄
I came to the channel off a feed from CEE engineering in queensland, This looks like an interesting channel as well
Hi guys. Just a theory, but to finish off you could fabricate a device that would hold a grinding wheel that would fit on the unit to give a lovely finish.
Merry Christmas.
what a great show case to show your skills,, ,getting Teddy's hands dirty ha ha ha looks great :) looking forward to the next vid Merry Christmas and happy new year :)
Good job Matt - I would have used a file, or three 😂
I will say that the dialing in of the flangerator would have been really interesting to see given the warping. Really interesting tool.
That is certainly an interesting tool I have never heard or seen of them in the 5 years that I have been watching machining content on youtube, both your channel and Kurtis's are my favorite Australian channels. Wishing you and your whole crew a very Merry Christmas and a Happy New Year, from Burpengary QLD
Thank you Matt. Wishing you, your family, personnel and dogs a very merry Christmas. From South Africa that is bloody well shut down the whole year! 🤭
Watching from the UK. I used to work in a naval dockyard. They had equipment like that to machine mountings for weapon and radar systems. Also had an 80 foot long lathe for machining propellor shafts off ships before they had on site machining gear. It sat unused for a long time, no one wanted to buy it, so I think it was scrapped eventually.
Just found your channel and love your can do attitude, You could almost be a Kiwi, almost. You guys have a great Christmas and a happy new year.
I would not have thought that such a thick plate of steel would warp that much.
This is coming from a Field Machinist running the same types of equipment almost everyday. In this instance I would have gone for an OD mounted machine just for the sake of rigidity and faster material removal. ID Mounted machines are great for certain things but in this case with the heat affected area and many interrupted cuts it wasn’t the best machine to use.
How would you ensure that the flange is perpendicular to the bore with an OD mounted machine? Don't you need a reliable datum surface to mount onto?
Awesome. Interesting tool. From uk
Just like watching paint dry, you are persistent good job
6:04 OK, that's got to be the first time I've ever heard a Machine actually Growl at someone because they touched it...
😄😁😆😅😂🤣
Let's do this guy's!
It's like a giant self advancing fly cutter on steroids! Very cool! Happy holidays from Arkansas!
Hi Matt
What an amazing machine.
As always very interesting
All the best for Christmas and New Year
Greg
Ulladulla
Nice job setting up the machine true, I wonder if a cobalt cutter may have helped.
Wow Just how big can you go? Amazing repair and using old school tools hand ground is terrific. Great job and as I am 95 I really liked watching. Could another flange be made up and added to the existing one? Maybe just a thought. Carl. My first lathe was flat belt drived from an overhead line..
From Cape Town, South Africa. My weekly fix.
Wonder if a grinder attachment could be designed for this type of facer? It would need brushes and slip rings for an electric grinder motor, but that's a pretty common application. Also you would need some type of spring tensioner and gauge to keep a constant grinder wheel pressure against the face as the grinding wheel wears down.
No problem for you guys, slight adjustments here an there, bobs your uncle, another job done boys, and quality work done as usual 👍😊. One of your best ones yet, Have a great Christmas and holiday, regards to you all and your families 👍
Merry Christmas to you all Heavy Rain where you are and 15 -20 cm snow and -22C here in northern Canada
Merry Christmas to you and your family from Wights Mountain. Qld. Great show.
Again another great video Matt, MERRY CHRISTMAS and HAPPY NEW YEAR from H town.
Enjoy the video very much you do so good cant wait to see the next one
Sharpsburg, Georgia USA
Great video, I've never seen that machine before, very interesting to watch. My first thought when i saw it operate at that slow speed was its like my shaper. I wonder if a bull nose shaped HSS cutter would handle those heat affected areas, ive had good luck but i don't think I've had to deal with steel that had 10 heavy passes of heat put into it, 2 or 3 maybe. Just an idea, i think its the problem solving part of the job that keeps us coming back.
Very interesting bit of kit.
Off the cuff, if the cutting bit was rotary (endmill) with greater step-over and depth, it might be quicker, idk.
Or, you could map how much these warp and keep a log of them. Then mill the opposite expected feature in it so it pulls straight when welded...if you could pull that off you've be revered forever as a wizzard. Have the beard to boot :)
Have a great Christmas
Fortunately, someone else had that same problem in the past, so they invented a flange miller. I cannot even imagine any other practical way to tackle that problem, short of having a milling machine that stood like 20M tall!
Happy holidays to you all at the shops.
Or a deep hole in the ground, haha.
Great video! Hope y’all have a Merry Christmas and Be Safe! Greetings from southwest Georgia,USA.