INSANE Machining Techniques Used on the Pump Housing
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- Опубліковано 9 тра 2024
- Continuing machining the pump housing on the Heller CP6000 using advanced techniques in Mastercam. Barry Setzer breaks down exactly how he machined the most challenging sections of the pump housing and how to keep from crashing your machine.
00:00 Next Steps to Machine the Pump Housing
00:43 Machining the Pump Housing
04:35 What is 3+2 Machining?
04:59 3+2 Machining Made Easy in Mastercam
06:21 Creating Toolpaths in Mastercam
17:06 Conclusion and What's Next for the Pump Housing
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#Machining #Machinist #Engineering #3DPrinting - Наука та технологія
thank you for leaving the macining sounds in,it helps when learning alot
I am a beginner French milling machine and I program on Mastercam 2018 and I really understand your explanations, I who have poor English. This software is really great. Thank you Titan of cnc machining I love you ❤
If you fill the big center hole with liquid cooling before cutting,you could drasticly reduce all vibrations of the part when milling. It was a method i used on aeronautic parts...
Did you fill a bucket and dump it in there or let the spindle get over it and hit feed hold? Lol
I’ve used that technique and it’s helpful when the chatter is in the part. It doesn’t really help if the chatter is in the tool.
Looks and sounds like the dream company to work for!
Barry this is really impressive, Thank you! When the ballmill made chatter noise, Jessie came straight to my mind... I imagine him in the background somewhere thinking "Barry at it again" XD. I love you guys =D
Thanks! And fun fact, a few weeks ago I was sliding my desk across the floor and it made a terrible squak, so Titan comes out of the office and says "Ohhhh I thought that sound was you machining something." LOL!!!
lol anytime I hear Barry's machine fire up, I go ahead and put my ear plugs in because I know what's coming 🤣🤣
@Jessie_Smith Lmao you and Barry get along so well and joke around so much. It's something every person should strive for in our great trade. Always gotta have fun 👍
@@Truckers2025 100%. If you can't find a way to have fun with each other then work is going to be miserable. I laugh at a lot of the comments that we get with people losing their minds getting mad over the smallest things. I think to myself, man these people must be so miserable to work with every day.
@Jessie_Smith exactly. So many people are miserable. If you can't take a joke, then stay inside and let the rest of us have our fun lol
That is some very demanding CAM work.....good thing you have some great software to walk through the simulation of the tool paths.
Nice breakdown, Barry!
Probably the most well explained 3+2 axis program from now. I kinda understand it even if I never touched a machine like that yet.
This was actually encouraging to see. Sometimes cutting conditions will just be bad and you have to power thru it. Have had this experience multiple times and feel like a failure even though it was done on time.
Good job Barry! Keep that Heller working. That noise is just the sound of money!!!
More tips like the one at 7:26 please that was super helpful.
I really liked this video. The tone, information, and execution are all on point. Great explanation and editing to show what is being done and how it is being done. Great job.
The teacher Barry showed up in this video. Outstanding work.
The level of mastery, awesome
Great video Barry! There's some next level CAM involved here. Good looking part!
Awesome!
Can't wait for the finishing videos and a completed part!
Definitely put (part #'s) on the video so we can know it's a continuation of the first video's
Keep em coming!!!
Absolutely lovely content man.
I feel you all the way doing this.
Awesome job
Awesome work Barry. Very helpful and interesting video. The 1/2" ball mill is the secret to your signature chatter pattern!
HAHAHA WHATEVER!!!
lmao yes!!!
@@barrysetzer Seriously though, great work. It's an intimidating part, just working out how to approach a job like that is hard. I'm inspired to try some new techniques! :)
Awesome job explaining it all Berry 😁.
Damn fine job Barry!! I'm going to be taking a 5 axis class in September and I'm so pumped to see what all I can learn!!
Heck yeah man! You're gonna love it. Like I said, 5 axis =freedom!
Love this! Have been waiting for this update video for weeks. Would be intriguing to see this same shape file converted and loaded into a TruPrint 5000 or similar additive machine to see how the manufacturing time, quality, and cost would compare. I say intriguing because I really don't know what the outcome would be. Wish I were in a place where I could run some competitions to see what the outcome would be.
Beautiful part and a very nice explanation!
Awesome machining! Given how much material there is to remove, this seems like it would be a good candidate for DMLS to start with and then machining your datums and critical features afterward.
Awesome video and machining also your Mastercam skills are super impressive.
I'VE BEEN WAITING FOR THIS VIDEO TO COME FOR A LONG TIME, YOU GUYS ARE GREAT
Thanks for your support bro!
I think a Lollipop ball endmill would be excellent for a part like this sneaking into some of those corners! Excellent work with this part and rank you for all the info you provide! :)
Stick out is the problem. Having a big ball on the end of an even thinner shaft would make it worse.
One op!? And without coolant… this is amazing! Makes me miss machining, even though I was pretty much just an operator/inspector
Can’t wait for the next video!
Must have been fun hearing all that the whole time! LOL!
Great work! It is what it is sometimes. Can't have perfect scenarios all the time.
Incredible work !!!
I always love how you post so early ❤
Not gonna lie, Barry explaining all those operations is pretty sexy.
See YOU get it 😂
Such a difficult part to program, I have a hard time imagining how long it would take you if you were just starting out. Thanks for sharing. Charles
The progress is way cool thanks
“Barry is just loving that chatter pattern! “Gorgeous 😂
- some random machinist
Also, that mastercam program looks painfully hard, you guys make it look easy compared to the basic shapes I do at work. This is an almost impossible yet possible part without a casting, this would be so much better as a casting,
I’m assuming it’s a one off part, meaning it’s probably cheaper as a milled part than a casting.
@@dakotareid1566 yeah you’re right, still a crazy hard part though
Good stuff, Barry. Very informative. I've been learning some of the 3D tool paths on Mastercam. Opti-rough is a life saver, lol
Opti rough is nice and all but man its an annoying toolpath. All kinds of crazy moves. Haha
@TritonTv69420 Yea I'm sure there are better tool paths to use in certain areas but as a beginner with 3D tool paths it's generally a all around kind of toolpath. So I'll stick with it until I'm more experienced
This was a nice video! Question for the next video, how long it took from mounting the stock to the finished part?
I love this freaking channel.
Ouch, that was hard to watch! Beautiful part, complex and challenging. But encouraging to know that sometimes its just hard to get a setup not to make noise. It seems liek sim simultaneous 5a xis movement might have allowed you to use a shorter tool.
Have you guys worked with Okuma's collision avoidance system on their control? Pretty awesome for axis work like this.
Waiting for the final video!!!
It would be cool to have a similar explination video going over plane manipulation for Y-axis programming on a lathe.
Best video in so long.
Awesome video, one question: how are you clearing out the inside of the channel (where the fluid or air would pass through)?
I think this is the main question that arises for everyone who watched this video
Amazing video and explanation as always! Just one question, wouldn't it be easier to do the undercut to the flange with a disk mill? You would still have to avoid collision, but with a tool small enough you can simply turn around the part, or am I missing something?
To remove the material left in the pocket at 9:15 you should try Kennametal KenFeed end mills instead of this super long 1/2" ball nose.
Depending on the diameter you choose, they might be too short, but all you have to do is to tilt your plane until you clear the flange with your shrinkfit holder.
BOOM !
I like to use a high feed cutter in those situations where you need the reach while roughing. Follow up by picking out the corners with an endmill.
Hey that's a really cool video buddy !! I have a question I've always been curious over, when you program a complex part like this one do you run it in attended on the hairy tool paths? Or are you like me and have both hands on the estop button?
If its the first time running it, my hands dont leave the knobs. I know me, and i dont trust me!
I feel like this part was designed to be cast and then someone said "actually fuck it, make it out of billet"
It could just be a one-off for a machine where you can no longer order spare parts.
The casting company probably won't start up a run for just one part - which will still need several machining operations to get ready for the end customer.
@@MrMBinder Not to mention all the cores you would have to make, it would be a big job. But I still dont see how you could use this machine to remove the material inside the pipe? Great for demonstrating the process though. Charles
@@465maltbie Yeah, the only thing I can think of for the pipe is to open it up from the other side to remove the material and then weld a piece back on.
Some 3D welding robots can "print" the entire structure, but the surface finish on the inside of the snail might be rougher than the casting.
We'll see for sure when the outlet port is machined. It's not even rough machined yet
I made one of those housings this weekend with my Dremel .
I realy love these kind of videos. I always wondered what kind of strategies and toolpaths professionals use sind I don't have anyone with any expirance to teatch me. This realy gave me some new insights is how more complexe parts are done. Thanks and reetings from the Netherlands! 😁 PS. I realy like to know how 5 axis parts are done in one go. Like, how you program them with an breaking edge. I've tried with some succes but I realy like tho know how jou guys do it 🙈
Can we get a whole video of doing a job from the very start to finish , that would be very cool to see how you guys do that.
Super awesome
man, that ball endmill sounded like a dinosaur dying... rest in peace material!
I am about 1 week away from finally getting myself access to SolidWorks & eventually SolidCAM, so i can work myself through all those training parts :D
슝크 클램핑 지그에 헬러 장비에 홀더와 앤드밀은 케나메탈.... 상상을 초월하는 가공속도. 대단하내요
it is loud to mill this way yes. I know it from our shop. But sometimes there is no other way ! Like to see the next Video!
Pyro=great machinist. Thanks man
Hello guys, pretty dope channel you got here. I'm in quality control. This part would be pretty cool to check on a CMM or Romer arm.
Liked the video. Is this part too big for the laser sintering printer? Also is there any leeway with the vendor to redesign the part for easier machining?
God I have had some times where my tooling sounds like that ball end mill and sometimes it is so stressful for some reason. Just listening to that vibration makes you sweat the first time you are proving a program out, but sometimes you cant avoid those crazy stick outs.
Ahhhh it always makes me happy the rare times i see intelligence in the comments. You sir, deserve a raise
Out of curiosity, is there a reason you used your long reach ball mill for the top flange instead of a radius wheel cutter? It looks like there is enough clearance for a good size wheel cutter.
Watching this while working behind me is a large horizontal 4 axis machine using a 63mm fast feed tool.
I hadda explain the same thing to my students today turning with cheap hobby chinese inserts and turning tools on a CNC lathe. "Its gonna sound like that, there's nothing we can do"
i put these planes in the part design, fusion360 being integrated is highly useful
Thanks for milling the turbo housing for my Honda civic
No critique, I am just wondering if this part would be easier to make if you 3d printed it? Or are my thoughts wrong? Love the videos. Keep up the great work!
Barry, gets the complex jobs,why?, He is worth his weight in gold, Hell of a Machinist!
I may be biased, but I agree. Hahaha, thanks!
that would be A LOT of gold 🤣🤣. But yeah, I guess he is a pretty decent machinist. Don't tell anyone I admitted that though
Is very good!
That's the most impressive paperweight I've seen.
How are you going to reach the inside, and machine the hollow part of the tube?
They wont, its not gonna be used for anything
@@AtMortenJthey are doing all this work for nothing?
@@gordybishop2375probably for advertising
Its just like that brake disc they a while back, just for content
You've never heard of a curved drill?
Thanks for leaving the original audio in.
While it doesn't sound *amazing* it's much better than whatever "music" some people might add over the video.
How about machining the inside of the snail, though? 🤔
It's starting to look like a job for a robot 3D-printer...
@@MrMBinder The inside of the snail is straight for 6" or so, and as it begins to curve, it opens up on the bottom of the part so it can be machined from the bottom.
@@barrysetzer Neat! Thanks for explaining.
It's pretty difficult to tell from the CAD shown in the video.
How many hours would it take to 3-D print this part versus the total number of machining hours?
4:00 +/- got a great goose call goin' on there!
Have you considered other options than machining out of a blank?
Metal 3D printing it would probably safe a lot of time/material and you could machine the necessary faces afterwards?
Really impressive btw look forward to seeing the end result!
Im not an expert so take what I say with a grain of salt. Printing the part out could possibly be faster than machining it out of a block, but it would require a lot of post processing (heating to relieve stresses, machining, etc). I feel that slm is great for geometries that would be very hard/impossible to machine out, otherwise its just more economical to mill out of stock.
How many tool paths and how long did this take? Great video!
Out of curiosity, ik i probably wont get an answer, but why did you go staight for the ball endmill? I would have use a toroidal cutter like 16r3 or even one with inserts (we use 32r2 in my company) to rough out the majority of the rest before you switch to a ball endmill.
Just a question: why didnt you use 3+2 automatic with manual planes?
Least satisfying Titans of CNC video ever (That terrible, but necessary sound 😣).
Still impressive.
I am really curious about machining the inside of the snail.....! Is there a video? If so give us the link!
Does the software record all the operations so that you can create more identical pieces without further interaction?
Damn that's a lot of careful cuts 😅
At what point do you just want to grab the customer by the neck and tell them to redesign the part? 😂
Excellent video as always. One question... Could this part be programmed in Fusion360, or is it not advanced enough for this type of job yet? Ciao, Marco.
At least the operations until now should be easily possible in Fusion360. There is even an option to retract the tool if it would collide with tool or holder. 5-axis operations are limited to the manufacturing package($$$), but not needed for roughing.
Yes, it can be.
Ouch, what rpm is on that extended tool??😮
Was there the thought of leaving the core solid to reduce harmonics? Also was it considered to drill everything possible to get the roughing out of the way? Not talking any shit by any means, just thinking of somthing i would have thrown out when considering malt...removal.
the past 3 months all i seem to use in Opti rough to rip, Opti rough to semi fin and drop unified (Z) plane paths on everything i can get away with.
Just know that i heart you.
Is the finishing out yet?
How do you get the material out of the "hose"? That looks really not accessible:
that is what interested me as well. seems like the most challenging part of this job
Awesome video! That would be so annoying to listen to that ball endmill for an extended period of time! At work I was roughing a really tall part so I had a 5in long 1 1/4 high feed. The roughing took a hour and a half and I was getting so annoyed listening to it!
How did you finish the inside of the housing?
Amazing programming, why no coolant?
That part really would have been better off printed. That being said, you did an impressive job at machining it.
printing wouldn't be nearly as strong (there's a reason this wasn't just cast) and printing is for unskilled dorks who want to feel smart and capable because they can follow a series of instructions for a plug and play device lol
Just one question, when you have that stickout and the vibration. Could you give us a few words on how the tool life is? Is the tool itself so chunky that that amount of vibration doesn't really affect it or...
Please, this is a really fringe, but mastercraft topic.
Hey bro, yes, chatter and vibration like that will give you around 30% less tool life. It sucks, but sometimes you cant avoid it
can you show how to anodizing aluminum 🤓
Hey barry, how much time did it take you to program this part in mastercam ?
About 3 days, give or take!
A 3/4" AB carbide insert tool just for aluminum would get rid of a lot of that chatter. A international mini mill would also help with that chatter.
Muito bom !
Barry, your hair stylist is fired
Yeah, good thing im not as dumb as I look 😂
Id really like to see a video of the whole program running. Block to “finished” product.
How do you open the inside of the round pipe? There is a radius section. CNC does not have that capability.
I was thinking EDM (Electro Discharge Machining) A tungsten sphere mounted on a spiral shape steel arm with matching curvature to the internal spiral axis diameter of the 'snail' could be secured to a 5 axis tool holder where it can slowly bore a spiralling circular hole through the entire 'snail' with very high tollerances from start to finish. It would require a quite large EDM Machine with a 5 Axis operation tool mount,
The comment section is quite the "echo chamber" (no pun intended) regarding tool vibration, when more people should be addressing this most important step in making the part which is fundamentally important for its completion.
Chatter solution, I don't know why this works but it sometimes does. If you take some of those car wash rags, the really fluffy ones, usually bright yellow and stuff them in the bore, add flood coolant, it dampens the chatter. In some cases, it has cut all the chatter out for me. There is something to do with water that has a frequency that seems to null out all sorts of stuff. It doesn't work in some cases, but i have made parts similar to this one and have stuffed rags in the hole, filled it with flood coolant and the chatter goes away. I have also done the opposite, and wrapped parts in fluffy rags with zip ties and it cuts down on chatter. I know, it's not perfect but it does work sometimes.
Yes, but only if the workpiece is not rigid. Here the problem lies with the long tools. only reducing the speed helps.
@@tobiasmuller2086 I agree. I would imagine every little bit helps though. Not sure as I have never done something like that.
Shouldn’t this be 3d printed the basic of the additive and then subtract by mill to get your tolerances?
"Screaming Eagle"!!!