Incredible Process of CNC Machining a Rocket Engine Turbopump
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- Опубліковано 21 вер 2024
- This real-world aerospace part, as seen at Blue Origin, is cnc machined on the Heller CP 6000 with Kennametal tooling, using advanced 5-axis techniques.
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#Machining #Machinist #Engineering
You never addressed how you hollow out the spiral. Could you please explain this
yea, and is this thing even real & functional? or is it just for entertainment & promotional purposes only?
I think the original part is made out of a cast iron shape. And the hole is there inside.
The cochlea hole can be made with a graphite electrode on a CNC erosion machine
@@prety7838 how long it would take?
It’s not , it’s for demonstration , it’s not possible with current technology to make that unless it’s 3d printed, or Cast.
Finally, you don’t know how long I’ve been waiting for the last episode of this
except this isn't the last episode, isn't this the same thing as the previous one?
@@mapsofbeing5937this is the same one
@@mapsofbeing5937i’m assuming it’s a recap so when they post the final episode it makes more sense to a newer viewer
@@camhines15thanks! You get it!
I've been wanting to see this piece completed for a while now. Looking forward to follow up videos. Just a suggestion and maybe you guys have done it before in the past, but I like to note what the weight of the work piece is at the beginning and then the end to gauge how much material was removed.
Usually we do that. But in this case i dropped the ball. Tomorrow ill check and let u know. But the next part i do on this machine is going to be super sick and a little scary. Ok alot scary. Its starting at around 2100 lbs…..and will be 36” tall 18” diameter mounted to the table vertically
ua-cam.com/video/mTQonWqiU4w/v-deo.html part 1
Love roughing but let's see the finishing!👏
i really like building patterns for cast pump housings, i am a pattern maker from germany, and we use some of your tips when building patterns with the help of cnc machines!
Amazing work! I remember when pump casings had to be cast. The ability to machine a casing from a block of solid material is mind-blowing.
I would love to see a comparison of an equivalent part made by casting to a CNC part both visually and dimensionally.
It’s still has to be cast or printed,
Not possible to machine inside that spiral of the housing , Lol. There’s a reason they didn’t show that part.
@@adammiller4879facts man. Keep in mind that we are showing the methods to machine similar parts. Clearly the spiral would be cast or printed on a production part. But even making this part from billet, it wouldnt be impossible to get the id. It would just be a long, slow process with a crazy extended lollipop
@@barrysetzer I would love to see that it would be insane. I forgot you mention that in another video, would be cast for production and machined for 1 off do to casting cost. That would still take an insane tool stick out to get inside that . Maybe a minature right angle head with a lollipop endmill😂
US and Soviet scientists did not even dream of such equipment during the space race of the 1950s and 1960s. All the more respect for them.
I used to help make a pump nozzle housing for Areo Jet back in the 1980s at a shop in Troy Mi. Hand formed Inco 625 Tig welded to a Machined base.
I used to work on the Delta and Titan programs (assembly and testing) for Aerojet in the 1980’s. This part immediately reminded me of those Titan IV engines.
Thanks for letting the sound of the cut be part of your videos. I dislike background music and such on technical videos. I want to hear you, the presenter AND the background noises which can offer useful information on the quality of a machining operation. I'm glad to learn that a good cut might sound "bad".
Love me some machining racket, too 😂
Looking good Barry. Can't wait to see the finished product!
Shouldn't the curved pipe be hollow? That will be interesting.
I think the original part is made out of a cast iron shape
Sir, that is complicated. You guys are just damn good. I've been a subscriber for a decade now. Can't even imagine what you guys will be doing 10 years from now.
Thanks Ron! Glad that youre still watching after a decade, and i hope that you still keep an open mind and learn a thing or two here and there!
Wow, what a beautiful Piece (so far)
I don't want to disturb anyone, but in first line I contribute this to:
- the fact, that there was talented people to cast a blanc workepiece to start, without blowholes
- the fact, that there was a genius brain to make the CNC work that way.
I would see the same piece as welding-part to make a direct comparison.
That would be a much more challenging work.
I love watching you guy make a master piece and you make it look easy.
That is such a cool machine and such a cool part! Awesome video Barry!!!
Thanks Donatello
Pumphouse is BACK Baby! Great video Barry and Brandon!
I hope you also do the inside of the housing.
That would be incredible.
that's the proprietary stuff
About how that one tool you mentioned made a ton of almost painful noise, I actually thought that was pretty cool. It almost sounded like the workpiece was screaming for mercy 😂
Right, i see that you are “one of us.” 😂
What if you could cut this process down to half the time machining it, if the engineer said, "yeah, I don't really GAF if it's perfect. The faces have to be flat, the holes have to be perfect, but you don't have to machine everything to glass smooth". I mean, really, it's a pump housing, nobody is ever going to see it or care that much. 🤓 It was a functional part in the last video!
That’s crazy slick!
Quick question: Is the fact that this is going to be used in a cryogenic application why you didn't send it to the pixie dust department and have it 3d printed?
Bwahahahaha my fave comment.
I've worked with 3d printed equivalents and turbine components from the same assembly. You can optimise the 3d print more but at least with machining from billet you know exactly what you're getting and it's fast
Witam, fajnie was się ogląda.
Thanks for watching!
Thanks for showing what the others won't.
1:10 I was waiting for a crash... apparently he has learned his lesson
Amazing work cnc machin
since this is just a recap, can we expect the follow-up soon?
Did you guys just write the code for this part, so over at BO they can mass-produce it?
Yes, the final video is currently in editing. The next time u see this part, it is the finishing.
What kind of genius is this
Excellent work 👏👏
Barry, walking the dog!!
Lol what up Arch
Stupid question maybe but how do you drill into the turbopump? to make it hollow
The cochlea hole can be made with a graphite electrode on a CNC erosion machine
i really love the machining process
i would unironically fall asleep to some CNC asmr
i have sleep acmia really bad, i usually mute the video because the talking would keep me up
Golden Engine
That is next level...
We print parts like this all the time on our Velo.
What is your total process time for this part from billet to finished part?
About 14 hours. It always seems super long just because we post so much in between
Speaking of turbopumps, you guys ever machined Mondaloy? I hear it’s worse than inconel.
Speaking just for myself, no! I actually have never heard of it. There are a few materials i have been wanting, guess ill add that to my list along with iron meteorite and transparent aluminum.
hello sir, I want to ask whether the CNC machine is for lathes made from iron blocks or cylinders; where did you buy it from?
Much Better 🙂
2:15 - Not sure how to explain this, but does the machine automatically adjust the feed (table rpm?) to compensate for the increase in material as the tool moves away from the center?
Yep!
A Ductile iron turbo pump...? please explain
как сделали обработку с повротмо оси? на небольшой угол шпиндель завалили?
I pretty sure you can not mill the hole, EDM, maybe, but that would be very tricky. Does anyone even make a 5 axis EDM ?
Can you imagine what Joseph Whitworth would say if we could show him a 5 axis CNC.
you better do some turning on that mill-turn
Dude whyyyyyyyy. I am a MILL guy 😂. Fine. Fine. I will turn something.
It didn't really take you guys like a year to make this pump housing though, did it???
why isn't cooling used on some of the machining?
No 3D printing here. What company do he supply these shells to?
When part 2 is coming
Rodnyey Dangerfield is back!
"I get no respect"
I feel like you would understand me if i said this was a machinist version of the “triple lindy”
😂
Did you do the impeller for this?
No. But i did spend a few years making impellers. Those were a tough few years, but i gotta say that Concepts NREC Max 5 and Max AB made my life sooooooo much easier
I can do this by hand 😅❤❤❤❤
You never addressed how you hollow out the spiral.
50 hours to finish this entire 5 axis job?
Turbopump is cool. But why this material? Just a test pump?
It will allow for the paint to stick....
🤯
Yeah guys, just wait another 6 months or so and we will show you the finnish. Longest cycle time of the industry on this part.
Can CNC make another CNC?
First!
No coolant?
That chip evacuation under the Pallet changer at 2:48 is terrible. Is there some flushing that you guys didn't use? This open design doesn't look very lights out machining friendly.
These machines are probably the worlds best when it comes to lights out. Thats why bmw, caterpillar, paccar, detroit diesel, ford, and pretty much every giant oem uses them. What you are seeing is a direct result of us turning coolant off for filming. And that includes all chip flushing
Ductile iron?!? Not inconel????? Just asking for a friend 😂
Inconel presents four issues in a part like this.
Issue 1: it is extremely expensive. Ductile iron will do the job for a lot less money.
Issue 2: it's extremely hard to machine. An excellent machinist like Barry has no problem creating parts from ductile iron. Inconel makes problems for you if you don't have enough of them already.
Issue 3: Inconel is heavier than ductile iron - .293 pounds per cubic inch for Inconel, .256 pounds per cubic inch for ductile iron. Rocket scientists worry about excessive grams because every gram your rocket weighs is a gram of lifting capacity you can't sell.
Issue 4: Inconel's primary advantage over other metals is heat resistance. In the motor's thrust chamber? Perfect Inconel application. But...this is a propellant pump for a rocket. Blue Origin could flow one of three things through this - liquefied natural gas, liquid oxygen or liquid hydrogen - and the warmest one of the three is -260°F. All this has to deal with is pressure, and ductile iron does that well.
In something like this, ductile iron is a good choice.
Man, i was laughing at the original question, but jmowreader literally gave a better answer than i ever could. Thanks homie
@@jmowreader9555 I am an aeronautical engineer. You are talking out of your %%%% because you have no idea what the part is for.
@@barrysetzer No problem sir, I hope 2024 goes GREAT for you and all at Titans. BTW, are you folks planning to get into waterjet or CNC plasma cutting?
You guys are still doing it? No wonder space parts are so expensive
Why did you guys leave Fusion 360.. Nowadays it's much better than MasterCAM
Im love my job but the management make me bad i dont know what to do aftzr 9 years doing great pièces
These parts are produced by casting, not by milling! You have produced many bags of metal chips and used many tools
Or you 3d print it
Could this part be 3D printed, then cleaned off in a CNC vertical mill?🤔🤔🤔🤔
Yes! And it could also be cast and then finish machined. But sometimes it is cheaper to machine a single part from billet.
the design doesent look like it is optimized for CNC... looks like it is optimized for partly casting, or lathe machining, with welding
Why isn't there lubricant?
my guess is "for filming purpose" as usual. though not all operations need one with the right tools
Dry machining of cast iron is better for the tools,otherwise you end up with an abrasive sludge.
Is this a reupload?
Its a compilation before the final vid. Just a recap.
Could be worse, the sound of processing.
Why didn't you use lubricant for the tool that sounds terrible.
Coolant would not change the sound.
@barrysetzer I've had different experiences, but it's ok
В трубе как?
ok
А отливку отлить нельзя было, сколько ненужной работы сделано
Dude, seriously, you need to learn to cut with a flat button cutter at almost all times. Ball cutters are the worst.
What would we do without CNC...can you imagine how many hours it would take to manually machine a part like this, and the setups and fixturing....yikes.
Parts like this have existed long before CNC. The old school way is to get a foundry to produce a casting, then all you have to do is machine in the critical surfaces. In fact, that's still the way turbos are mass manufactured to this day.
That's very true, and I know that for a fact since I designed castings for many years....the big difference is that you have to design the casting, then have the molds made, then make the fixtures to pick up the datums to start the critical surface machining and along the way xray the castings to make sure you didn't have any voids in it. The turn around time for us was 16 weeks, being able to take a large block of material and go straight from the CAD model to CAM to a finished part was a major cycle time saver especially in the prototype phase. @@JaenEngineering
@@ericsandberg3167hahaha i love it when people like you comment. To your point, a massive casting company quoted $12k for the prototype. But we could easily do it for $6k
Profoundly stupid idea. Just assemble it from what are evident parts in this assembly.
Yourself is machinis not engineers...This is why yoi keep repeating videos ..
You guys can do lots of creative things buh 😢
We would love to hear what you would like to see us do! Let me know
Awesome gear. Awful music.
REPEATED VIDEO...
This video is new. It is just a compilation of everything up to the finishing, which will be the next video. Kinda like how when you are netflix binging a series, and you get the recap at the start of the next episode.
Вытачивать деталь из целого куска стали, изготовленную под технологию литья - это дорого и глупо.