The great thing about CNC machines is they do exactly what you tell them to do. The bad thing about CNC machines is they do exactly what you tell them to do.
I agree. As soon as you drop your guard that's when something bad seems to happen. Especially when trying to rush at the end of the day just to get it done so you can go home.
Was running a Mazak Integrex 300-IVS. Was setting up on a job of 1000 parts to run overnight, the transfer uses macros to adjust the work offsets and for cut off locations. I had just switched from a 3jaw with external chucking on my sub side spindle to a collet chuck with internal chucking, I forgot to switch the chucking type and crashed the W into the part. I then reset and fixed the chucking issue but forgot to clear the macro that had moved my work offset for the cut off, Z went straight into the sub spindle chuck at 100% rapid and knocked my B axis out of alignment by .01. We have since switched over to esprit cam for our lathe department which outputs actual X and Z locations for the cut off instead of macros. We still have all of our creo programs as reference files so it’s something we have to watch for when running older programs
100%. I was learning CNC and the way I was taught was to load every tool, touch them off then run the program. The guys were telling me I can save time by having the program load every tool and touching them off as I go. Crashed a few tools trying this before I told them to "F off I'm doing it my way."
I told myself I would be very, very careful my first time machining...and I chipped an insert within my first few hours. Left me shaken for sure! I can only imagine the nerves of steel machinists develop over the years.
The first time I cut Titanium was nerve wracking. I was used to cutting only Aluminum and mild steel before. Every subtle noise that the machine or even people around me made would make me flinch lol. Now it's not that bad, it's just slow and wears the tools down exponentially faster. Broken tools also don't risk scrapping the part as much as with Aluminum, with carbide embedded in the material.
Today I reprogrammed my thread operation to threadmill a thread feature on an Inconnel AMS5663 Bushing job I've been working on. The first helical pass went well, no problems it did exactly what I wanted. On the 2nd pass I was watching it like a hawk and about 20% into the cut the whole Capto holder popped out mid cut. I hit feed hold and stopped the rotation right on queue and to my luck there was no damage to the part or the holder, or the $214 tool. If I hesitated another .5- 1 second I think it could have really fucked shit up. I'll be sure to tighten the Capto bolt to 40nM every time now with a click torque wrench as the holder prescribes. Wooooo just another day on the job.
@@13anomalous16 i have some jobs at work that are crazy loud i one time asked my boss if there was anything i can do to make it better he looked at me and handed me ear plugs.
its not really nerves of steel, its just confidence in your material knowledge and process knowledge. theres plenty of materials i dont like cutting at all, but i know how to cut them and how to utilize the tooling to cut them so there isnt really a reason to be afraid unless im taking a risk
@@dharaosgaming That reminded me of this time a thread mill was blown free from the holder. I wasn't the one setting up but I did load the tools. It didn't seem loose but the tools already come built and ready to load so we don't have the torque wrenches to check. It actually cut the threads in sync and then when the guy setting up stopped the machine to check the first hole, it blew the tool out of the collet holder doing whatever automatic thing a mazak does when shutting down the spindle. Didn't scrap the part, whew, those parts are like 1 inch thick by 10 or so inches wide and then over 100 inches long.
if i need to speak to someone that is focused on the machine i always try to stand somewere where the person can see me, and i just wait for him to talk to me when he is ready for it
I wish people in the shop I work at would learn this...I'm the 2nd shift lead off in the CNC department and one of my operators just yells my name across the shop ugh. We ain't playing freakin Marco Polo here lol. Or he'll come right up behind me and say something and scare the shit outta me. I can't count the number of times I've whacked my head on some part of the machine from him doing that. Makes me wanna throw whatever I have in my hand at him. (Obviously I've never actually done it since I still have my job haha)
i mean that happens. I seen someone run a 1.5" boring bar in to the wrong side of a predrilled part... Only 1 side was pre drilled, the other side was closed, guess what happens when it is going in at full rapid. And thats back to aligning the machine again.
I did that once with a .625 solid carbide drill in aluminum bronze. I don't know what the SFM and chip load was but it actually punched a hole right through. Luckily just drilling clearance and everything was good to go. Older style programming where offset follows a point on the part instead of always being bottom of part so I had it set bottom of part, not top of part. Would've eventually hit the vise floor though if I didn't stop it.
My old boss (the owner of the company, who had no understanding of CNC work) used to interrupt me, while I was programming and doing setups or repairs, by walking up behind me, and asking random, completely unrelated questions, usually within two feet of me. He didn't warn me that he was there either. One day, he startled me, during a head change on the water jet. I swung around with a 36" crescent wrench, and nearly took his head off. It was close enough to move the hair on his head. He stopped getting close to me, and always waited until I was done, before asking me anything again.
A coworker once told me a story about him asking another guy (who worked at a conventional lathe at that time) where to find a certain tool (he was new). The guy working at the lathe went to show him a few tools and asked him which one he needed. All while the late was still moving towards the chuck. Eventually the machine crashed. The tool broke, the part flew out of the machine.
Well the guy operating the machine started to swear in Hungarian which was apparently quite hilarious. So only a broken tool, scrapped part and an angry worker.
@@iizvullok I think I remember something like that happening at college. Something was maxxed out in travel yet it was in power feed mode so whatever was left of that gearbox was turned into metal flakes from what I could tell from the horrible grinding sound.
I crashed a Daewoo DMV3016 VMC in January of last year. Co worker walked up to me talking while I had to put a hard jaw on top of an inconel pin to clamp it in a set of soft jaws. I was talking to him and forgot to take the hard jaw off the top the vise, closed the door and pressed the green button and then BOOM! Thank lord it was at 50% rapid though. I had run thousands of these pins. Learned a lesson that day and still have the hard jaw as a trophy.
Timely video. Just last week I said to our scheduler (who is assigned to ask each machinist "where are you with this?" a few times a day) "never interrupt them when they are programming - ever". Instead, she stands there and waits. That's just a bad right? LOL Great video Donnie!
I was working at a company called True Trace years ago when I heard a big bang at the other end of the shop so I walked over to check it out, what had happened was Rusty a guy that had worked there for 20 years forgot to take out the chuck key from our big lathe and started it, the key went through🤔 the roof and we never found it.
Couldn’t have said it any better Donnie, I really wish my supervisors could watch this video , I have had instances in conversational programming a Hurco mill, i fat fingered. The wrong offset, and another machinist who was bored running a high quantity part would bug me between cycles, while I was DTG my part luckily I hit the interrupt button just in time before I had a huge Z axis crash.
I can tell you, from my experience driving big rigs, that we, too, can have a disastrous outcome from being distracted for even one second. These things are over 70 feet long and can weigh 80,000 pounds. Even talking with a passenger can be too distracting. It only takes 1 second to just totally ruin your day and, potentially, many other people's day. 1 second. Oh yeah, I can totally relate! 😊
Reminds me of running the Mazak V100. It's a massive machine and it doesn't stop on a dime like most other machines. The accel and decel is so slow that if it starts to move and then you think, oops I better hit feed hold it's long too late. The gantry of the machine, which may very well weigh more than a (legally) fully loaded big rig, crashed into the machine table. This was before I worked there and those who were here said it felt like a tremor before an earthquake.
I'm pretty fortunate that I have the ability to survive distractions, I actually thrive on them. This allows me to stop in the middle of a set up/program to address one of my guy's questions, or help them solve a problem, and go right back to what I was doing.
Thanks for sharing your mistakes with honesty. I have a rule when I'm operating my desktop CNC router. If I'm jogging the machine, loading some new code or changing bits, do NOT disturb me until the program is running!! I'm acutely aware that the smallest lapse in concentration can come with the largest repair bill (or worse, injury). I can only begin to imagine the butterflies that come with operating such a beast of a machine. My little Shapeoko CNC provides me with more than enough adrenaline!
I had one time when I was at a production shop where I was flipping the parts and a coworker came up and talked to me and it distracted me enough that I forgot to turn on the vacuum fixture. So it started twirling the part of the end mill so it trashed the fixture since it was on pins. Because of the high stress environment at that shop stuff like that happened regularly. Another time a guy forgot to turn on the vacuum and it launched this part through 2 machine doors. The guy was lucky he walked away from his machine and the nobody was flipping the machine across otherwise it would have been ugly
Same thing happened to me with a brand new 5 axis a few weeks ago our wood machinist are always interrupting while we are machining on the cnc's. I had drill operation third hole was set to go to 0 instead of 400 went straight into a 1" plywood jig I managed to stop within a few inches of it going through the jig but it was still enough to throw the spindle out of position only just got in realigned today as the cnc manufacturer doesn't have any written instructions of how to realign the spindles and don't have any technical technicians available in the UK its been a huge learning curve for us learning how to realign the machine not sure if this is standard for cnc manufactures to have these kind of instructions to hand over when you purchase a cnc.
my worse crash was using gibbscam, same thing reran the program like 6 times, trying to take the taper out of a part, moved what i thought was the final time, took another .0005 out in the program to chase the taper out, the one time i didnt check the simulation, that .0005 just so happened to freak out the post to where it finished the cut, the rapid to X0 after the move. i was holding onto .120 in the chuck and had a center in it, it was a interesting seeing the part get knocked out and more interesting walking through everything with the lead to figure out what happened and seeing that the one time i didnt check my simulation was the time it just so happened to freak out over a taper line.
It's better to choose OKUMA Multus machine with Collision Avoidance System as a standard equipment. Than you will have a lot of additional time to do what you really want:)
I fully sympathise with this. I'm only an apprentice but last week I was setting up an old dual spindle Mazak lathe to run a proven program when I noticed the boring bar was loose, so I started to reset the Z length when another apprentice stopped to chat. It was the last half hour of the shift and I forgot to finish resetting the Z length. Normally it would've been fine as there's no night shift on that machine, but I was off sick the next day so my supervisor ran the program not knowing that I'd found the boring bar loose and the machine crashed and scrapped the part. I took full responsibility for the crash because I forgot to pass on the info that the boring bar wasn't set, but having someone come over to chat during setup can be enough to stop paying attention to one of the most important parts of the job. I even had three people come up to me the next day saying "I heard you caused the machine to crash yesterday" which was hugely embarrassing. So to anyone that works in a place with machinists, please don't start chatting if the machinist is trying to focus unless it's actually important 😅
I would pass a good part of the blame to the supervisor for not watching the DTG and catching that, especially if he knew that was to be the first part off of that setup. if I have to leave in the middle of a setup I usually leave a sticky note on the control saying "not proven" or something of that nature. on top of that, we always run with the rapid down low on the first part of the program, even if its been proven the day before, its just how I was taught.
I couldn't agree more. I worked for SecoTools here in New Zealand (now retired) for 28 years travelling the country promoting, testing and trouble shooting customer jobs. One thing I never did was to interupt an operator while he was running the machine. To me it was common sense. I am a qualified machinist and understand exactly what you are getting at. Cheers Ian
I am glad I am not the only machinist that has severe anxiety every time i try to hit a green button. I love set up, I love inspection, i love programing. But, that green button is the ultimate proof what you did was right. I was making a ring the other day and it sounded weird while removing the excess stock on a side 2 run. I had my finger on the NC reset button just incase that noise turning into something, it did, part lifted and i broke 1 carbide insert before i stopped it. I was able to replace the insert push the part back down and keep running.
I’ve crashed my B axis into my sub. Always some anxiety when running a new program that the mill turn will crash into itself. Glad it all worked out in the end.
When machining precision parts one doesn't talk to someone not involved with your machining. I had my own shop where I was the only machinist on my machines and didn't have the problem seen here however, when my machine shop began to get slow I would do outside work at a small CNC shop and when I was working on parts the employees left me alone.
It happens to the best of us and it sucks bad. I have never ran this Doosan but I have a multus. This had CAS collision avoidance system. I believe it would have saved you in this case.
We got a Doosan 2600 SY, a couple of years ago. I was a Haas guy, never ran Doosan, or a sub spindle. I had a coworker, a decent manual guy. He almost drove me crazy. Everytime I was at the control he wanted to talk. I am glad he is gone. Thus far I haven't crashed it. To be honest some if not most people don't understand what we go thru mentally on a daily basis.
I have a good crash on a big standard 2 axis lathe. Mind you, this machine was brand new. It was placed and wired up that morning. I get in for 2nd shift with the next part loaded. I did not check part length and hit go. The part was 1/4" too long and threw it out of the chuck and broke the door glass, and misaligned the turret at 11pm. I know your pain.
This makes me smile ... this happened to me at work ... indexed a bore bar straight through the work peice straight into the saftey glass ... Nice to know its not just us amateurs that make mistakes
The day is coming when CNC machines will have enough intelligence and situational awareness within their work envelopes that they won't allow crashes like that to happen. They'll detect the conflict before it becomes physical.
Doesn't matter how many years experience you have mistakes can happen...I've literally just had 2 weeks off work because I was running the Manuel lathe and was putting the jaws in the chuck..instead of pressing the button to rotate the chuck slowly to put the next jaw in I pressed a button with makes it run at full speed and the first jaw flew out and hit me in the nose splitting my nose open...Be careful out there
I had a bad crash last year for a similar reason. I was running a small batch of new parts on the lathe, but I was ordered to stop and make something urgent on the same machine. I had already made a program for it in the past so I load the program and replace several tools that were missing from the turret with some that were used in the small batch. I guessed there would probably be tool interference with the turret so I turned on the option stop, because I always program a M01 just before a tool change as a habit. What I didn't know was that this machine, for some reason, when you go from MEMORY mode to EDIT mode and the other way, turns off the option stop. It's the only machine that does it at our shop, I don't know why. So I was adjusting a bunch of things, pushed the option stop button, went back to the beginning of the program, go in memory mode, start the program and focus on the cutting. Near the end of an operation, a coworker comes behind me to talk about something. I was confident that the machine would stop before changing tools so I turn around to listen to the man. The machine didn't stop, changed tool with the wrong tool number, went in rapid for the next operation and crashed 2 tools together into the jaws and chuck. One tool holder broke in half and went flying, then the machine went alarm. Everyone heard the BANG. The coworker said "sorry" then ran back to his machine.
Oh man! That’s almost not your fault at all though. In my opinion having a machine that turns off optional stop at any point for any reason is pretty whack.
A real problem is a day shift employee working into the wee hours of the night. Easiest shortcut to "one little mistake." 12+ hours is asking for fatigue related incidents.
I find I am good until the 36 hour point. Then I am useless. I haven’t been in that position in about 8 years but back when I worked like that I always noticed a severe dip in my abilities after a day and a half
@@donniehinske that tracks. Studies show people tend to partially recover reaction time at the 22-24 hour mark but its never as good as being well rested. Wherever we are we need to take care of each other; humans are more important than hardware.
It’s fun sharing these stories with the world of machinists! It was such a disaster while I was going through it but looking back on it these are the things that make us better!
Send it to the Studer. Run it with plated CBN. It will be a little slower probably but save on inserts going through that interrupted cut. Seems like a waste to tie up a monster 9 axis machine for a rework roll. Waste on Studer also. Could run rolls on a much older, cheaper, worn CNC external. Just some thoughts from my experience working at a roll shop. Thanks to all of you for the great and informative videos. Im always looking foward to the next one.
I know for the integrexs at our shop it will not allow you to start a program if the W axis is not homed out, which would have prevented this specific crash, but I wouldn’t be surprised if there is a way to block/disable that safety feature
@@tyknott422some machines come with safety features that have to be unlocked, by the manufacturer, for an extra fee. They prefer you don't access those features, so they can charge huge fees for repairs later.
I wanted my 2 axis to back out to 26 inches in X on a Haas TL-4. I wrote the complete program on the spot. Everything cut as programmed, but instead of X26.0, I put X260. For those who don't know, no decimal means thousands of an inch. So instead of coming to the face and going 13 inches from the center of the 4" diameter part, it was coming from X4.0 Z-4.0 tp Z1.0 X.26 through a 4 " diameter part. I had the rapid on 5%, but didn't stop it in enough time before it left a spiral. It was only a spacer, but it could of been costly.
Greetings from Germany, I did that too in the third year of my apprenticeship on an older machine :) and we had to get somenone from another company to fix that 👌🔥
Supervisor (who is also programmer/sometimes machinist) at my shop always bangs on the machines. Nearly sent my indicator into a part once because he did that while I had the door open.
I was running a 5 Axis in front of a film crew on a program that was previously proven out but the procedures and paperwork to tell you what tools need to be where wasn't that good so a short tool was where a long tool was supposed to be and the only reason we use long tool holders is purely for clearance so naturally it didn't clear and started digging into the fixture not the part and we got it on film. Every time it crashes no matter who's fault it is I'm the one who has to realign it. In this case though we were lucky that nothing moved and no parts were scrapped.
Back when I was an apprentice the guy who trained me up told me he's worked in shops where guys would intentionally delete lines of code or mess with your offsets and I'm so glad I've never worked in place like that
Hi guys, I am a Kuraki KBT15 boring mill operator, and can't stand any horse play around me. My worst crash was leaving Z toggle on in jog at3.3 ipm spindle off and forgot about it. Slow motion crash. Lots of twisted sheet metal. If you leave the machine, change the selector to handle. Take care and be safe.
The only thing I would disagree with in this video is "you can't just leave it like that". If one of my guys crashes a machine late at night like that, not only is it okay to go home...I expect it. Make sure it's safe and no further damage is occurring, put a sign on it and leave. Go home, get some rest, we'll call the customer if necessary, and we'll start fresh in the morning. A tired and frazzled operator has a high probability of making a mistake, and as the saying goes, "there is no situation so bad that you can't make it worse."
I've had sheet steel automation arms wig out and fail and lift whole machine pallets off the machine and unload them like a sheet, i've had full 5'10' sheets of 3/4 inch steel fly off the pallet changers because the sheet was too wide for the bottom table, i've ripped cutting heads completely off, etc etc. at the end of the day, if you can fix it you're golden.
This is probably one of the best videos on this channel because it really sucks being interrupted in process. I've gotten in the habit of just putting my pointer finger up sternly when people try to talk to me. Works wonders. Most people understand it. It doesn't stop the material handlers or fab guys from slamming stuff around, but still.
I made a double programm on my 4 axis Robodrill. Forgot to add another H on the second side and the machine went down in Z FAST. Luckily it stopped fast enough and only cracked the Endmill. Also lucky was that I used aluminum chucks.
I crushed a grinding machine while doing the x-axis check, but i selected the z-axis and in one second that i pressed the grinding wheel crushed in z on the piece, the wheel was destroyed so i changed but the alignment was not so good anymore so need to be fixed to have some nice squaring on the machine. Also the bearing needs to be changed since some time.
when i was taking a finishing cut on the front of a part with 5 ft bar of material sticking out of the back side of the chuck, 250 rpm....... no i fat fingered 250sfm........... the tool jumped to the center of the part and spun the chuck to max rpm............ the machine started jumping up and down.
When I was an apprentice I crashed the same machine, three times. It was an old Mori Seiki running an early Fanuc controller, and I was constantly bouncing between that and I believe a Mitsubishi M4000 running an Anilam controller. 1st time, the Fanuc controller operated in microns, so 60dia would be 60000, I came from the Anilam controller, put a Y rapid of 60 instead of 60000 and plunged straight it and parted off. Second time, had a 32mm U drill, set the feed to 0.06mm/rev but missed the decimal spot and had it plunge in at 6mm/rev. The machine took it like a champ, it cored that MF and the swarf that came off was so thick you could use it as a tightrope Third time, one of the senior blokes came by and adjusted my 2nd home offset instead of my tool offset, cue turret rapid into soft jaws doing 3500rpm. Broke all the shear pins in the turret and knocked it straight out of alignment.
I had what I called a $1000.00 Saturday morning by that same exact reason. Running an Okuma lathe, someone simply asked me a quick question, I turned around and hit go, and realized I forgot to reset z 0 by a few thousandths. I hit the stop button, but too late by a couple milliseconds, and boom. Huge part, and all 3 chuck jaws fell into the pan. Bent the chuck body, had to realign everything plus hunting down another complete chuck. Luckily, the part was okay.
So, I'm not a CNC operator, but I'm doing the initial setup in the factory for CNC machines. One day it was pretty busy and people constantly wanted things from me. I was in the process of measuring out the tool change position, that's usually an area where you really have to be careful because you have to turn off the collicion detection and you can hit a lot of things in that area that you better shouldn't. As I was kinda distracted I forgot to retract the spindle before jogging out of the tool change area and bent a piece for blowing off the spindle nose. Luckily it was only that, spindle only had a small dent on one outer edge, all the contact surfaces were still intact. Just reminds you that you sometimes have to take your time and not rush things, or something like this will happen and make the work take even longer.
So, picture this - it was one of those hectic days in the shop. I had a bunch of similar parts to make, but they had different lengths. I was running the Mazak Quick Turn, and the pitch was 25mm (or 1 inch for my American friends). I was in a rush, trying to get everything done, and that's when it happened - I accidentally crashed the Mazak right into the spindle! It was a facepalm moment for sure. 🤦♂️ The whole mishap was because I forgot to change a single number in the program. And you know how it goes with those thread cycles - once you start, there's no stopping it unless you hit the emergency stop. But at pitch 25, there was just no time for that! 😬 Lesson learned the hard way - when you're juggling multiple parts with varying lengths, take that extra moment to double-check everything, especially those critical settings. It's all part of the machining adventures, right? 😅 #MachinistLife
Had this exact same scenario happen to me once. QC guy came to tell me my part was .003" off nominal on a +/- .005" tolerance. Distracted me for that 1 second with my hand on feed hold, still enough time to crash the spindle into 5th axis unit on a fresh set up. I was furious in the moment because my part was all good and in spec, but he wanted to tell me it could be closer to nominal as if i didnt already know🤯. In the end it was still my stuff to handle, ripped that unit out and put in our other one aligned it and set back up after a few hours. I learned how to truly ignore people after that, or to always play it safe and press feed hold before letting someone talk to me. 👍
im in my 3 year as a basicly self tought lathe guy on a haas st 20 and 30 yes i run 2 machines ..i had like my coworker said good crashes nothing major but the feeling sucks !!! the cutoff tool tuched the spindle on 5% G0 speed -..yes you have no time to react even if you fingers are on hold feed or emergency button !! insane !!
After hearing some of this it made me think of my situations lol. People wonder why the hell I stand there quietly while they are concentrating on what they are doing and usually it is because I am waiting for an opportune time to talk with them and not interrupting what they are doing so that way a crash does not happen but at times it does give them a jump scare when they turn and see me there lol. If I am proving something out or concentrating on something I usually put things on hold or ask if they could come back soon so I can make sure I don't have an issue popping up. And with the banging, I am 1000% behind not doing that! I have Mild CP and things like that make me jump and throw me out of sorts as well, I remember when I was in college in the machine shop and was talking with the instructor while doing something on a manual mill and someone just tossed a piece of scrap in the scrap bin nearby causing a loud bang, I jumped, and the instructor went over to the person and pointed out that it might be better to set things down instead of dumping them. Mind you I am 6'2 and built like a linebacker so making me jump is very noticeable lol but thanks to some youtube creators with CP I have learned that it is part of my condition as well and made sense of a lot of "quirks" I have lol. So in short (yes I wrote a lot) I am all for everything said in this video!
Not a machinist yet so I haven't had this exact experience but I've had comparable ones. Between welding, machine maintenance, and loading/unloading trucks I've racked up quite a few minor injuries and a couple severe ones due to people distracting me. Unless it's relevant to what I'm doing in that exact moment, wait. I'd rather miss out on the score of the big game than end up in the hospital again.
I was an apprentice once at a shop. Only three of us and the other was gone. I was milling down a metal plate to spec and the guy said let’s go to lunch. I said I wanted to stay to finish the side I was milling but he forced me to leave. I was new, he told me to loosen the vice and once I came back I forgot it was loose.. I was smart enough to hit the emergency stop but a nice chunk of metal was gone from a corner. Like I took a bike from it. Luckily no one was hurt.
I was caught by surprise when making a small work coordinate change in our "safety" program. I was using MDI to move and check the position of our production fixtures half the day. EOB was just a force of habit with every block I'd written. I manually made a change to our "safety" and entered in EOB out of blind habit. Basically looked like this: Original G90 G10 L2 P1 X5.0 Y-10.000 Z-16.5929; After Edit G90 G10 L2 P1 X5.0 Y-10.002; Z-16.5929; Anyone who is aware of modal commands knows what the machine did when I ran the program. Our "safety" ran first and BAM!!! 100% rapid into the back of the fixture. The machine shook the floor and I about had a heart attack. It took me an hour to figure out what the hell happened.
I run a manual tool change cnc machine. I change the tools by hand after an M0 Stop. However, one day, the program wrote an M1 stop, not an M0 stop. Was running a 12 blade aluminum fan about 2 inches thick by 15 inch diameter. Took my face cut while that was going at 800rpm max speed for my machine. Someone came up and started talking to me, turned my back to the machine, and it finished the face cut. The tool came up and away from the part. Blew threw the M1 and loaded the bore bar tool offset in and proceeded to rapid into the fan spinning 800 rpm at 250IPM. Needless to say, the part ripped out of the chuck threw the part out of the machine(not a fully enclosed machine) about 50 feet across the aisle and started spinning like a hubcap on the ground. It also shattered 7 of the blades off and threw those all over the place. Luckily, the guy that was talking to me and myself were behind the guard, so no one got hurt.
I work for my dad and he is an old school machinist. I do all the CNC. He still seems to think you just hit go and walk away...... when he calls me over to talk to him he seems to expect me to just run to him right away not understanding I'm doing a stressful set up or first article. It can be extremely frustrating.
I used to program and run CNC Wire EDM. Before the days of CAD, we would program it all manually. Had a job that was somewhat routine, small little variances and that was it. Programmed it in the machine, did the touchoffs and started the cut. Came back a while later and to my horror, I had sliced the workholding vise jaw in half. A simple mistake by omitting a (-) in the program cost several hundreds of dollars.
I just recently had a crash that broke a hydraulic arm of a fixture. I was clearing tools back, and went to set a drill back 10 parts from 100 to 90 because the drill still looked good so there wasn’t any reason to change it yet. But when I set back the tool, I put 90 in the tool call up instead of the tool life, and tool 90 happened to be a 1 inch diameter boring bar rougher. So it called it up in place of a 27/64 drill. And slammed into the back of the part. And I was away at the time. Last 20 minutes of shift, it was a part running overnight for the next shift, I went to wash my hands. I came back to it alarmed out with a broken 5\8-11 tap in the spindle and 5 broken tools in the magazine. Needless to say I stayed an extra 2 hours indicating the fixture, the cones under the fixture (pallet pool system with multiple tables) and changing a lot of tools. Moral of the story, pay attention to what and where you’re typing.
Yea im about to get into this stuff and not looking forward to my first crash :) I guess what I will do now because of this video is re-proof the program if anything at all is changed. You guys are the best at this and if it happens to you guys, it'll happen to everyone. Keep up the amazing work you do!
one of the most important things to remember is to not get cocky with the machine, much like learning to shoot a gun its good to have a little bit of apprehensive anxiety cause that means you have respect for what the machine can do and that respect will make all the difference getting started
Both have their uses, oftentimes at the same time. You should have your finger over feed hold anyway, but single blocking is better for large, simple moves, holes, or during/right before a rapid. Please do not single block any cutting, especially when the tool is being pushed hard. Dry run first. Leave witness cuts.
Some machines can avoid this crash like Okuma with their Collision Avoidance System or machines with the FANUC 3D Interference Check. The DMG Mori NTs (with lower turret and subspindle) I work with do this, but you have to do the work and load all models of your tools and work holdings in the control to work. It prevented lots of collisions and makes the opereation much safer and faster.
I don’t have any CNC experience, but I had a guy come up behind me and speed up the power feed on a Bridgeport I was milling on without saying a word before doing it. He won’t ever do it again…
I used to work at a place where the guys smack the cowling, and labours would not take the nice hints so one day all 7 machinist became very mean to everyone else we'd start yelling if they came up to talk, HR got involved and told us to be more kind so we switched our tactics one sweeper got soaked by a mazak mill wash down hose. The distractions stopped.
I am definitely not a full-fledged machinist by any means, but after breaking two end mills in one night at my university (along with several other close calls on previous nights) I made a rule for myself that I wouldn't do anything after 11pm.
damn that happened to me as well right as i looked over as someone asked me something wrong tool came out and slammed was on a Friday end of day i fixed everything went home and thought about it all weekend non stop. one of the biggest mistakes i think ive ever made in my short carear in cnc(1 and half years in). it made me alot more cautious and overall that made me better at my craft in a way.
Some brands(Okuma) have Anti Collision system, and it works good if you have done everything buy the book. This should not be possible if you have the Collision system "ON" of course.
When open offices became a thing one of the big tech companies introduced a policy of if someone is wearing a red baseball cap don't interrupt them. Might work for you.
Yup, was working as an intern in a tool and die maker. Was running a maho when someone dropped a bag of metal rods on the floor above me. Never smashed a red button faster in my life😅
My first time using a cnc haas desktop mill, i forgot to raise the Z axis up so when i hit cycle start the cutter didnt get enough time to get to full speed, plunged in to do a hole and cutter broke, 2nd time it broke my fixturing wasnt rigid enough, 2 cutters broken in less than 20 mins but that was my first ever time
Crashing a machine because you lose focus after a long day is something anyone who has any ammount of experience can relate to. I certainly can, In my 22 years I crashed quite some (personal dumb-dumb record: I mixed up + and - in a parameter for a subprogramm. "Safety clearance -5mm" does quite a bang, I tell you...) . Anyone saying "This would never happen to me!" just openly addmits that they are slacking off.
The great thing about CNC machines is they do exactly what you tell them to do. The bad thing about CNC machines is they do exactly what you tell them to do.
I could not of said it better myself 😂
CNC machines are pretty dumb in that regard. They have made some strides when it comes to crash avoidance.
Never be over confident. & You do not Learn when everything runs great all the time ..When you make mistakes you learn from it and move on ..
My teacher use to always tell us that. Lol
That's true which proves all CNC machines are men.
The thing about Donnie is he doesn’t have to be at your machine to hear him talking. You can hear him all over the shop 😂
Donnie needs to grow a beard and put some base on his voice. I keep thinking he is 14 years old and: How did he get this job/must be a child prodigy.
🤣
Is he the son of Titan?@@ak54539
@@ak54539wait? He's not a 14 year old prodigy? 😂
First law of machine tools(in my experience): the moment you feel confident with a machine is the moment you are more likely to crash it!
I agree. As soon as you drop your guard that's when something bad seems to happen. Especially when trying to rush at the end of the day just to get it done so you can go home.
This is exactly what happened to me tonight I got too confident
Yep. . . . never get complacent!
Was running a Mazak Integrex 300-IVS. Was setting up on a job of 1000 parts to run overnight, the transfer uses macros to adjust the work offsets and for cut off locations. I had just switched from a 3jaw with external chucking on my sub side spindle to a collet chuck with internal chucking, I forgot to switch the chucking type and crashed the W into the part. I then reset and fixed the chucking issue but forgot to clear the macro that had moved my work offset for the cut off, Z went straight into the sub spindle chuck at 100% rapid and knocked my B axis out of alignment by .01. We have since switched over to esprit cam for our lathe department which outputs actual X and Z locations for the cut off instead of macros. We still have all of our creo programs as reference files so it’s something we have to watch for when running older programs
100%. I was learning CNC and the way I was taught was to load every tool, touch them off then run the program. The guys were telling me I can save time by having the program load every tool and touching them off as I go. Crashed a few tools trying this before I told them to "F off I'm doing it my way."
I told myself I would be very, very careful my first time machining...and I chipped an insert within my first few hours. Left me shaken for sure! I can only imagine the nerves of steel machinists develop over the years.
The first time I cut Titanium was nerve wracking. I was used to cutting only Aluminum and mild steel before. Every subtle noise that the machine or even people around me made would make me flinch lol.
Now it's not that bad, it's just slow and wears the tools down exponentially faster. Broken tools also don't risk scrapping the part as much as with Aluminum, with carbide embedded in the material.
Today I reprogrammed my thread operation to threadmill a thread feature on an Inconnel AMS5663 Bushing job I've been working on. The first helical pass went well, no problems it did exactly what I wanted. On the 2nd pass I was watching it like a hawk and about 20% into the cut the whole Capto holder popped out mid cut. I hit feed hold and stopped the rotation right on queue and to my luck there was no damage to the part or the holder, or the $214 tool. If I hesitated another .5- 1 second I think it could have really fucked shit up. I'll be sure to tighten the Capto bolt to 40nM every time now with a click torque wrench as the holder prescribes. Wooooo just another day on the job.
@@13anomalous16 i have some jobs at work that are crazy loud i one time asked my boss if there was anything i can do to make it better he looked at me and handed me ear plugs.
its not really nerves of steel, its just confidence in your material knowledge and process knowledge. theres plenty of materials i dont like cutting at all, but i know how to cut them and how to utilize the tooling to cut them so there isnt really a reason to be afraid unless im taking a risk
@@dharaosgaming That reminded me of this time a thread mill was blown free from the holder. I wasn't the one setting up but I did load the tools. It didn't seem loose but the tools already come built and ready to load so we don't have the torque wrenches to check. It actually cut the threads in sync and then when the guy setting up stopped the machine to check the first hole, it blew the tool out of the collet holder doing whatever automatic thing a mazak does when shutting down the spindle. Didn't scrap the part, whew, those parts are like 1 inch thick by 10 or so inches wide and then over 100 inches long.
if i need to speak to someone that is focused on the machine i always try to stand somewere where the person can see me, and i just wait for him to talk to me when he is ready for it
That’s good on you!
I do this shit to our programmer all the time. He always looks so focused I never want to break it😂
This is my preferred way to get someone's attention when they are busy. Doesn't require any response on their end but communicates effectively.
This is my go to move as well.
I wish people in the shop I work at would learn this...I'm the 2nd shift lead off in the CNC department and one of my operators just yells my name across the shop ugh. We ain't playing freakin Marco Polo here lol. Or he'll come right up behind me and say something and scare the shit outta me. I can't count the number of times I've whacked my head on some part of the machine from him doing that. Makes me wanna throw whatever I have in my hand at him. (Obviously I've never actually done it since I still have my job haha)
Spot on with this one! It's all fun and games until a 2" drill slams into your part during a full rapid... Ain't that right Barry? 🤣
How would I know? LOL
good thing with heller that ain't to bad. but with the speed titan goes sometimes it sounds like a crash even though it ain't
i mean that happens. I seen someone run a 1.5" boring bar in to the wrong side of a predrilled part... Only 1 side was pre drilled, the other side was closed, guess what happens when it is going in at full rapid.
And thats back to aligning the machine again.
I did that once with a .625 solid carbide drill in aluminum bronze. I don't know what the SFM and chip load was but it actually punched a hole right through. Luckily just drilling clearance and everything was good to go. Older style programming where offset follows a point on the part instead of always being bottom of part so I had it set bottom of part, not top of part. Would've eventually hit the vise floor though if I didn't stop it.
My old boss (the owner of the company, who had no understanding of CNC work) used to interrupt me, while I was programming and doing setups or repairs, by walking up behind me, and asking random, completely unrelated questions, usually within two feet of me. He didn't warn me that he was there either. One day, he startled me, during a head change on the water jet. I swung around with a 36" crescent wrench, and nearly took his head off. It was close enough to move the hair on his head. He stopped getting close to me, and always waited until I was done, before asking me anything again.
A coworker once told me a story about him asking another guy (who worked at a conventional lathe at that time) where to find a certain tool (he was new). The guy working at the lathe went to show him a few tools and asked him which one he needed. All while the late was still moving towards the chuck. Eventually the machine crashed. The tool broke, the part flew out of the machine.
You might check out my lathe story comment
is that the end of the story or does it get a lot more grim ?!
Well the guy operating the machine started to swear in Hungarian which was apparently quite hilarious. So only a broken tool, scrapped part and an angry worker.
@@iizvullok I think I remember something like that happening at college. Something was maxxed out in travel yet it was in power feed mode so whatever was left of that gearbox was turned into metal flakes from what I could tell from the horrible grinding sound.
You need to put a BIG ORANGE witches cone on your head if you're proving a program....BANG💥😂
Donnie is king when it comes to keeping old footage around. Truly helps in the editing.
I wanna respond to this really bad... but I'm gonna let you live today 😈
I crashed a Daewoo DMV3016 VMC in January of last year. Co worker walked up to me talking while I had to put a hard jaw on top of an inconel pin to clamp it in a set of soft jaws. I was talking to him and forgot to take the hard jaw off the top the vise, closed the door and pressed the green button and then BOOM! Thank lord it was at 50% rapid though. I had run thousands of these pins. Learned a lesson that day and still have the hard jaw as a trophy.
Dang! That’s cool you kept the jaw! I wish I had kept more of my disaster trophies
The fear of crashing machines is real! 😬 Great story!
In this shop Im at, we have a rule that, if someones at the control panel, do not interrupt them. Stand back and wait or come back later.
Bro that’s fuckin WILD 😂😂😂
Timely video. Just last week I said to our scheduler (who is assigned to ask each machinist "where are you with this?" a few times a day) "never interrupt them when they are programming - ever". Instead, she stands there and waits. That's just a bad right? LOL Great video Donnie!
Yea I’ve had a few awkward moments with people just staring at me while working 😂 have a good day mom!
The answer: semaphore flags. They set a flag that they need to talk and you go talk to them whenever you notice the flag is set.
I was working at a company called True Trace years ago when I heard a big bang at the other end of the shop
so I walked over to check it out, what had happened was Rusty a guy that had worked there for 20 years
forgot to take out the chuck key from our big lathe and started it, the key went through🤔 the roof and we never found it.
I have a saying:
There are two types of machinists, those who have crashed a machine, and those that WILL.
Word lol. My college teacher used to say something similar: If you ain't crashed a machine yet, you ain't been doin it long enough haha
Love the footage from the story!
Couldn’t have said it any better Donnie, I really wish my supervisors could watch this video , I have had instances in conversational programming a Hurco mill, i fat fingered. The wrong offset, and another machinist who was bored running a high quantity part would bug me between cycles, while I was DTG my part luckily I hit the interrupt button just in time before I had a huge Z axis crash.
Hahaha love that you have the actual video from the story. Nice.
Great reminder Donnie! Well done with the video!
Great video!! Never interrupt while setting up!
I can tell you, from my experience driving big rigs, that we, too, can have a disastrous outcome from being distracted for even one second. These things are over 70 feet long and can weigh 80,000 pounds.
Even talking with a passenger can be too distracting.
It only takes 1 second to just totally ruin your day and, potentially, many other people's day.
1 second.
Oh yeah, I can totally relate! 😊
Reminds me of running the Mazak V100. It's a massive machine and it doesn't stop on a dime like most other machines. The accel and decel is so slow that if it starts to move and then you think, oops I better hit feed hold it's long too late. The gantry of the machine, which may very well weigh more than a (legally) fully loaded big rig, crashed into the machine table. This was before I worked there and those who were here said it felt like a tremor before an earthquake.
@@commandercody38 Inertia can be a bitch 😊
I'm pretty fortunate that I have the ability to survive distractions, I actually thrive on them. This allows me to stop in the middle of a set up/program to address one of my guy's questions, or help them solve a problem, and go right back to what I was doing.
Thanks for sharing your mistakes with honesty.
I have a rule when I'm operating my desktop CNC router. If I'm jogging the machine, loading some new code or changing bits, do NOT disturb me until the program is running!! I'm acutely aware that the smallest lapse in concentration can come with the largest repair bill (or worse, injury).
I can only begin to imagine the butterflies that come with operating such a beast of a machine. My little Shapeoko CNC provides me with more than enough adrenaline!
"Bro...I'm working!" hahaha
🤣😆
I had one time when I was at a production shop where I was flipping the parts and a coworker came up and talked to me and it distracted me enough that I forgot to turn on the vacuum fixture. So it started twirling the part of the end mill so it trashed the fixture since it was on pins. Because of the high stress environment at that shop stuff like that happened regularly. Another time a guy forgot to turn on the vacuum and it launched this part through 2 machine doors. The guy was lucky he walked away from his machine and the nobody was flipping the machine across otherwise it would have been ugly
Same thing happened to me with a brand new 5 axis a few weeks ago our wood machinist are always interrupting while we are machining on the cnc's. I had drill operation third hole was set to go to 0 instead of 400 went straight into a 1" plywood jig I managed to stop within a few inches of it going through the jig but it was still enough to throw the spindle out of position only just got in realigned today as the cnc manufacturer doesn't have any written instructions of how to realign the spindles and don't have any technical technicians available in the UK its been a huge learning curve for us learning how to realign the machine not sure if this is standard for cnc manufactures to have these kind of instructions to hand over when you purchase a cnc.
my worse crash was using gibbscam, same thing reran the program like 6 times, trying to take the taper out of a part, moved what i thought was the final time, took another .0005 out in the program to chase the taper out, the one time i didnt check the simulation, that .0005 just so happened to freak out the post to where it finished the cut, the rapid to X0 after the move. i was holding onto .120 in the chuck and had a center in it, it was a interesting seeing the part get knocked out and more interesting walking through everything with the lead to figure out what happened and seeing that the one time i didnt check my simulation was the time it just so happened to freak out over a taper line.
Oh man that’s terrible 😂 it’s crazy how the second you get comfortable is the second something happens
It's better to choose OKUMA Multus machine with Collision Avoidance System as a standard equipment. Than you will have a lot of additional time to do what you really want:)
He preached a real machinists sermon here. Well said! Let us get through our setups without being disturbed!
I fully sympathise with this. I'm only an apprentice but last week I was setting up an old dual spindle Mazak lathe to run a proven program when I noticed the boring bar was loose, so I started to reset the Z length when another apprentice stopped to chat. It was the last half hour of the shift and I forgot to finish resetting the Z length.
Normally it would've been fine as there's no night shift on that machine, but I was off sick the next day so my supervisor ran the program not knowing that I'd found the boring bar loose and the machine crashed and scrapped the part.
I took full responsibility for the crash because I forgot to pass on the info that the boring bar wasn't set, but having someone come over to chat during setup can be enough to stop paying attention to one of the most important parts of the job.
I even had three people come up to me the next day saying "I heard you caused the machine to crash yesterday" which was hugely embarrassing.
So to anyone that works in a place with machinists, please don't start chatting if the machinist is trying to focus unless it's actually important 😅
I would pass a good part of the blame to the supervisor for not watching the DTG and catching that, especially if he knew that was to be the first part off of that setup. if I have to leave in the middle of a setup I usually leave a sticky note on the control saying "not proven" or something of that nature. on top of that, we always run with the rapid down low on the first part of the program, even if its been proven the day before, its just how I was taught.
I couldn't agree more. I worked for SecoTools here in New Zealand (now retired) for 28 years travelling the country promoting, testing and trouble shooting customer jobs. One thing I never did was to interupt an operator while he was running the machine. To me it was common sense. I am a qualified machinist and understand exactly what you are getting at. Cheers Ian
I am glad I am not the only machinist that has severe anxiety every time i try to hit a green button. I love set up, I love inspection, i love programing. But, that green button is the ultimate proof what you did was right. I was making a ring the other day and it sounded weird while removing the excess stock on a side 2 run. I had my finger on the NC reset button just incase that noise turning into something, it did, part lifted and i broke 1 carbide insert before i stopped it. I was able to replace the insert push the part back down and keep running.
"It was getting to be like 11 o clock", so many fun machining/welding/fabrication stories start with a similar phrase.
I’ve crashed my B axis into my sub. Always some anxiety when running a new program that the mill turn will crash into itself. Glad it all worked out in the end.
When machining precision parts one doesn't talk to someone not involved with your machining. I had my own shop where I was the only machinist on my machines and didn't have the problem seen here however, when my machine shop began to get slow I would do outside work at a small CNC shop and when I was working on parts the employees left me alone.
It happens to the best of us and it sucks bad. I have never ran this Doosan but I have a multus. This had CAS collision avoidance system. I believe it would have saved you in this case.
I respect the fact that you completely 100 percent owned your mistake.
When I had to do my first cut off using synchronized spindles. I told my colleagues to not disturb me for the next hour.
I think cutoff/ transfers on multitasking lathes is one of the worst pucker moments in machining IMO
We got a Doosan 2600 SY, a couple of years ago. I was a Haas guy, never ran Doosan, or a sub spindle. I had a coworker, a decent manual guy. He almost drove me crazy. Everytime I was at the control he wanted to talk. I am glad he is gone. Thus far I haven't crashed it. To be honest some if not most people don't understand what we go thru mentally on a daily basis.
whenever the machine crashed i get extra stressed
I have a good crash on a big standard 2 axis lathe. Mind you, this machine was brand new. It was placed and wired up that morning. I get in for 2nd shift with the next part loaded. I did not check part length and hit go. The part was 1/4" too long and threw it out of the chuck and broke the door glass, and misaligned the turret at 11pm. I know your pain.
This makes me smile ... this happened to me at work ... indexed a bore bar straight through the work peice straight into the saftey glass ... Nice to know its not just us amateurs that make mistakes
The day is coming when CNC machines will have enough intelligence and situational awareness within their work envelopes that they won't allow crashes like that to happen. They'll detect the conflict before it becomes physical.
That already existe, but is freaking anoying so nobody use it
@@PetSize21 I turned mine off because it was too cautious, it wouldn't let me get the tooling where I needed.
Doesn't matter how many years experience you have mistakes can happen...I've literally just had 2 weeks off work because I was running the Manuel lathe and was putting the jaws in the chuck..instead of pressing the button to rotate the chuck slowly to put the next jaw in I pressed a button with makes it run at full speed and the first jaw flew out and hit me in the nose splitting my nose open...Be careful out there
No freaking way😖😖😖😬
I had a bad crash last year for a similar reason. I was running a small batch of new parts on the lathe, but I was ordered to stop and make something urgent on the same machine. I had already made a program for it in the past so I load the program and replace several tools that were missing from the turret with some that were used in the small batch. I guessed there would probably be tool interference with the turret so I turned on the option stop, because I always program a M01 just before a tool change as a habit. What I didn't know was that this machine, for some reason, when you go from MEMORY mode to EDIT mode and the other way, turns off the option stop. It's the only machine that does it at our shop, I don't know why. So I was adjusting a bunch of things, pushed the option stop button, went back to the beginning of the program, go in memory mode, start the program and focus on the cutting. Near the end of an operation, a coworker comes behind me to talk about something. I was confident that the machine would stop before changing tools so I turn around to listen to the man. The machine didn't stop, changed tool with the wrong tool number, went in rapid for the next operation and crashed 2 tools together into the jaws and chuck. One tool holder broke in half and went flying, then the machine went alarm. Everyone heard the BANG. The coworker said "sorry" then ran back to his machine.
Oh man! That’s almost not your fault at all though. In my opinion having a machine that turns off optional stop at any point for any reason is pretty whack.
A real problem is a day shift employee working into the wee hours of the night. Easiest shortcut to "one little mistake."
12+ hours is asking for fatigue related incidents.
I find I am good until the 36 hour point. Then I am useless. I haven’t been in that position in about 8 years but back when I worked like that I always noticed a severe dip in my abilities after a day and a half
@@donniehinske that tracks. Studies show people tend to partially recover reaction time at the 22-24 hour mark but its never as good as being well rested. Wherever we are we need to take care of each other; humans are more important than hardware.
It’s fun sharing these stories with the world of machinists! It was such a disaster while I was going through it but looking back on it these are the things that make us better!
Send it to the Studer. Run it with plated CBN. It will be a little slower probably but save on inserts going through that interrupted cut. Seems like a waste to tie up a monster 9 axis machine for a rework roll. Waste on Studer also. Could run rolls on a much older, cheaper, worn CNC external. Just some thoughts from my experience working at a roll shop. Thanks to all of you for the great and informative videos. Im always looking foward to the next one.
how are there not internal controls to prevent this from happening?
Normally cam does that for you, if the machine is simulated. I guess he changed lines manually and boom
The machine is only as smart as the operator/programmer. The machine is a SLAVE. It WILL do as you tell it.
Pros: Machines do everything you tell them to. Cons: They do *everything* you tell them to
I know for the integrexs at our shop it will not allow you to start a program if the W axis is not homed out, which would have prevented this specific crash, but I wouldn’t be surprised if there is a way to block/disable that safety feature
@@tyknott422some machines come with safety features that have to be unlocked, by the manufacturer, for an extra fee. They prefer you don't access those features, so they can charge huge fees for repairs later.
I indexed a turret on a moving chuck once, lovely sound.
I wanted my 2 axis to back out to 26 inches in X on a Haas TL-4. I wrote the complete program on the spot. Everything cut as programmed, but instead of X26.0, I put X260. For those who don't know, no decimal means thousands of an inch. So instead of coming to the face and going 13 inches from the center of the 4" diameter part, it was coming from X4.0 Z-4.0 tp Z1.0 X.26 through a 4 " diameter part. I had the rapid on 5%, but didn't stop it in enough time before it left a spiral. It was only a spacer, but it could of been costly.
Greetings from Germany, I did that too in the third year of my apprenticeship on an older machine :) and we had to get somenone from another company to fix that 👌🔥
Riot Shields in COD are the WORST! Very happy you don't ever interrupt people while they're machining Donnie!
Supervisor (who is also programmer/sometimes machinist) at my shop always bangs on the machines. Nearly sent my indicator into a part once because he did that while I had the door open.
I was running a 5 Axis in front of a film crew on a program that was previously proven out but the procedures and paperwork to tell you what tools need to be where wasn't that good so a short tool was where a long tool was supposed to be and the only reason we use long tool holders is purely for clearance so naturally it didn't clear and started digging into the fixture not the part and we got it on film. Every time it crashes no matter who's fault it is I'm the one who has to realign it. In this case though we were lucky that nothing moved and no parts were scrapped.
Back when I was an apprentice the guy who trained me up told me he's worked in shops where guys would intentionally delete lines of code or mess with your offsets and I'm so glad I've never worked in place like that
Hi guys, I am a Kuraki KBT15 boring mill operator, and can't stand any horse play around me. My worst crash was leaving Z toggle on in jog at3.3 ipm spindle off and forgot about it. Slow motion crash. Lots of twisted sheet metal. If you leave the machine, change the selector to handle. Take care and be safe.
Donnie's mouth moves at 2,000 WPM - Good info btw. Thanks Donald
OK who th is this? LMAO to your photo
Read the name ... she knows ;)
If it was easy anybody could do it !!!Love this trade ❤❤❤Its the only one where you can measure exact and realisticly how good a job you have done
So shit happens to experts like you too. I am discovering that I am not alone... but still we must be very very careful and humble in this field.
There’s no such thing as being above making mistakes
The only thing I would disagree with in this video is "you can't just leave it like that". If one of my guys crashes a machine late at night like that, not only is it okay to go home...I expect it. Make sure it's safe and no further damage is occurring, put a sign on it and leave. Go home, get some rest, we'll call the customer if necessary, and we'll start fresh in the morning. A tired and frazzled operator has a high probability of making a mistake, and as the saying goes, "there is no situation so bad that you can't make it worse."
I've had sheet steel automation arms wig out and fail and lift whole machine pallets off the machine and unload them like a sheet, i've had full 5'10' sheets of 3/4 inch steel fly off the pallet changers because the sheet was too wide for the bottom table, i've ripped cutting heads completely off, etc etc. at the end of the day, if you can fix it you're golden.
working between spindles on a mill turn can be quite sketchy, i have never crashed when i did but i had quite a few VERRY close calls
This is probably one of the best videos on this channel because it really sucks being interrupted in process. I've gotten in the habit of just putting my pointer finger up sternly when people try to talk to me. Works wonders. Most people understand it. It doesn't stop the material handlers or fab guys from slamming stuff around, but still.
I should record myself when that happens, running like a headless chicken trying to figure out what machine made the sound.
I made a double programm on my 4 axis Robodrill. Forgot to add another H on the second side and the machine went down in Z FAST. Luckily it stopped fast enough and only cracked the Endmill. Also lucky was that I used aluminum chucks.
I crushed a grinding machine while doing the x-axis check, but i selected the z-axis and in one second that i pressed the grinding wheel crushed in z on the piece, the wheel was destroyed so i changed but the alignment was not so good anymore so need to be fixed to have some nice squaring on the machine. Also the bearing needs to be changed since some time.
when i was taking a finishing cut on the front of a part with 5 ft bar of material sticking out of the back side of the chuck, 250 rpm....... no i fat fingered 250sfm........... the tool jumped to the center of the part and spun the chuck to max rpm............ the machine started jumping up and down.
Omg that’s INSANE 😂 hopefully no one got hurt
When I was an apprentice I crashed the same machine, three times.
It was an old Mori Seiki running an early Fanuc controller, and I was constantly bouncing between that and I believe a Mitsubishi M4000 running an Anilam controller.
1st time, the Fanuc controller operated in microns, so 60dia would be 60000, I came from the Anilam controller, put a Y rapid of 60 instead of 60000 and plunged straight it and parted off.
Second time, had a 32mm U drill, set the feed to 0.06mm/rev but missed the decimal spot and had it plunge in at 6mm/rev. The machine took it like a champ, it cored that MF and the swarf that came off was so thick you could use it as a tightrope
Third time, one of the senior blokes came by and adjusted my 2nd home offset instead of my tool offset, cue turret rapid into soft jaws doing 3500rpm. Broke all the shear pins in the turret and knocked it straight out of alignment.
Great content today .
I had what I called a $1000.00 Saturday morning by that same exact reason. Running an Okuma lathe, someone simply asked me a quick question, I turned around and hit go, and realized I forgot to reset z 0 by a few thousandths. I hit the stop button, but too late by a couple milliseconds, and boom. Huge part, and all 3 chuck jaws fell into the pan. Bent the chuck body, had to realign everything plus hunting down another complete chuck. Luckily, the part was okay.
So, I'm not a CNC operator, but I'm doing the initial setup in the factory for CNC machines. One day it was pretty busy and people constantly wanted things from me. I was in the process of measuring out the tool change position, that's usually an area where you really have to be careful because you have to turn off the collicion detection and you can hit a lot of things in that area that you better shouldn't. As I was kinda distracted I forgot to retract the spindle before jogging out of the tool change area and bent a piece for blowing off the spindle nose. Luckily it was only that, spindle only had a small dent on one outer edge, all the contact surfaces were still intact. Just reminds you that you sometimes have to take your time and not rush things, or something like this will happen and make the work take even longer.
So, picture this - it was one of those hectic days in the shop. I had a bunch of similar parts to make, but they had different lengths. I was running the Mazak Quick Turn, and the pitch was 25mm (or 1 inch for my American friends).
I was in a rush, trying to get everything done, and that's when it happened - I accidentally crashed the Mazak right into the spindle! It was a facepalm moment for sure. 🤦♂️
The whole mishap was because I forgot to change a single number in the program. And you know how it goes with those thread cycles - once you start, there's no stopping it unless you hit the emergency stop. But at pitch 25, there was just no time for that! 😬
Lesson learned the hard way - when you're juggling multiple parts with varying lengths, take that extra moment to double-check everything, especially those critical settings. It's all part of the machining adventures, right? 😅 #MachinistLife
Had this exact same scenario happen to me once. QC guy came to tell me my part was .003" off nominal on a +/- .005" tolerance. Distracted me for that 1 second with my hand on feed hold, still enough time to crash the spindle into 5th axis unit on a fresh set up. I was furious in the moment because my part was all good and in spec, but he wanted to tell me it could be closer to nominal as if i didnt already know🤯. In the end it was still my stuff to handle, ripped that unit out and put in our other one aligned it and set back up after a few hours. I learned how to truly ignore people after that, or to always play it safe and press feed hold before letting someone talk to me. 👍
im in my 3 year as a basicly self tought lathe guy on a haas st 20 and 30 yes i run 2 machines ..i had like my coworker said good crashes nothing major but the feeling sucks !!! the cutoff tool tuched the spindle on 5% G0 speed -..yes you have no time to react even if you fingers are on hold feed or emergency button !! insane !!
After hearing some of this it made me think of my situations lol. People wonder why the hell I stand there quietly while they are concentrating on what they are doing and usually it is because I am waiting for an opportune time to talk with them and not interrupting what they are doing so that way a crash does not happen but at times it does give them a jump scare when they turn and see me there lol. If I am proving something out or concentrating on something I usually put things on hold or ask if they could come back soon so I can make sure I don't have an issue popping up. And with the banging, I am 1000% behind not doing that! I have Mild CP and things like that make me jump and throw me out of sorts as well, I remember when I was in college in the machine shop and was talking with the instructor while doing something on a manual mill and someone just tossed a piece of scrap in the scrap bin nearby causing a loud bang, I jumped, and the instructor went over to the person and pointed out that it might be better to set things down instead of dumping them.
Mind you I am 6'2 and built like a linebacker so making me jump is very noticeable lol but thanks to some youtube creators with CP I have learned that it is part of my condition as well and made sense of a lot of "quirks" I have lol.
So in short (yes I wrote a lot) I am all for everything said in this video!
Not a machinist yet so I haven't had this exact experience but I've had comparable ones. Between welding, machine maintenance, and loading/unloading trucks I've racked up quite a few minor injuries and a couple severe ones due to people distracting me. Unless it's relevant to what I'm doing in that exact moment, wait. I'd rather miss out on the score of the big game than end up in the hospital again.
I was an apprentice once at a shop. Only three of us and the other was gone. I was milling down a metal plate to spec and the guy said let’s go to lunch. I said I wanted to stay to finish the side I was milling but he forced me to leave. I was new, he told me to loosen the vice and once I came back I forgot it was loose.. I was smart enough to hit the emergency stop but a nice chunk of metal was gone from a corner. Like I took a bike from it. Luckily no one was hurt.
I was caught by surprise when making a small work coordinate change in our "safety" program. I was using MDI to move and check the position of our production fixtures half the day. EOB was just a force of habit with every block I'd written. I manually made a change to our "safety" and entered in EOB out of blind habit. Basically looked like this:
Original
G90 G10 L2 P1 X5.0 Y-10.000 Z-16.5929;
After Edit
G90 G10 L2 P1 X5.0 Y-10.002;
Z-16.5929;
Anyone who is aware of modal commands knows what the machine did when I ran the program. Our "safety" ran first and BAM!!! 100% rapid into the back of the fixture. The machine shook the floor and I about had a heart attack. It took me an hour to figure out what the hell happened.
I run a manual tool change cnc machine. I change the tools by hand after an M0 Stop. However, one day, the program wrote an M1 stop, not an M0 stop. Was running a 12 blade aluminum fan about 2 inches thick by 15 inch diameter. Took my face cut while that was going at 800rpm max speed for my machine. Someone came up and started talking to me, turned my back to the machine, and it finished the face cut. The tool came up and away from the part. Blew threw the M1 and loaded the bore bar tool offset in and proceeded to rapid into the fan spinning 800 rpm at 250IPM. Needless to say, the part ripped out of the chuck threw the part out of the machine(not a fully enclosed machine) about 50 feet across the aisle and started spinning like a hubcap on the ground. It also shattered 7 of the blades off and threw those all over the place. Luckily, the guy that was talking to me and myself were behind the guard, so no one got hurt.
I work for my dad and he is an old school machinist. I do all the CNC. He still seems to think you just hit go and walk away...... when he calls me over to talk to him he seems to expect me to just run to him right away not understanding I'm doing a stressful set up or first article. It can be extremely frustrating.
I used to program and run CNC Wire EDM. Before the days of CAD, we would program it all manually. Had a job that was somewhat routine, small little variances and that was it. Programmed it in the machine, did the touchoffs and started the cut. Came back a while later and to my horror, I had sliced the workholding vise jaw in half. A simple mistake by omitting a (-) in the program cost several hundreds of dollars.
I just recently had a crash that broke a hydraulic arm of a fixture. I was clearing tools back, and went to set a drill back 10 parts from 100 to 90 because the drill still looked good so there wasn’t any reason to change it yet. But when I set back the tool, I put 90 in the tool call up instead of the tool life, and tool 90 happened to be a 1 inch diameter boring bar rougher. So it called it up in place of a 27/64 drill. And slammed into the back of the part. And I was away at the time. Last 20 minutes of shift, it was a part running overnight for the next shift, I went to wash my hands. I came back to it alarmed out with a broken 5\8-11 tap in the spindle and 5 broken tools in the magazine. Needless to say I stayed an extra 2 hours indicating the fixture, the cones under the fixture (pallet pool system with multiple tables) and changing a lot of tools. Moral of the story, pay attention to what and where you’re typing.
Yea im about to get into this stuff and not looking forward to my first crash :) I guess what I will do now because of this video is re-proof the program if anything at all is changed. You guys are the best at this and if it happens to you guys, it'll happen to everyone. Keep up the amazing work you do!
Keep an extra set of pants in your toolbox..Ya know, just in case 😁😁😂😂
You WILL crash. Multiple times if you do this long enough. No way around it. Feed hold is your friend. Cat like reflexes my friend
one of the most important things to remember is to not get cocky with the machine, much like learning to shoot a gun its good to have a little bit of apprehensive anxiety cause that means you have respect for what the machine can do and that respect will make all the difference getting started
When circumstances aren't ideal and the risk for crashing can happen or if you are unsure...
SINGLE BLOCKING IS BETTER THAN TITTY TWISTING FEED KNOB
From what i'm hearing in the video, i don't think that would have saved it....
Also, i do both 😊
Both have their uses, oftentimes at the same time. You should have your finger over feed hold anyway, but single blocking is better for large, simple moves, holes, or during/right before a rapid. Please do not single block any cutting, especially when the tool is being pushed hard. Dry run first. Leave witness cuts.
@@ArikaStackdefinitely agree. Dry running away from the part helps to see exactly what the machine is gonna do and has saved a few parts of mine 😅
Some machines can avoid this crash like Okuma with their Collision Avoidance System or machines with the FANUC 3D Interference Check.
The DMG Mori NTs (with lower turret and subspindle) I work with do this, but you have to do the work and load all models of your tools and work holdings in the control to work. It prevented lots of collisions and makes the opereation much safer and faster.
I don’t have any CNC experience, but I had a guy come up behind me and speed up the power feed on a Bridgeport I was milling on without saying a word before doing it. He won’t ever do it again…
I used to work at a place where the guys smack the cowling, and labours would not take the nice hints so one day all 7 machinist became very mean to everyone else we'd start yelling if they came up to talk, HR got involved and told us to be more kind so we switched our tactics one sweeper got soaked by a mazak mill wash down hose. The distractions stopped.
I am definitely not a full-fledged machinist by any means, but after breaking two end mills in one night at my university (along with several other close calls on previous nights) I made a rule for myself that I wouldn't do anything after 11pm.
damn that happened to me as well right as i looked over as someone asked me something wrong tool came out and slammed was on a Friday end of day i fixed everything went home and thought about it all weekend non stop. one of the biggest mistakes i think ive ever made in my short carear in cnc(1 and half years in). it made me alot more cautious and overall that made me better at my craft in a way.
Some brands(Okuma) have Anti Collision system, and it works good if you have done everything buy the book. This should not be possible if you have the Collision system "ON" of course.
When open offices became a thing one of the big tech companies introduced a policy of if someone is wearing a red baseball cap don't interrupt them. Might work for you.
Then I would just wear it all day, I don't like being interrupted even when I'm just watching the machine run
Yup, was working as an intern in a tool and die maker. Was running a maho when someone dropped a bag of metal rods on the floor above me. Never smashed a red button faster in my life😅
My first time using a cnc haas desktop mill, i forgot to raise the Z axis up so when i hit cycle start the cutter didnt get enough time to get to full speed, plunged in to do a hole and cutter broke, 2nd time it broke my fixturing wasnt rigid enough, 2 cutters broken in less than 20 mins but that was my first ever time
Have cracked some hard jaws on a cnc lathe. Went plus instead of negative on Z work offset
Yeah been there,one decimal in a Haas canned cycle and scrapped a part destined for Universal Orlando
Crashing a machine because you lose focus after a long day is something anyone who has any ammount of experience can relate to. I certainly can, In my 22 years I crashed quite some (personal dumb-dumb record: I mixed up + and - in a parameter for a subprogramm. "Safety clearance -5mm" does quite a bang, I tell you...) . Anyone saying "This would never happen to me!" just openly addmits that they are slacking off.
Dude , missing a decimal point while busy programming . Learnt that one quick ..