CUT DOWN Your Machining Time to SECONDS with CUSTOM Form Tools
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- Опубліковано 26 кві 2024
- Cut down your machining time to seconds with custom form tools. Using the GF Cut P 550 Pro Wire EDM, carbide inserts and tool holders from @HornUSAinc for a pneumatic spool valve. This process makes life easier for Donnie on the Tornos DT 26 to have the fastest and easiest process on the in creating this part.
00:00 Combining Technologies
00:23 Creating a Stable Flow of Current
01:31 Setup for Wire EDM on the GF Cut P 550 Pro
02:37 Machining the Horn Inserts
04:00 Setup on the Tornos DT 26
05:30 Machining the Pneumatic Spool Valve with Form Tools
06:35 Donnie and Trevor Check the Finished Part
08:51 How the Inserts were made in SolidWorks
10:05 Closing Thoughts
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„You’re an accessory to my success“😂😂
Classic Donnie
🤣 throw that one in my dad pocket. "I'm just and accessory to your success"
I had an absolute blast working on this project with Donnie and Corey, I love when you can combine two technologies to improve a process! Thank you guys for watching!
Pls make a wire edm playlist with tips and good practices I’m currently at school for lathe and mill however when I return home in a few weeks I’ll be running all the wire edms at the shop. the old guy will be retiring soon and wont be able to teach me everything else in such a short time frame
If your sinker edm has an c axis. Could you take an electrode thats like a coild spiral and then like spiral down in a workpeace?
Love when the machinists work together on projects!
I love that Horn has tools like this sitting on the shelf that can be easily converted into a form tool. I've used a lot of Horn tools and they have made a lot of custom tools for us and they always worked great.
Horn's engineering team is incredible. They have helped me with some odd grind reliefs created by some inexperienced engineer. (necking tools). The relief could have been done with off the shelf tooling, but my engineering team was too intimidated to question the dimensions.
Seriously good one today guys. They say "Creativity is intelligence having fun" and you guys are examples of that. And killer editing too, nice job editors!
Cool!
Ich bin CNC Fraeser bei Horn in Tübingen( Deutschland ). Es freut mich immer wieder, wenn ich meine Werkzeuge im Einsatz sehe.
Macht weiter so, es macht Spaß euch zuzuschauen👍🏻
That’s awesome man! Your products are really good! Thanks 🙏
TEAMWORK makes the DREAM WORK! What a great showcase of machine tool / department collaboration!
So good! Great job Donnie and Trevor!
The two nerds having fun !
just have to say, i love the goofing around that gets added at the end
Awesome teamwork! That part looks amazing!
So awesome! It’s cool to show people how combining technologies like this can save you a TON of time and headache!
Donnie! What’s the tool life like on these guys? Do they wear evenly or differentially?
@@ReactionTime344they last a really long time. If you were cutting aluminum like I am you are talking tens of thousands of parts before changing the insert
That was so educative. I used to make spools with conventional programming, but now I know a priceless method.
I love the team ups like this!! Seeing where different manufacturing processes come together is just beautiful. BOOM! Good work y'all!!
Love the Trevor Donnie tag team! And, as always, Corey's videography is amazing!
Awesome shots on both machines! Great work Donnie and Trevor!
Its amazing how much the Tech has progressed in just my lifetime. From Tape Readers in my 1st yr, to this magic, in only 35yrs !
Amazing
Love it when you show us the full proces it took to make that part as fast posible!
Great work guys!
Donnie never fails to make me laugh out loud 🤣 Amazing work as always!
Great video guys. Love the teamwork👏
I’m blown away every time I watch a titan’s vid! First thing that crossed my mind was how they don’t get any problems clearing the cut but that oscillation “g” code is impressive! Especially with my past experience making spool valves and brake and clutch cylinder pistons with a micrometer and hand feed!
Awesome job guys! You get to play with the coolest machines. 👊💪😎
You guys are awesome , thanks for bringing us good meal of all the time 😊
Just hearing "3 micro-inch" made my skin shiver
Thank you for sharing all your tips.
Great video! I remember having to grind down inserts and boring bars just to make a job work. Ordering custom tooling gets expensive and the lead time can be unfavorable.
hy Sara , any news from the stone i asked last week ?
@@pirminkogleck4056 Hi Pirmin! Thank you for your question. One of our store representatives, Russell, responded to your inquiry on Facebook yesterday. Providing quality, customer service is priority to us. Rest assured, we are making every effort to provide you with a response a quickly as possible. We appreciate your patience.
yes true , i also asked in the titan fb group ! its just i am super curious an impacient sometimes. no worrys , i have all the time it needs.
This is so fascinating!
Amazing job! Even more amazing the transition from tool to tool was so flawless. Bercause it is not as simple as shown here, especially on the long run when the inserts wear out
I really enjoyed watching this video as I used to grind tangential form tools 50 years ago on a jones & shipman 540 surface machine. A form similar to the one in the video over a 5" length would have taken over a day to make. The tool steel was rough-milled before hardening
love watching these videos then going to work the next day and using a clapped out old manual lathe and bridgeport from the 60s.
This looks like a spool for automatic transmission. We’ve made hundreds of thousands of these in our shop. Great job guys!
Great video. Really enjoyed it.
Love the shadow graph vs comparator story line continuing.
More than useful xD often thought of milling my tools but it seemed to be more work than reward. EDM is a gamechanger :D
I would have to make some cost per part calculations to know how good it is. Normally in companies in my country we try to limit the amount of the "special" tools like that. Tho it is used. Especially for milling tools.
Must remember this when making new key pins.
Sounds great for small run production.
I'm not an EDM guy, I didn't know that current flow through the table also need to be considered for EDM process. Thanks for the knowledge.
Looks like a spool valve, what a cool way to machine as opposed to single point.
Amazing job 👍
I actually did this with one of PhHorns broaching tools to make a weird internal spline. It saved me a ton of hassle from outsourcing the part for EDM and one insert lasted through 2300 steel parts.
LOL... Looking good!
a video about the far future of machining would be cool. what new technologies are on the horizon that won't be available in near future.
Or like what you think is going to be the standard by 2100
Impressive, interesting, efficient way
Holy tool pressure Batman.
Hi Ronnie, good job but you missed something fundamental on the tool geometry.
Problem with plunging tool they get dull pretty fast base on material used, and you will start to have build up edge who will affect your tool performance, dimensions and surface finish.
That’s the time when you will need to reshap your tool, but your tool was not design with constant geometry so you can’t resharp from the top without affecting the geometry.
Basically you need to calculate your rake angle that your tool profile stay consistent so you can regrind it from the top.
We use to do that all time on Escomatic tool..😅
But that probably a topic for your next video…😉👍🏻
Stay 💪🏼 Boom !
Love the video!
You can also use the split bodies feature with the extrusion and then delete the second unnecessary body in the model
Greetings from Bern 🇨🇭
Awesome video!
I'm amazed that tiny looking diameter could handle the tool pressure
I wish we had an EDM for stuff like this. I could speed up a ton of our processes.
Funny to see this. 20 Years ago I did an apprenticeship on 30+ Year old mechanical multi spindle lathes using form tools. Typical part time: 6 to 10 seconds. So the Idea has been around for a while... And we also did the chip breaking thing. We just grinded some groves into the curves controlling the tools...
that was a smart way of doing it, i like it, i can imagine that if you would have to make 10.000+ parts that this is a huge time an therefor money saver, good plan guys
Donnie and Trevor you guys rock..... But Barry makes bigger chips 😂
Hilarious
Vrry Cool. I'm curious how many uses you get from these before they're worn and no longer make in tolerance parts.
This method we usually use. Especially for CU and AL. It is really conveninet and fast.
Cut age 3 degree is enough
Yeah I saw one of these custom form tools at a flea market a few weeks ago for 2 bucks, the guy was selling a bunch of special lathe tooling.
You should do a speed comparison between form tools and standard tooling
Great job guys. Still a comparator Donnie.
You’re a comparator
Brilliant
could you make a video on minimum quantity lubrication (MQL) technique
Super
Incrível !
That is so cool. Wire EDM is an incredible technology.
Are you guys going to CMTS in Toronto at all?
I saw how you put relief into the drawing but how did you achieve it on the EDM? was the wire feed tilted or the jig?
Damn, I miss working on my wire edm at my old job.
Okay making the insert is all well and good, simple enough. But now how do I add the custom insert into my cam software so I can program with it properly.
Boom
I love you guys 😂
Is there EDM training on creating the relief angle? Is it just a matter of shrinking the bottom tool path (U/V) of the wire EDM to create the relief?
Is it also possible, to meet your guys on friday at EMO
Oh bois, Accessory to my success!. 😁
Wow 🤩
It seems to me that it is possible not to project each line and arches separately, but simply to use a Boolean operation.
After subtracting your part from the cutting insert, you will get all the contours automatically.
This will speed up the process of creating a contour by about ten times.
And you love speed and simplicity ;)
7:00 valve body plunger for a cable shifted automatic transmission.
We use a thing for cutting plastic on our Citizen sliding heads, not should what it does, but it breaks plastic chips.
I went over to the dark side of Inspection about 10 years back form CNC turning, I have arthritic problems now
and I don't think I could stand up all day without getting in pain.
That is why I don't Know much about the new Tec.
Any recommendations for a shop that can EDM a tool like this for me?
COOl VIDEO DUDES 👏🏻
0.25mm thick wire is thick for us, biggest we use is 0,15 but average is 0,05mm to 0,02mm
In my workshop we're working almost every aluminium part with formtools.
"the audible ohms setting" --say it with me, "continuity mode"
@@trevorgoforth8963 RTFM
is there a dwell when the form tool is at the depth or does it retract immediately? i am wondering how round the part is.
Yes there is a .3 second dwell when the tool is done cutting. Roundness was .0003”
Hey guys, just a heads up in solidworks, you don't need to do the convert entities + cut extrude, you can just use the cavity feature and it will do all that for you. Makes it much easier.
Are you sure? That sound like it will essentially revolve cut the body from the tool, and it will have no relief and not be a 2d shape
Хехе, уже лет 5, на GF, проволокой оцинкованной 0.1мм делаю резцы PCD и CBN.
Random question guys…. At my shop we have a Mazak with a spindle problem we think…after machining a plain block of aluminum with a 4 inch end mill and we check it up and down with an indicator on the Z it’ll be 0 at the bottom and by the time we get to the top it’s .010 off…..could the spindle be crooked or what would cause this? The spindle did just get serviced because it wouldn’t change tools properly so we’re thinking they did something incorrectly when they made the repair?
Sounds more like a gib issue. As your spindle travels in Z, if the gib is loose, it will cause a taper in your machined surface. Are you seeing any chatter on your machined surfaces?
Put a 1” dia. solid end mill holder in the spindle. Then put a 1” dia bar stock in the holder and tighten it. Put an indicator base on your table and put the indicator needle on the holder. Grab the bar stock, push and pull in all directions and see if you have movement on the indicator. Make sure needle is on holder and not bar stock.
Good luck
I'm dissapointed that you didnt guys create some nice holding rig for machining these holders.
How come chatter isnt an issue? I suggested doing something like this for some small thin domed parts to my manual machinist coworker instead of tons of small step over spiral cuts with a ball end mill on the 3 axis cnc (we dont have a cnc lathe) but he said chatter would be way to much and the mill would be easier. (It wasnt, they kept bending in the chuck, I didnt get home till like 10 : / ) Was he right about that or did he just want to pass the parts onto me?
Machines making machines, WHERE WILL WE STOP😂
Get some dang pennies for under your clamp-jack screws in that EDM!
It is awesome tech. In what range of production volume is this the way to go? Because I'm not sure how big the window between very fast conventional lathes and the multirotor revolver lathes is for this. The tooling is for sure very expensive in comparison.
The problem that I see is: The machine is aready very special as the spindle power for such an operation and the cutting forces are SICK. May it be twice as fast as a very fast standard lathe setup. With standard quick change tooling, you can certainly use higher cutting speeds, as inserts are much cheaper than these tools, which prevents this to pull ahead very far.
And then if you use a specialized machine with custom tooling, why not going full beans with a revolver lathe that probably still beats this by a solid factor - again with cheap (in comparison) standard tooling?
Don't get me wrong, I like the shots that you presented here A LOT!
genius
how long would these tools last before theyre inaccurate from wear?
For that really fine valley? I'd probably wager 100 parts. It could still be in print, but it'll probably start showing some wear. Probably 500 before something chips or snaps.
If you really want to you could probably redress the carbide a couple times if you catch it before they break. Just have to keep an eye for the wear. Plunge a little extra deep to compensate for the draft angle.
So they might be able to use those 4 inserts across a couple thousand parts. With careful eyes. With less careful eyes, probably be 500 before a few are toasted somehow.
EDM is the only technology I haven't worked with yet.
Why did the part look so wobbly when you were cutting it, that can't be good. Not trying to be an a hole, you guys are amazing keep up the great content.
Because the pressure is insane and the variation of depths with a rake angle make that the cutting edge isnt on center anymore and the part is trying to climb over the tool.
Hey guys did I see it correctly, did the shaft end wobbled at the plunging on the end?😳
A little more finesse on the final plunge might be necessary, but it's not uncommon for this approach to cause a lot of side load and the part to subsequently give a wobble.
It can be ironed out with some workholding or just a slightly easier approach on the final cut, if they're desperate to eliminate it. Some jobs don't absolutely need it.
Are these carbide inserts, uh, naked? Is it even practical to EDM coated inserts? I'm a bit of a materials nerd, but I don't recall if any of the common coatings are conductive. I don't have any idea how the tool will wear or even if it would cut properly with the relief uncoated.
Hmmmmmm interesting donny
This was funny, more ??
My boss and co worker will be at emO