Can We Conquer The Impossible? Machining 2200lbs Of Steel Vertically
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- Опубліковано 10 тра 2024
- The first CNC machining operation for the TOWER of TERROR on the Heller CP 6000! 2200 pounds of steel being machined at speeds NOT recommended...something might break!
Crazy Deals on Schunk Here:
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00:00 Time to get 1200 Pounds Off
01:02 SKETCHY Pallet Change
01:35 Let's CUT Some Metal
02:22 Tower of Terror Overview
03:25 Let's CUT Some Metal Pt. 2
04:02 Programming the Tower of Terror
04:49 Let's CUT Some Metal Pt. 3
06:19 This Can BREAK Your Tool
09:14 Finishing Operation 1
#Machining #Machinist #Engineering - Наука та технологія
Took my students to tour their shop and we got to see this up close and personal. Great guys and very accommodating.
Do they always dry cut stuff and have sparks flying everywhere? if so their tool supplier must fucking love them.
@@suicidebylifestyle9267 its for the camera
The camera's mag mount looks like a sea urchin from hell.
We call them blue porcupines 😂
CNSEA Urchin?
I like the blue porcupine that kept growing through out the cut
If everything Barry does is "sketchy", none of it's sketchy. Most impressive!
Remember boys, these aren’t real world applications. This channel just shows what the machines and tooling can do.
Those chips and patterns left by the tool are beyond amazing!
Love how you sacrifice tools for our education! Can't wait to see what breaks next on that giant steel monolith!
That pattern looks pretty sick and its just roughed out. Can't wait to see the final product. Good stuff here and the music and videography is always on point. 💪
ayee GJ Barry and Adam!
😍Been waiting for this video to come out so long
Very excited to see more of this Mr. Barry
That diamond pattern at the top and bottom remind me of the Chrysler Building in New York, pretty slick!
Now I know why you milled all that metal down, you can rest your elbow on the chunk more comfortably on it as in the last shot.😊😊
Just awesome Barry. Look forward to the next phase!!
Thanks Tony!
Sick! So much metal.
너무 재밌게 잘보고있어요~^^
타이탄 화이팅~~
It's so good video and i watch it all. Titan 💥 boom^^
Not bad, that takes a lot of balls/confidence. Some parts just take a long time. Few would dare even try.
Back in the 90s I would be doing this work on a brown and Sharp ballscrew machine 😅😅. Man have times changed ❤
Wow @ 7:18 there is a non default holder. Finally! Seriously though if you are showing people ways to do things... talking about properly modeling tool holders and making tool libraries should be something spoken about. Especially with multi axis toolpaths.
You guys should make a video about setting up a machine sim. I'm trying to get an okuma mu 4000 setup in mcx 2024.... Nobody seems to really know how to add a new machine sim setup.
Also... the endmill broke when the engagement increased on the other side of your fancy cone........ so your "solution" created it's own problem. Just pocket out a bore with straight walls. It will rip of way smaller tabs. A lot of people swear by solid holders but just like you said the screws came loose. I have seen more issues with solid holders and set screws than I ever had with ER collets or hydraulic holders or shrink fit.
Berry is a beast 👊😎
I love the process. 💯
Loper its bArry 😂
@@barrysetzer keeping it swanky 😎
The mass of that thing is definitely helping with the work holding.
I run a 5ftx10ft table 5" spindle G&L HBM and THAT was some material removal. Damn
Awesome job! One day I will make big blue chips of greatness like you Barry. Keep up the great work 👊👍
Hahahaa GET SOME
U know never thought about it, but that camera mount made me think. A high powered magnet that can be turned on and off might be pretty useful for clearing chips from the cutting area.
@barrysetzer that was soooo sketchy 😁🤣. When the end mill broke it looked more to me from that angle like it came loose and just fell out. Great looking part so far, very geometric.
IVe being busting for part 2 to come out you did it
wow that finished roughing already looks amazing.almost like a modern piece of art. if cnc machining does not work out anymore for barry he can always start making art with his trademark chatter patern.
Hahahahaha
Was there any practical reason for making that out of one piece or was it just to look cool. Either way that was a great video!
I actually like that surface. It's almost like a cosmetic feature
guys, seriously: get yourself a WFL Millturn machining centre for parts like that. Milling (or slowly gnawing) chips away like that is not efficient.
Barrrryyyy!! You're the man. But brother did that new tool cut well. Some science to check out, temperature of material + work input from cutting(actual energy energy to cut metal/theoretical minimum energy to cut) = final work done = temp of chip + change in temp of material + tool tip temp. Therefore if final temp of chip is super high you are putting in way more energy to cut, in this case, friction. That why the rig stopped flexing as much when you did the tool change. Monitor the machine torque and axis/vector forces to tell when the cutting edge has dulled. Forces needed by the machine increase substantially. Round 2 🎉
But then KM wouldn't get to sell as many $1k endmills to guys "trying to put food on their table." Instead those endmills would get reconditioned for a fraction of the price and get re-used a number of times. Most (all?) nice machines have metrics on spindle load, servo load, and vibration that can be used to trigger a tool change. I know Siemens 840D can, at least on DMG machines.
@@dwaynesykes694 very cool! Can those carbide mills be reground? I would have thought that would be the norm these days with electronics, auto change based on load and vinration. I guess they are seeing just how many lbs they can get off without touching the tool. But makes you wonder if you had 5 endmills for the job, and used them until then needed a regrind but not killed them, would the job go faster and more efficiently? Because you were cutting at optimum for more of the time. But the machine puts it through at the same speed so guess you wouldnt notice a difference, machine energy consumption would have to weigh in.
@@zimbab5748 they absolutely get sent back to the manufacturer for reconditioning (their fancy term for. re-grinding) at most shops.
Claiming that you can make more money by blowing up a $1k endmil, potentially a $1k toolholder, and sending a ~2lbs chunk of carbide flying through a million dollar machine is just reckless. Great way to make money if you make videos and sell tools for a living, horrible way to make money if you make parts for a living.
@@zimbab5748 for some perspective on how "smart" the advice in this video is, a comparable endmill from everybody's favorite Swedish tooling manufacturer -- whom I shall not name to avoid having yet another comment nuked -- is 862 US greenbacks new yet can be reconditioned by the manufacturer for a mere 72 bucks up to four times.
Amortize the cost of the tool and four regrinds and you're at 230 per wear-cycle on the tool, which makes the cost of solid carbide a lot more palatable. Those numbers are also list, any shop running enough material to justify 1 inch solid carbide is likely to have an account and consequently lower numbers than that. Regrinds on anything less extravagant than a 1" wide x 4" cutting depth 7 flute monster are substantially cheaper, making it even more sensible to NOT break your tools.
The ability to regrind, plus the fact that blowing up a tool almost always wrecks a a fancy hydraulic toolholder (or at least the collet if using one), and you can begin to see why no one else is out there telling you to intentionally break your endmills... except shameless shills.
Barry is a BETTER machinist then Titan. 7 days a week and twice as good on Sundays!
Barry is an excellent machinist, wish I had a co worker like him
Thanks Dan! We would have a blast!
My coworker don't even know what a micrometer is and I'm supposed to train them on 12 axis Nak Mill Turns
Maybe he has digital ones 😮
iam from india and iam using fanuc and simens control...i like your all videos
Sir Could You use Carbon insert End-mill since you Not Using Coolant and Carbon insert loves heat ?
Love it!!!!!💓❤🧡💛💚💙💜🤎🖤🤍
❤❤ love you... Suuuper sketchy 😮😂
Click clackiddy duck... Barry lookin sweaty as Foooook... Good video dudes 🤘🏼🤘🏼
Barry is the greatest!
That some bad ass pattern.
That roughing pattern looks rad. I think you'll get better tool life by not standing there watching the tool. I just sit back and listen 🎶🎵 Since quantum mechanics proves observation changes behavior, I figure the tool is better off not having a person stare at it hoping it doesn't break 😆
That may have just been my favorite comment of all time
@@barrysetzer 😆thanks brother, I appreciate what you guys do 💪
Nice roughing job!
If you break 3 $1,000 end mills and save 50 hours, you are ahead. BUT if you break 5 end mills and take 45 hours longer...
At 2:50 you mention high feed milling and how it produces much longer cycle times based on limited depth of cut.
I wish you guys would address this point in greater detail. I’ve commented before about how it would be nice to go in depth about high feed milling vs hem and when to utilize either of these strategies, or possibly some guiding principles, and why.
Also it is my understanding and experience that both hfm and hem can be very productive it is just dependent on numerous factors. So to say that hfm undoubtedly produces longer cycle times than hem is a bit of a generalization, no?
So, I don't know what is mote impressive. The machining method or the amount of chips the camera magnet held onto.
You can see the heat pattern at the bottom of the cut earlier showing the end of the flutes were dead before the rest. If you sent an indexable in to sort all the little tickling with the end of the cutter it would have lasted the whole part
Think of the beer money from recycling a inch endmill 😂
That SMX3100st seems like it would be a better fit for this job… also is that the part deflecting on some of those heavy cuts or just the video playing tricks with the z movements?
How do you reliably convey chips out of the machine without a liquid? Seems like it'd be way more likely to jam up a chip conveyor.
I can smell the colour 7
Hi there! I'm 9:55 into the video. Was someone babysitting this machine the entire time? What was the immediate procedure when a tool broke? Do you hit the E-stop? Do you pause cutting? Is tool breakage auto-detected?
After that, do you just back up 100 lines in the gcode and resume, or a complete restart, or...?
Barry wasn't joking when he said hes busy creating chips and fire
Hahaha told ya!
That endmill had a really rough day
It would be interesting to see how your cycle time compared to just simply roughing this with a 2.5 hi feed button cutter
Bring on part part 3
Just a quick question...When I had long running parts such as this, I anticipated tool wear/failure and programmed in mutltiple tools and figured in "chip time" on each tool. In this case, I probably wouldv'e done (3) 1" diameter E/M's. How come this wasn't done? Not pointing out flaws, just trying to gain knowledge.
Holy crap you killed it great job. Did you have to use the power of the combover yet or are you saving it? You get no respect!
I noticed on the 2nd tool, there was a portion that was especially obvious at 10:01 about a quarter inch from the bottom that was cutting very poorly. Was this by chance a chip in the tool that came from breaking the first tool and being unable to clear what might have lodged itself into the steel? I've seen this happen in multiple cases where I work yet I feel like its something I never see acknowledged.
8:18 What are those two rings that formed around the tool? Could it have lasted longer if it was cleared/ had a chance to cool?
Tool post-mortems could make an interesting video.🤔
4:00 Funny to see that the big, high end machine shops are still using plastic totes for mill chips 😂
I think that's the only time I have seen Titan VISIBLY terrified of what was going on! That's how you know Barry is the "Sketchy King."
I am curious, was the tool holder trashed after the set-screws loosened? And is that a common problem, or just a Barry problem?
Does Heller CP 6000 have a load sensor in the spindle. Like if it is doing a tool path and suddenly the load changes from x watts to much less watts it can sense that the endmill did break. Or were you just lightning fast on the emergency stop button...
Def not load change, otherwise itd stop when you you are finishing a cut. Vibration sensor could be though
Have you considered running a tank of crushed dry ice inline between your machine air supply & the tool?? The cold air & semi solid CO2 combo would be similar to running coolant with the CO2 possibly acting as lubricant.
That will just build up ice on and in the line, and it will be pure water, you don't want that in any part of your machine... Also dry ice evaporates to pure nitrogen, not something you want to blow in a room for 30 hours...
@@clubdjmarcus Dry ice is pure CO2 it does not contain notable amounts of nitrogen unlike the atmosphere. Compressed air also has very low water by volume. What is present will freeze inside the mixing tank before entering the lines. To raise CO2 from base 400 PPM to dangerous zone of 40,000 PPM. In such a massive room would require multiple tons of dry ice to be melted with all ventilation removed. Also liquid nitrogen is already being run in machine tools with no issues at even lower temperatures.
creating all those stock models, do you do this by hand or are you using some "simulate this path being cut" software and use the outcome?
Its a mastercam toolpath!
this is what my school shop teacher swears he made back in the 80’s with 3 high speed steel endmills and a manual mill😂❤
it can be done with a rotary table and a large enough mill. it would just take half a year. and fuck ton of filing. lol. dont knock a high speed steel end mill. they can take some shit. not like carbide of course. but they can take some shit. feed and speed is waaaaaaaayyyyyyyyyy more important in that regard. but. its gotta be good shit. not accupro. its gotta be Cleveland or something like that.
Hiya, just a spectator here. How come cooling is not used for roughing, or any particular reason this is an exception here? Except for maybe not blidning the cameras?
What is the most efficient way to change tool, and start milling again. If you break your tool middle of run in place that is not mapped as scheduled tool change spot.
You use line numbers in a program usually. Tool breaks, check the line number of program, put new tool in, start program up a few lines before to be safe, hit cycle start. Good controls have a mid file start option that checks the code for any g and m codes that might need to be set before returning to the cut (like tool length offsets or something)
Some machines remember where the tool broke, and then it will back up a few lines, and you can then restart a couple moves before hand.
...You guys use coolant on a lot of your end mills. We use Guhring tools, they call for about the same speeds and feeds as your kennametal end mills, but they recommend using only air. Does kennametal recommend only using air but you found it better to use coolant?
In my own opinion coolant is usually better. Flushing chips with coolant usually negates the negative effects of thermal shock
HPC at 1000 psi some Swiss Blaser, he could have done that with one end mill. And secure it better than set screws, maybe them locking end ones
So why no coolant? For video? Would coolant save at least a $1000 in a broken end mill?
Inheritance Machining made a Mobius cube manually on a Bridgeport mill. Could this be done on a cnc?
the problem there was holding the part nice and still in a chuck or a holder. the same problem would be with CNC, however, you would get to remove hard reaching zones from different angles with a 5 axis machine, Inheritance had only 3, only a top down approach
Surely needed some serious coolant in there; have to let us see though, I guess.
Why not pre-drilling all the pockets? And if no coolent..what about cryo-cooling. That topic has not been touched by you? For very rough materials like Monel etc. it would be interesting to see what tools could be applied....or for hardened steel...love your channel. Follow it for years. Not a mechanik anymore but still live the craft.
PLUNGE MILL MOTHA FUKA!
Might be a silly question, but how do you continue in a hour long CAM-Block after your tool breaks without letting it run again?
Most machines will let you return or start on any line of code. Depending on the machine this can be very easy or just requires a few extra steps. In a program like this you go back 20 to 100 lines of where you pressed stop.
Odd tool oscillation at 1:50
Is that the beginning of loose setscrews?
Good eye!!!! Yes it actually happened happened 5 or 6 times before the endmill finally gave up. The last time i used red locktite on the screws 😂
@@barrysetzer was red loctite the fix for the screws coming loose?
I had this happen, just assumed it was not tightened enough plus didn't have weldon flats on the tool. 1" holder too!
@@NickMieloszyk it did end up working, but i decided to switch to the hydraulic holder after the tool broke. I assumed the same as you, that i hadnt tightened the bolts enough. But after the first time they came loose I used a 2 foot long cheater bar and they still came loose. And my tool did have weldon flats. I think its just a combination of heat, torque, and vibration
the violin is sick
I would've just rotated the part 90 degrees each side and rough plunge milled it with no coolant, personally. You're super lucky you didn't get a chunk of carbide embedded into that steel or work harden badly.
what is it you made?
Look closely at 5:50, that Big stock is moving a bit when you do a cut, but with that speed/force and the BIG sketchy Stock and humongus Iron chunk
oh yeah, I thought that was camera shake but nothing else is moving
The stock is being moved by the machine. It is not static in there, one of the CNC's axis is moving the workpiece into/out of the end mill.
watch @ 1:47 and re think your comment.....
@@TritonTv69420 Me? at your timestamp we see the spindel start.. not the work-piece shaking like at 5m
Lol its just the camera shaking. Comsider when this endmill broke. When you break a tool that big, your stock would almost ALWAYS move. Not here
Little tweak's to increase tool life???
How about turning on the coolant???
was wondering how come there's no use of coolant
You absolutely should try to avoid breaking endmills. Running faster to trade tool life for lower cycle time is fine, but not to the point of failure. It's not just the endmill, it's the holder and potentially the machine that are at risk from breaking a tool, especially a large 1" solid carbide endmill. High end hydraulic toolholders aren't cheap, and you can pretty rapidly push a job well past the cost of a little extra cycle time when you start breaking things. And forget running lights out like this, no one wants to come in to find a crashed machine in the morning because a tool broke.
I think they know what they’re doing bro
@@cambrowndrums They do know what they're doing. They're selling you on the idea of breaking tools to save money because they're sponsored by tooling companies that are happy to see you break a $1,000 end mill instead of stopping 10 minutes sooner when the tool is at a point that it's dull but can be resharpened. An end mill like that can have multiple life cycles if resharpened.
Also no coolent was used so I'm sure they were aware of this happening
Love your work and I'm not trying to be mean here but I think you'd look better bald. I started losing hair when I was 19 and buzzing the rest of it it off was one of the greatest decisions I've made. Looks much better than a combover IMO, and much simpler to maintain.
LOL i was bald for 15 years. Wife didnt like it tho. So what can i say 😂
@@barrysetzer Lol, can't argue with that! Keep up the great work man. Love your content!!
Nice big overflowing chip bins and no safety glasses is deff the sketchy part heh
Can someone explain it to me what's that structure supposed to be?
Приятно смотреть мужики 👍
Why did you cut dry? Was it only for ease of video capture or would you normally run it dry?
It was just for video. Coolant makes machining boring
Lol fair enough@@barrysetzer
the entire part was ran without coolant? :o
i need advice, i am working as an apprentice machinist and intern but i'm not learning anything for almsot 2 years, do i find a new place?
Definitely!
110% 👊 all in mm ?
8:24 pretty sure your helix is what caused the endmill to break in the first place. Honestly i cant see how the material left behind you destroy such a hefty cutter. Also if you do these heavy cuts, why not use high speed milling or use endmills with inserts? Could make much more beefy rough cuts with them
A fraisa MFC cutter could just helix entry and rough inside to out. No need to do the thread mill trick 😊
Is there a reason to cut dry?
track id @5:50 ?
People in the comments always get a nervous breakdown when there is no coolant 🤣
"B-b-but. Must. Use. Coolant...Arrrhg!"
is this an actual part or just for video purposes?
That's a stupid question
@@user-gv4sv8bb5t that's a stupid answer
the steel came and the CNC Conquered
How do you calculate machine shop rates
You calculate how much money the mill costs you per hour, the purchase, the shop space, etc. Think about how much you want to pay back your machine, the profit you want to make and look at the rates other shops in the area will charge
You need to demag that material.
How do u know the tool will break around there?
When the spark starts to wrap around the tool, its a clear indicator your cutter is chipped
Running a 1" endmill until it breaks is pretty inefficient. Inspect the tool, mastercam even has an option for this after time or inches in the cut. Saves you chasing where you were in the program and saves your holder, part and spindle.
What about the cost of a tool breaking when noone is there to stop the machine and replacing it. What if you break 4 more tools that are more expensive or not as easily replaceable.
why do you cut clockwise along the direction of rotation instead of against the rotation of the tool
For most materials in a cnc you'll almost always be climb cutting (with the cut). You get better tool life, surface finish, and chip evacuation. In a manual mill you tend to do a conventional cut (opposite of climb) because the mill isn't rigid enough and the table often gets pulled along the cut causing problems or tool breakage. You don't have that problem with most cncs
@@Marlfox570 aye, thanks for the detailed explanation bud!
So I guess Titan does not has that rate of 65 dollars an hour anymore
Cool video