Machining Videos

[Drew Price]

I took some videos cutting a scrap piece of aluminum I had while I had a high speed video camera on loan for one of my classes, I thought you guys would get a kick out of these.

If anyone has anything along the same vein post 'em up, I couldn't find the old thread with the Matsuura 5-axis machine going to town, but machining vids in general are pretty consistently on our office computer.



Slow-Motion Machining

2-flute end mill shallow (http://www.youtube.com/watch?v=rZf4AjOu5TE)

2-flute end mill deep slow feed (http://www.youtube.com/watch?v=8D5TFxR7WIc)

2-flute end mill deep fast feed (http://www.youtube.com/watch?v=WI3jlEhEGrQ)

5-flute scalloped roughing cutter (http://www.youtube.com/watch?v=eoXGpKe5mQc)



Best,
Drew

[Drew Price]

I took some videos cutting a scrap piece of aluminum I had while I had a high speed video camera on loan for one of my classes, I thought you guys would get a kick out of these.

If anyone has anything along the same vein post 'em up, I couldn't find the old thread with the Matsuura 5-axis machine going to town, but machining vids in general are pretty consistently on our office computer.



Slow-Motion Machining

2-flute end mill shallow (http://www.youtube.com/watch?v=rZf4AjOu5TE)

2-flute end mill deep slow feed (http://www.youtube.com/watch?v=8D5TFxR7WIc)

2-flute end mill deep fast feed (http://www.youtube.com/watch?v=WI3jlEhEGrQ)

5-flute scalloped roughing cutter (http://www.youtube.com/watch?v=eoXGpKe5mQc)



Best,
Drew

[Pennyman]

That's pretty awesome dude. I assume you were using something like a Sony HDR-HD3 or something similar?

I've wanted to take high-speed footage of our formula car during cornering/braking events for a while now. That would be sweet.

[Drew Price]

It was a Casio Exilim EX-F1 - 300fps video will shoot at 512x384, with a decent size lens. It would be great for shooting tire deflection or vehicle attitude changes. It will also burst shoot at 60fps up to 60 frames at full resolution for as long as you hold the shutter, which would be great for mid-corner capture stuff too.

I didn't get a chance to mount it to the side of my car to try to get lateral deflection of the tires before I had to take it back, but that's my next project if I can borrow it again.

Best,
Drew

[kapps]

Nice, but why conventional cut? Climb into that and get some nice toasty chips. Conventional cutting in aluminum just builds too much heat IMO. Also, air blast will help prevent re-cutting chips (especially evident on the roughing cutter)

I don't have a high speed camera but I have been brave enough to get in macro with my point and shoot...

http://gallery.me.com/kapps/100039/IMG_1571/web.jpg?ver=12440824010001
http://gallery.me.com/kapps/100039/IMG_1604/web.jpg?ver=12440825520001

[Drew Price]

Those are bitchin photos, how many lights did you have to set up to get the shutter that fast?

On conventional v. climb cutting, I was more interested in how interesting the video would turn out, but climb cutting on our older powerfeed manual machines bangs the slides up pretty bad. That machine has ball drive leadscrews and behaves decently, but most of the rest of our manual machines have really worn out split nut drives, so we are all in the habit of conventional cutting most of our parts.


Best,
Drew

[kapps]

No lights. I think I had it on 'auto' at the time so iso and shutter speed are up in the air. I was in macro probably 6 inches from the cutter (dodging smoking chips). It's just a little Canon SD550 point and shoot. Out of the 50+ photo's I took, these were the only two that really got the chip as it was being cut.

I was cutting these at 3k rpm, somewhere between 30 and 40 ipm.

[Zhefei Li]

That's awesome. I love my SD1000, I think about everyone on our team now has a Canon SD of some capacity, except the guy who's into photography, who shoots with a D70.

Dammit, I did NOT need extra things to detract from my re-learning diff eq's over the weekend for finals....



Best,
Drew

[Drew Price]

Oops, was on my room-mate's computer.

+1 post for Zhefei.



Drew

[rjwoods77]

SGS tooling FTW. Check out there machining videos. Not slo-mo but shows capabilities.

http://www.sgstool.com/products/highperformance.asp

[Drew Price]

Those SGS videos are awesome, their promotional stuff showing the factory floor, stock rooms, and design facilities are absolutely breathtaking.

Cubic Machinery (http://www.youtube.com/user/CubicMachinery) has some wicked demo videos on Youtube, mostly high speed cutting brass for dramatic effect, but their videos of the gang tool lathes, multi spindle lathes, and Swiss-type lathes (http://www.youtube.com/watch?v=mXAem1f74Qs&feature=channel) are fantastic.

The Matsuura guru videos of the Ferrari V8 block are all-time favorite though, you can't beat the Japanese-techno-funk-fusion music for high speed machining, especially when they turn the coolant floods back on and the whole view window goes frothy, and an engine block flies out 20 mins later.


Best,
Drew

[Bone R]

Hey Drew,
Is this the Matsuura 5 axis video you were talking about? I got it saved in my favorites.
http://www.youtube.com/watch?v=GU32Q6QXtWQ

[Drew Price]

I like that one a lot too, really takin' out big pieces.

The one I was talking about is here, http://www.youtube.com/watch?v...kE-o&feature=related (http://www.youtube.com/watch?v=QsmiIeAkE-o&feature=related) it's a Ferrari (allegedly) V8 block.

Skip ahead to about 6:40, my favorite bits of finesse machining cutting the tops of the cyl bored, and then a little farther in cutting the water jacket relief, absolutely rediculous.

It really looks like dancing to me, very romantic.....

...then your sister woke back up....


http://fsae.com/groupee_common/emoticons/icon_biggrin.gif


Best!
Drew

[Bone R]

I think thats the same block. But the video I posted was missed titled.

Man, my sister must be famous. I got Drew talking about her.

[Thrainer]

I like these two, they come in handy for CR calculations.
http://www.youtube.com/watch?v=uAcBU2iqkKE
http://www.youtube.com/watch?v=Sebko0n6uJ0

[Faterooski]

I thought I was the only one nerdy enough to sit around and watch CNC machining videos. The high-speed threading operations impress the hell out of me. On Thrainer's 2nd video, I wasn't all that impressed (not as much as the first video anyway) until I saw that the chips were blue and realized the material was steel. Then my jaw dropped.

[Bone R]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content"> I thought I was the only one nerdy enough to sit around and watch CNC machining videos. </div></BLOCKQUOTE>

No there are others out there.

http://www.youtube.com/watch?v...H6CU&feature=related (http://www.youtube.com/watch?v=ttZJzauH6CU&feature=related)

[kapps]

Faterooski, no you're not the only one. Even my SAE buddies sometimes think I'm a bit off when I whip out my iPhone and start watching Youtube videos of machining when I'm bored. I'm also amazed at blue chips flying off a cutter. That SGS video of machining aluminum at full depth in one pass is pretty insane. Man I wish we had a better mill. There's one video around that is machining aluminum at 1800 or 2000 ipm. Absolutely amazing.

Not quite CNC but take a look at some of the manufacturing done here (http://www.shipsnostalgia.com/guides/William_Doxford_and_Sons#The_Manufacturing_Process ). Some of those guys had balls of steel...

[cjanota]

Bone R, the company that made that mill (Ingersoll) used to make our uprights and brake calipers. They honestly used a 50HP mill with a ways about that big to make them (smaller tool obviously.)

[cjanota]

Careful, these may blow your mind.

http://www.youtube.com/watch?v...GtKI&feature=related (http://www.youtube.com/watch?v=KMdBIBzGtKI&feature=related)

http://www.youtube.com/watch?v=gUEcagEmmZo

[teemee]

6-side machining:

http://www.youtube.com/watch?v=hjBYZn5y2-I

The "smallest" Mill from Zimmermann:

http://www.youtube.com/watch?v=nNP0NnVzqno

[Adambomb]

Here's another one for "machining freaks"...some end mill on end mill action, and some end mile on file action.

http://www.youtube.com/watch?v=fD2Mo-UrUU0

[Mikey Antonakakis]

:O

I just found this thread, and I'm speechless. I don't think we're even in the ballpark of what our machines can do...

I think our CNC mills are 15hp. What kind of speeds feeds and depths would you guys run on them?

[kapps]

It comes down to lots of research and practice. I became a bit obsessed with machining a couple years ago. Look for forums... practicalmachinist.com is one that I'm on.

We only have a 5hp, 40 taper machine with 3k rpm spindle. I have roughed aluminum at up to 40 ipm, .300 depth and 50-60% stepover with a 3/4" 2 flute. I've been playing around with higher doc with less stepover to take advantage of some chip thinning action to allow more feed with our limited spindle speed. 15hp is a good amount of power. You should be able to throw around some 1" and up endmills pretty good. Remember, feeds and speeds don't change with spindle power. You just can't take as deep a cut with a low-power or less-rigid machine. Do some googling, can find good approximations for SFM (changes with stock material) and chipload (depends on end mill material and diameter). From there, you should be able to calculate feeds and speeds.

[Jersey Tom]

A little unpleasant chatter in one of those Cubic machining videos. Cutting brass?? C'mon, amateur hour... also looks like they mislabeled some aluminum as steel.

http://www.youtube.com/watch?v=kmReHL3n0FM

Ceramic cutters are fun.

[Mikey Antonakakis]

Awesome, thanks.

Yeah I'm taking a computer aided manufacturing class and we've been going over cutting theory but I haven't really had a chance to try putting any of that into practice. I also might be completely wrong about the machines being 15hp... but still, I can't wait to start applying some theory here, I am completely blown away by those videos.

[Jersey Tom]

15hp is enough to push a lot of metal.

More often than not, workpiece, machine, and tool rigidity are the limiting factors. When you get into really aggressive MRR's, chatter breaks tools very quickly. Good reason to design your billet parts so they can be clamped very rigidly and milled with big tools. It can for example reduce the cycle time on a billet upright from ONE WEEK to ONE HOUR. That's no joke.

Go carbide all the way if you have 7500+ rpm on your spindle. If you can't get the SFM up past 500 or so, might as well use tool steel.

with a 0.500", 3FL flat carbide EM in aluminum.. 6000RPM / 70IPM would be an easy starting point (say full 0.500 radial, 0.150 axial DOC as a starting point). 8000RPM / 100IPM isn't unreasonable.

In steel I've become a big fan of TiCN coated 6FL tools lately. Think we were taking 3000RPM / 45IPM, full width 0.200 axial DOC cuts in 1018.. on a 23 year old machine. Fun fun. Indexable tooling rocks as well. Absolutely amazing the feeds and speeds you can run with good Kennametal tooling.

But like I said.. rigid work- and tool-holding comes first. From there you can go bananas.

Edit - Also... forget setscrew toolholders. That shit is whack. Shrink fit toolholding is probably overkill at the university shop level.. but collet chucks at a minimum. Most of our shops had at least a few ER16 and ER32 holders around.

[AxelRipper]

http://www.gaskrank.tv/tv/moto...aishin-cro-10963.htm (http://www.gaskrank.tv/tv/motorrad-fun/36-kg-schwerer-alu-daishin-cro-10963.htm)


essentially cnc pron

[kapps]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by Jersey Tom:
Also... forget setscrew toolholders. That shit is whack. Shrink fit toolholding is probably overkill at the university shop level.. but collet chucks at a minimum. Most of our shops had at least a few ER16 and ER32 holders around. </div></BLOCKQUOTE>

I disagree. I've seen endmills get pulled out of collet chucks when doing heavy roughing. Not the case with tool holders. Also, collet chucks are $150 a piece plus the collets (we have 3/8-1" in 1/64's plus a couple smaller sizes). Tool holders are $50-60 a piece. More than likely, you have a few endmills that will perform 90% of your operations. Get a tool holder or two in each of these sizes and maybe one collet chuck for odd-sizes or finish machining.

Shrink-fit tooling is nice but WAY OVERKILL for what we're doing. I've heard it also creates an almost too-rigid connection so harmonics of the cut can cause problems.

As for tooling, 2-3 flute for aluminum. Solid carbide will last forever as long as you don't run it into the vice or something. Just remember, carbide is harder but is more brittle than HSS; it likes less chipload than HSS but it also likes heat. This means you can pump the speed way up. The 5-6 flute TiCN coated solid carbide are money in pretty much any steel you can throw at it (including hardened gears...).