Modifying a Sumitomo 10" Long Wave Mill

Relieving the neck on a 10" long Sumitomo Wave Mill. I also cut 1" off the end of it to fit the application I have for a customer at work. Simple stuff, but I supported the end of the cutter in an unusual way.
Contact me:
[e-mail]

[@andypughtube]

Are you sure that the aluminium piece was adding anything? It feels like the system could simply hinge about the cutting tips. With 3 or more flutes it would add support, but with two I am not convinced.

[@chrisrollins3519]

That’s exactly what I was thinking. It would be an interesting test to put an indicator on it and induce some forces to see how much movement you get with and without it. 🤔

[@AlwaysSunnyintheShop]

After the video was done I decided I wasn't happy with the surface finish and played around a bit more. I didn't put my tool on it and was getting chatter. Put the aluminum on the end and the chatter stopped. Would have made a bigger difference with more flutes/inserts touching it, but it was actually doing something. I was skeptical, too though.

[@theessexhunter1305]

@@chrisrollins3519 I was shouting at the lap top with that set up...lol ###### ###### sake

[@bcbloc02]

@@AlwaysSunnyintheShop Interesting as I have cut similar with a pcd insert and not had chatter issues and get a glossy finish even with very shallow depths of cut. I am sure having that aluminum bit would dampen it a fair bit. Maybe because my lathe turns so slow I avoid the chatter.

[@jeromeprater183]

@@AlwaysSunnyintheShop The aluminum slug might have acted as a vibration dampener.

[@joell439]

👍😎👍 looks like another great sunny day in the shop 😄

[@jordanlangton8273]

Coincidently I literally modified the exact same tool at work today myself. I will say you had a clever way of doing it but it wasn't necessary. You don't need that much support, you don't need the tailstock and the tool isn't that hard for doing some minor turning on it. I also read from another comment that you wanted to flood coolant? Not necessary for this kind of work. You don't need the part to necessarily run true in x if you are parting off. I am not trying to be a dick but I'm just giving you my thoughts on it as I've done the same thing. They are tips rather than criticisms. If you are not sure then you should always work precisely and carefully so hats off to you there.

[@BruceBoschek]

My wife thinks I have a problem, but I'm in love with your 6 jaw chuck. The drill chuck is pretty okay, too! Very interesting thoughts. Thanks for sharing.

[@tiredoldmechanic1791]

I was just checking to see if KZbin had dropped your channel from my subscriptions because I haven't seen a video for a long time. I didn't realize that it was this long. I hope you're just busy and there isn't anything wrong.

[@paulhunt598]

Aaron, I wish that you would tell us more about your day job. It must take you places to see some very interesting things. I spent my career inside the the walls of only one manufacturer making only parts for ourselves. I never verified the actual numbers, but we probably had 300,000 active part numbers, machining 200,000 variations each year. This let me see a lot of variety, especially after we switched from volume machining to "one piece flow". We machined only for our product build. We did no job shop work. Our primary machining functions were milling, turning, gear machining and grinding, cylindrical and flat grinding. For many years we also did our own sheet metal work with CNC laser and full CNC sheet metal shop. Machining was mostly CNC. We operated around the clock. This variety was always bringing interest to me as I was a maintenance technician and then a working maintenance supervisor. Yet my experience limited me. We had a lot of processes. We machined almost exclusively from solid stock, so our emphasis included high volume chip load. We bought a used CNC mill (mid career) and I was sent to validate the machine. This type of outing pretty rare for me. We kept a clean shop, but I was stunned by how much cleaner this other shop was than ours. Our chip load daily filled 55 gal drums or large dumping chip hoppers. This shop mostly finish machined cast components and their similarly sized machines to ours had 5 gal pails under the chip conveyors. Just the chip load and related coolant mist in the shop air was huge in reducing shop filth. This simple observation prompted a many year quest on my part to reduce our shop dirt and filth. Our processes made this a insurmountable battle, but that shop visit prompted changes that would improve our storm water pollution standing with the state, chip handling procedures, coolant and coolant maintenance approaches, coolant purchasing and disposal practices, coolant mist filtration and control, etc. I was a valuable expert in my shop, but a disadvantage was being limited to the functions and processes that we did inhouse. These reasons make me eager to see other shops, see their processes, experience their challenges and see how they address their obstacles. Since I last commented on your channel I have built a new hobby shop building. I am prepping to wire it and install the garage doors. The nominal 4800 sq ft building has 3200 sq ft of shop space with 16' ceilings. My old shop will convert to exclusive woodworking. The new shop is for mechanic work, machining and fabrication. I intend to spend much hobby time in this building for my own self instruction and many hours with grandsons. I realize that your employment travels may take you places where practices are guarded, but I imagine that you could share more content than you do. My shop equipment has seen more unloved hours than yours. Your restorations for low use expectations are a delight to watch. I probably won't ever take my projects as far as you do, but our approach is similar. I need to purchase some material for a Cub Cadet restoration upgrade that a 13 year old grandson is doing. He and I will hopefully do the machining, his dad will help him do the welding and he will do the mechanic work. This is the collaboration effort that I hope will be very common. I have 16 grandsons.

[@MartsGarage]

Good luck with the new shop and thanks for the interesting read.

[@MattysWorkshop]

Gday Arron, again I don’t know how I missed this video, awesome job as always mate, Cheers

[@mcoen]

Just wanted to let you know that I really appreciate the high quality of your videos! Always lovely to watch. :)

[@AlwaysSunnyintheShop]

I appreciate that! I definitely put in the effort- I just need to improve my skills on each video as I go.

[@hilltopmachineworks2131]

@@AlwaysSunnyintheShop Camera angles were great. It is always a challenge to get those tight shots without the camera getting covered in chips and coolant.

[@minproceng1218]

I will contribute to the algorithm and get pedantic by pointing out that when you put a load on the "system" with the aluminum adapter and the center in the tailstock you were putting it in compression not tension. As if it matters.

[@DudleyToolwright]

Interesting approach.

[@guerro327]

You should use a couple of drywall anchors and screws for that soap dispenser. The double sided tape doesn’t always hold.

[@Steve_Just_Steve]

That insert style is badass in AL. I don't have PCD but the shape works great for me.

[@jackheath6623]

cool video. i was surprised when you were able to part that off.

[@EngineersWorkshop]

Nice work Aaron!

[@MathieuThomachot]

Thank you Aaron, for this interesting job.

[@Steve_Just_Steve]

I think I would have machined a bore in the AL to slide over the tool with the inserts out of it. I'd have been too worried to break one expensive inserts like that. Those things are high!

[@AlwaysSunnyintheShop]

That's what my original approach was going to be, but my friend suggested this would be more fun. But yeah, I'm with you.

[@gordonaddison435]

Hi Aaron, hope you are ok, come back! I miss your videos

[@andyZ3500s]

Aaron I was just thinking that it has been a long time since you're last video. I am hoping that everything is alright with you and your family. Andy

[@TheKnacklersWorkshop]

Hello Aaron, Nice work as always... Thanks for sharing... Cheers. Paul,,

[@melgross]

Unless I’m missing something, I don’t understand the need for all of this fixturing. The bar is made of alloy steel. Very strong and rigid. You’re removing a small amount of metal for a short distance. It needs no support for that. As far as cutting the end off goes, it’s even less critical. Interesting about the pinions. Buck says that for my Adjust-Tru, which just has two pinions, for greatest accuracy and repeatability, just tighten the same one pinion every time. It’s marked with an arrow. For less accuracy but greater tightening, tighten both pinions. I’ve tested that and confirmed it.

[@paulmace7910]

Thanks Aaron.

[@davidaarons2488]

Boy that cut smooth in alum. I take it you are enjoying your new chuck. Jesus Does Save

[@euroman12000]

Will you post more, or are you moving on?

[@bacuu4407]

Loi, It took that much of time and effort to cut a relief on a steel shank inserted emill?

[@zachaliles]

Hey, just checking in. I hope all is well with you.

[@davidfarmer]

I need to get a chuck like that, very jealous.

[@AlwaysSunnyintheShop]

Yeah it's pretty fantastic.

[@barryboyd7973]

I’ll second that covet and include the gorgeous lathe as well, never mind the smoking deal he got it for.

[@monsterg4603]

Not sure that Aluminium piece done anything, in fact it probably introduced run out on the part. You was choking it up close to the chuck anyway did you even need center support? in the manner support was given it would not have done anything, too many joints. given how nice the part parted off turning it down would have been easy.

[@accuracymark]

My experience with that lathe insert, a minimum of .010 cut is needed for the best surface finish.

[@olitomesek9677]

Grandfather using inches?

[@jeremycable51]

You alright buddy been awhile

[@bulletproofpepper2]

Thanks for sharing !!! Very useful !!!

[@euroman12000]

No more videos? :(

[@jpsimon206]

Sorry if this question is obvious, I only run old manual machines. When you cut the shank I was shocked to see how big the coolant hole was. What would be the advantage of it having such a large diameter if both the inlet and outlet are small diameter holes? Is it perhaps in case a chip made its way into the oil?

[@hiddenworldforge374]

Less restrictions with flow

[@AlwaysSunnyintheShop]

It helps to avoid starving the tool of coolant. A high pressure system would never really have a problem supplying coolant to the inserts, but not all machines are created equally so this helps older, low pressure machines keep it flowing.

[@jpsimon206]

@@AlwaysSunnyintheShop thanks very much for the response. Always happy to learn something new.

[@peterhaan9068]

Why is my left thumb hurting?

[@danmooney6881]

Been so long since I saw a video from you, I was worried a jealous husband had caught up with you! lol Just kidding, Great video as always!

[@AlwaysSunnyintheShop]

Lol, hey now, I put another video out just two weeks ago! Before that though....

[@stumccabe]

The aluminium supports for the 1inch shaft seemed totally unnecessary. It was stiff enough, especially with such light cuts. A complete waste of time in my opinion.

[@barryboyd7973]

Maybe so, but hardly worthy of such a negative comment. Maybe someone can make us of that idea in another application where it is required to stabilize the part.

[@MCEngineeringInc]

Neat way to do it. 👍🏻

[@shortribslongbow5312]

Very nice video and modification. Thanks for sharing. :o)

[@PRick-mo8fp]

Where you at

[@outsidescrewball]

Enjoyed

[@mudnducs]

What happened? Did you quit?

[@kevinplowman8982]

y didnt u make it all the same size

[@AlwaysSunnyintheShop]

What do you mean? Make the entire neck the same dimeter as the end of the tool? Removing extra material is only done if necessary- taking steel off the shank makes it just a bit weaker, so it’s good to take the minimum needed to clear the interfering feature.

[@Jacob-64]

Would have been better if you left the aluminium fitting in the chuck on the tailstock rather than use the centre ,which wasn't contributing anything to the op

[@dh-_1011]

Do you have 3-phase power at your shop or do you use a phase inverter? Sweet Vid man.

[@AlwaysSunnyintheShop]

I use digital inverters on each machine. I’d like to get a whole-shop phase converter.

[@bid6413]

@@AlwaysSunnyintheShop Aaron, make one yourself. I made one using a 15 hp Fairbanks hollow shaft well pump motor I was given; it was brand new. I’ve used it for close to 30 years without a failure. The 8” angular ball bearing runs in an bath and will last forever. That motor detail is irrelevant as any 3 phase motor will work. The “balanced load” isn’t perfect but close enough. It has powered everything I’ve ever wanted it to, including an old Lincoln R3S power constant voltage power supply, a 10hp Axelson lathe, a number of lower hp tools and it even powers my Bridgeport E-Z Trac just fine. If you’re interesting let me know and I provide more details. BTW, I control it with a fob on my apron that controls a 115v coil in a large solenoid so I remotely control the phase converter. The unit is outside and is so quiet I had to put a light on the wall so I wouldn’t forget and leave it on. Keep the Monarch doing nice work. Cheers, Will

[@barryboyd7973]

@@bid6413 Your shop sounds pretty sweet!

[@dannywilsher4165]

Interesting!!! Thanks for sharing!!!

[@theessexhunter1305]

Guessing you don't run the coolant for 2 reasons... 1 it makes a mess 2 it would spoil the filming. ? Neat as always just over thought on the process.

[@AlwaysSunnyintheShop]

Correct on both counts. If I was running the machine every day I'd be more inclined to flood, but I'd be fighting the mess and health of the coolant all the time. My new wash bottle squirting with coolant seems to be doing a good job.

[@theessexhunter1305]

@@AlwaysSunnyintheShop Having run machines since 1977 you don't have to flood the job just enough...also keeping your hands out the work area to a minimum is good practise. If that bottle was in any UK shop the lads would drill a tiny hole in the bottom..... lol

[@georgegeorgiev2610]

New video soon? 😁

[@TommiHonkonen]

when things start falling you need to call the exorcist

[@jeffperry8068]

Cool!!

[@texnikmexanik8086]

Hi, what is 5:28? And 17:08 oil?

[@AlwaysSunnyintheShop]

The first one is a wash bottle (like you'd use for acetone) with TrimSol coolant in it. The other one is a 20cc syringe with a Luer lock dispensing tip full of Rapid Tap. They each allow me to make less of a mess for the videos and still have lubrication where I need it.

[@cardenben]

Where can I get one of those nifty sanding blocks?? Thanks for the videos, awesome lathe!

[@AlwaysSunnyintheShop]

I got several of them from MSC. They're color coded so you know what grit is in the holder before you use it. They're called belt sticks, made by Lumberton Industries.

[@ctprjcstv3998]

This machine color turns me on :)))

[@MF175mp]

To the question, pointless imho no offense. Nice 6-jaw. And a Llambrich drill chuck it seems like, they are pretty accurate for a drill chuck

[@AlwaysSunnyintheShop]

No offense taken- I was skeptical it would matter, too. The drill chuck is Accupro, made in Spain. I'm very pleased with the quality and being able to put a wrench on it for extra tightening is a great feature. I've recorded most of my next video and I show a detail of that so keep an eye out.

[@MF175mp]

@@AlwaysSunnyintheShop it looks 1:1 to a Llambrich. It's also Spanish made. 👍

[@number40Fan]

Another sad story of a machinist discovering the fame and fortune of KZbin and getting into the hard stuff*, only to be never heard from again. *ie. tool steal 🤣

[@MsOldTime]

Czechoslovakia ♥️ where his grandfather was from Czechoslovakia. I cordially greet you from the workshop from Slovakia. IG @jozefko_garage

[@AlwaysSunnyintheShop]

I would love to visit some day. My great grandfather was from Jaroměřice nad Rokytnou where the family lived for hundreds of years.

[@jpsimon206]

It's called Czechia now.

[@jimurrata6785]

Are you sure Aaron's grandfather and/or the live center weren't made on the Slovak side of the current border? When I tell someone that I've been to Rhodesia and they try to correct me, I tell them Zimbabwe didn't exist for me to visit in 1970.

[@jdmccorful]

Looks good! Enjoyed.