Casting Final Operation On Mazak

[@chrisyboy666]

Peter I’ve been an applications engineer for 30 year I served my apprenticeship as tool maker in a little company in uk called Rolls Royce making Turbines for Nuclear power stations ....Then I moved onto the Apps started @ Mazak, Went to DMG then pietro carnaghi Then Hermle now I am @ WFL i have wrote programs and told some of the biggest companies in the world 🌍...how to tool up jig and fixture wise and program their parts some real complex work that takes months to get the project going from drawing to finish component after all this experience and knowledge I thought I had, I am constantly in Awe of the ability and skill you have...you are a true thoroughbred Peter a natural...your a solid tactical planner with a flair for producing the right prg with the right method for the right part your in the top 1% in your field kudos to you Peter...your worth every Penny or cent as you say you charge...

[@EdgePrecision]

Wow! Carlos high praise from someone who knows. Thank You!

[@baccus61]

I bet the customer was very happy with the results and the carbide mill blank through the holes is testament to the accuracy of the machine. Very well done. I find your videos very soothing and relaxing.

[@DougHanchard]

Professional. Truly respect your approach to each Op and checks. Your videos just get better and better every time I come to watch one.

[@aarondcmedia9585]

The surface finish you are getting is unreal. Love seeing a big machine doing real work.

[@craigwalker3256]

Holy crap I wish I was 10% clever as you Peter!! Fantastic!!

[@canonguy9448]

Great job, Peter. Love watching a master work! I also like the format of this video. Footage + commentary of your thought process is very helpful to beginners.

[@cpifer5762]

Thanks for taking the time to post , your experience is priceless !!!

[@adamGeuc]

Peter, thank you again, best machining videos on the net.

[@alanmunroe8332]

In respect to your concern about dowel pin removal for the fixture. There is available, a collet type slide hammer, used in the auto engine machine shop (old school stuff). Outstanding fixture & process!!!!👍👍👍

[@JosephColihan]

Got the best guy for that job ! Unbelievable.

[@Ujeb08]

very nice! Man you like to cut it close on those cutter lengths! Any young machinists and learning machinists who are watching these fantastic videos you should soak up all you can and ask many questions to Peter. This is a great opportunity to learn precision machining/toolmaking! Thank you Peter!

[@tylersawyer8645]

I absolutely love watching your videos. Keep up all the good videos and work you do! I cant wait to see mor evideos from you

[@CapeCodCNC]

Very cool to see you take a very complicated job and make it seem like just another day! Keep them coming, they are awesome.

[@Marthis218]

So glad I discovered this channel. The content here is fantastic.. I'm sure many more followers to come.

[@EdgePrecision]

Thanks Lee, hope that’s true.

[@micahhunter2706]

Awsome video, Peter. Can't wait to watch it a couple of more times.

[@KK10155]

Glad I stumbled onto your channel, please keep em coming!

[@jcurran2414]

That's one sweet Lathe. all the best for the coming year.

[@ianpendlebury3704]

Once again, fascinating. Best wishes for 2018 and please keep the videos coming.

[@SolidRockMachineShopInc]

Hi Peter, Love you're videos, awesome job!

[@akfarmboy49]

very busy part, you are so calm about every thing, it's easy for me to follow your procedures, that Inagex machine is handy, to bad they aren't as common as a Bridgeport i'd have one.

[@lorenlieder9789]

Great work Peter you are the CNC man!!

[@key2010]

that is the first time i've seen cast stainless steel, i didn't even know it's a thing! very interesting rough texture

[@nash0427]

Peter, would you mind doing a video on the pricing for a complex part such as this one, even a fictitious one!

[@floodo1]

Yeah, I'd love to know the machining cost and the overall cost (including casting) for a part like that ... looks pricey (-8

[@EdgePrecision]

There seems to be a lot of questions on this subject. It would make a good subject for a video.

[@nash0427]

Would love to see that video!

[@brandonspencer309]

I agree, would be a very educational video for all your subs, of all trades!!! Thanks again for your time and consideration put into every single video! Cheers

[@thatdamplatypus9896]

Been watching a few days now and couldn't get past how familiar your voice sounds until I figured it out. You sound a lot like Taofledermaus in your voice over sections and you explain things in a similar way which I really like.

[@vkoutsovoulos9425]

Great video series ! Thanks a lot for sharing.

[@norandavis856]

Castings are probably the most tedious materials to run. Many of the castings that I work with took a lot of time to design and make fixtures for but it ended up being worth it in the long run because mounting them in those fixtures has taken several hours off the overall run time of the job. I use a HAAS ec 1600 for most of the casting jobs I do because I can mount multiple fixtures in that machine and do all the operations in one set up. If it’s a one off job it probably isn’t always worth making a fixture, but if you have a regular customer that you do special castings for, it’s far more efficient and repeatable to make fixtures for casting jobs.

[@4n2earth22]

Freaking truly amazing. You rock, no matter the offset. Calibrate till the darn cows come home, and you are gonna be spot on. I totally enjoy your work, vids, and information. Please do keep on keeping on!! Most sincerely..... Me.

[@РенатРоссия-ь3е]

Качество обработки реально впечатляет! Современные станки сегодня выдают максимум, что возможно при нынешнем уровне материалов! Для ещё более лучшего необходим прорыв в материаловедении ну или нужно использовать другие физические принципы обработки.

[@yogisworkshop]

I always enjoy watching your videos!

[@mannycalavera121]

You're a magician on this machine.

[@TheNefastor]

I love good work, I can watch it all day.

[@TuanNguyen-md8cc]

the experience you have in machining tech is valuable to any shop. and that all reall not just book. i don't know if you have anychance so us how you do speed and feed on milling on cetain tool from drill, tap to endmilling for inconel and ss teel. thank for show us these tech.

[@scottlundy257]

If I had parts to be machined you would be the man I would call . perfect is close enough

[@nash0427]

Peter, Really awesome, I've got a question, do you chase each bore on each part or can you run a couple without changing parameters on the boring heads?

[@EdgePrecision]

Thanks! Yes on every part I back off the boring head and run it to dimension. I cant or wont take the chance on scrapping a part to save a few minutes of time. Not when I have this much invested in them. On a simpler less expensive part I might.

[@nash0427]

Thanks for your response. Yes, that's what I'd have guessed. Great work!

[@aldricdentremont3570]

Wow... loved it,nice setups

[@mahoneytechnologies657]

I am learning a lot form your videos! Thanks. So far in all of the machining videos I have watched the story ends when the part is removed _ But as Paul Harvey use to say " The Rest of the Story" is important information to know, deburing, Polishing, Anodizing, or how to get those showroom finishes when needed. For example deburing is fundamental and I think requires a lot of just doing to develop good technique, maybe you can give us some examples of your techniques to get started, like how much pressure to apply, in general, I know varies with the material etc., not as much fun as learning to use a 5-axis milling machine but need to know. I would include grinding too as well as using things like Cratex. Thanks and and please keep producing your videos to teach and share your experience! Happy New Year!

[@EdgePrecision]

Yes all good points I will keep them in mind.

[@carllaniak]

Really interesting and fun to see your work.

[@Mcfryguy5555]

Ship it, charge them extra for all that probing! Thanks for sharing!

[@LeifMaginnis]

Really love these videos.. So rich in information..

[@gredangeo]

8:07 Something I missed the first time watching this video. What does all those different "Block Skip" numbers mean? Can you get this machine to see different types of 'Block Skips'? and be more specific in coding than just your basic [ / ] ?? If so, interesting.

[@EdgePrecision]

The Mazak has 9 additional block skips (Or Deletes). If you put a number after the /. For example /1 or /2 all the way to /9. Than when you select the Block delete 1 soft key it only skips /1 in the program. Or /2 it only skips /2. And so on up to /9 max. Now on the soft keys you can select as many as you want or all of them if necessary. Hope that makes sense. It's a little hard to explain in a comment.

[@gredangeo]

@@EdgePrecision That's pretty amazing. Explanation sounded good. That's a nice extra level of program control at the machine. Opens up possibilities of scenarios of "Just because I can" :)

[@HurtigrutenExcursion]

Amazing video and very detailed look at the steps. Can I ask how many hours did it take to make the program and what was the cut time per part (only if you want to give that info out). Thanks!

[@sunppaa]

Beautiful.. You are a genius no doubt about that! May I ask why do you prefer using coolant when rough facing steel? Chip removal? Some insert manufacturers say it's better to rough without coolant due to thermal shocking. Just wondering whether or not to use coolant myself.

[@sunppaa]

Woops, just realized the coolant was only on when finishing :-)!

[@EdgePrecision]

I would use coolant when roughing with a plain face mill. With a feedmill coolant is not recommended (I was blowing air thru the spindle that's OK in fact its the best.) because temperature fluctuations of getting hot than chilling of the inserts by the coolant. This can fracture the carbide at its cutting edges. One thing about using feedmill or ceramic tooling is if you are roughing a lot of material off to cool down the part by just playing the flood coolant on the part before making your finish cuts. I once ran a Inconel part that we roughed a pocket in the center wit a ceramic cutter (No coolant on ceramic) The part got so hot and we didn't cool the first part before drilling a hole pattern around the OD. When the first part went to inspection the hole pattern was out of tolerance because the part cooled and shrank as the holes were drilled. Something to be aware off.

[@billyc2572]

sunppaa there is no shock cooling with flood. Only your squirt bottle unevenly showering ur cutter here and there does that ;)

[@jimhimesjr]

Billy C actually you can get shock with flood coolant also. I rep for a company tool company that’s used in many of Peters videos. We don’t recommend coolant over around 300ish SFM when milling in steel (and some stainless). Reason is the carbide substrates are so hard these days that they handle wear much better than the past so we can run faster speeds. When running these high SFM’s (in low carb sometimes over 1000SFM is common), the insert edge still heats up when engaging the material then cools and shocks when not cutting. We see about 30% better life with flood off typically. Air blast is preferred, if no air blast available I’d rather see coolant than double cutting chips.

[@BrutusJones]

Video is very well made in my opinion especially despite the coolant.

[@jcims]

For jobs like this, would the customer ever consult your team to vet the pattern design for the casting or do they just drop off a pallet of parts and say 'make it so'?

[@EdgePrecision]

Not really unless you were in on machining the prototypes wit their engineering. This particular part was a piece they machined in house in their California facility. They closed down that facility and brought this product line to Texas and resource the parts. So the drawings don't reflect the tolerances necessary to make the assembly work. They just knew how to make it in their own shop. The half a thousand tolerances on the holes aren't necessary just for a shaft that hooks to hand levers but its on the drawing. In one of the previous videos in this series I show a photo of the finished assembly. In this case with the castings we had to as you say "make it so".

[@DieselCrawler86]

Nice work as always, now we just have to get you to get rid of those Fowler Micrometers :P

[@allancnc]

Awesome workpiece, would like to work with stuff like that :-)

[@byron3373]

I wonder if when probing the probe can make a mistake if it touches the coolant layer before it touches the metal and then maybe thinks it touched the metal and gives a false reading ?

[@EdgePrecision]

There is a certain amount of force it takes to deflect/ trigger the probe. This is more than enough to displace the coolant and get to the metal of the part or fixture. Depending on where your probing.

[@diegoaguilar9219]

Great work! What type of boring head is that? Also why did you run the rougher with no coolant? Were the insert a different kind of carbide than the finishing tool? Thanks again!

[@EdgePrecision]

Thanks Diego! It is a Iscar ITS boring head. But Iscar buys then from D"Andra so they are really that brand. In fact all the parts are interchangeable. I my humble opinion they make the best boring heads.

[@ray-charc3131]

a marvelious 5 axis machining in this type machine。it seems you finally got a handy and precision probe to help。

[@EdgePrecision]

Thanks Raychar c. This is actually the first time I have used the spindle probe on the Mazak. I use it all the time on the Mitsubishi horizontal mill. Using the probe on a machine that rotates the spindle angle is slightly different than a fixed spindle machine. It might be a worthy video subject for the future.

[@allancnc]

Very difficukt job done well :)

[@billdlv]

Nice job Peter. The alignment you're getting on those 0.750 holes is spot on. I'm still trying to figure out how you can get that with the casting. I see you use one location to set the other but the first one has to be referenced to something machined? I'm assuming that the machined areas edges are deburred with your nsk tool, but what about the rest of the areas of the casting? Are they shot peened or something?

[@EdgePrecision]

Thanks Bill. If you remember in the video the second time the probe ran it was probing on the faced surface to set the Y axis zero on these holes offsets. The Z offset remains fixed to the fixture. The X axis is probed at the beginning for the spot faces. I will be doing some of the deburring with my NSK grinder. Centerline has a deburring department that will do the rest. I'm sure the guys there will appreciate the work things are still kind off slow here.

[@fourtwo7612]

Excellent series Peter, very interesting and informative. So how do you account for wastage on a job like this? Does the client provide some extra castings? Or do they just provide x castings and expect x finished parts?

[@EdgePrecision]

We were able to save the part I screwed up in the video. They allowed us to put a bushing in the hole. There is no allowance for scrap what ever you scrap you pay for. They ship so many parts they expect that many back. I'm sure in their accounting they order extra quantity allowing for the possibility of lost material but we don't know or consider that.

[@somebodyelse6673]

Oi, I think even one of those parts would cost more than my car. And that'd be a fair cost for all the demanding work which went into it. You're better than good, sir :)

[@EdgePrecision]

Thanks Somebody else.

[@Videowatcher2.0]

You do interesting work

[@DanRich01]

Hallo Peter, do you use coolant even if it was cast iron?

[@EdgePrecision]

These parts are cast steel. But I would use coolant on certain tools in cast iron as well.

[@brianbures4478]

Great work very informative!!!!

[@jimsvideos7201]

I do hope they paid dearly for the combination of such tolerances and such screwy castings! Any thoughts on how they could get from art to part more efficiently?

[@EdgePrecision]

The parts after making the fixturing don't run bad. Possibly the could get more precise castings or take more care in the casting process. I don't really see a better way considering the end use of the part.

[@jimsvideos7201]

Ok, thank you for the reply and all the trouble you put into your videos!

[@michaelphillips9037]

Very interesting,Thank you.

[@Hirudin]

Are you going to be doing all that deburring by hand? There's gotta be dozens of edges on there... Phew!

[@DSCKy]

Doesn't he have a little power thing he de-burrs with?

[@EdgePrecision]

Fortunately I don't have to do all the deburring Centerline has a deburring department that will do most of it. Yes it will have to be done by hand on castings like this It is very difficult (read that as very expensive) to do it automatically.

[@johnboforsyth5970]

very nice work P!

[@soychivaspues6375]

At 9:02 what is the name of that tool?

[@EdgePrecision]

The tool is actually made to measure ID thread pitch diameters. Its a Gagemaker number PD-6000. Go to www.gagemaker.com for more information.

[@hamieh1]

i think i need 100 years to know half what you know about milling :) .

[@Panzax1]

Great work! I thought about this project while working out and I have a question: Were you informed or knew about the quality of the castings before you gave a firm price ?

[@EdgePrecision]

Thanks Panzak! No I agreed to the price before. It has caused a little difficulty but with castings you have to expect these kind of things. That's why the fixturing needs plenty of adjustability.

[@kevind1865]

What was a rough time for all the fixturing and setup to run the first piece?

[@EdgePrecision]

You know Kevin I didn't keep accurate track of the time on this. I was making videos and doing the work at the same time. I will tell you this I spent more time on making the videos(six of them) than doing the fixturing and programming for this part. In this video alone there were 72 video clips taken and over 120 cuts and edits in the timeline not to mention recording and editing sound (of witch I still have a lot to learn). I'm not complaining I enjoy doing it. So I got a little side tracked and didn't keep track of the time. If I had to guess I would say I spent about four days making the fixtures for both operations and programming for the machining. The actual cycle time was 6 parts a day on the first opp. and 8 parts a day on the second opp. That is figuring on a ten hour day.

[@kevind1865]

Thanks for the reply! That's honestly incredible. Looking at these jobs you do, I imagine several weeks of setup. The quality of the videos and editing is top notch. Editing and commentary is all very smooth, and it feels like we're looking over your shoulder as you do the job. You've got the only true CNC machine shop channel on youtube. The detail you show, and how well you explain it awesome. Thank you very much for showing us machines that most of us will never even get to see in person!

[@davidpomella6786]

I was wondering if the majority of the jobs you work on come from the oil and gas industry?

[@EdgePrecision]

Yes at the moment they are.

[@paulmace7910]

Don’t you love it when an engineer designs stuff that is so difficult to build? I bet that part could have been done as a bolted assembly/weldment for half of what those castings cost plus all of the fixturing you had to do to get the job right. You nailed it though. Perfect. Keep up the good work. Love your channel.

[@EdgePrecision]

Did you watch the first video in this series? In that video I showed a photo of the assembly this part goes on. I seems to be about as simple as it could be considering Its function. I think some of the tolerances on some of the bores are closer than necessary though.

[@paulmace7910]

Edge Precision Yes, I saw the finished tong assembly. I bet you though if they gave you 30 minutes and a sketch pad you could come up with something better. I’m an engineer and have been humbled many times by skilled machinists that can look at a drawing and instantly fix what took me and Solidworks many hours to screw up. It’s good for you because you get paid to build whatever they design. Their employer should make them spend some time with you to understand the costs of their designs.

[@RRINTHESHOP]

Beautiful job, took some time.

[@EdgePrecision]

Yes it did. I was glad to be done. Thanks Randy.

[@TheEternalHermit]

Does it being soaked in coolant make the probing less accurate?

[@EdgePrecision]

Of course if any shavings got in the way but coolant by is self no.

[@monit111]

Hi I was wondering if i can run a job we got by you? We got a part we need to make a fixture for but im a little lost when it comes to holding Thanks

[@EdgePrecision]

Yes I will look at it. This is a hard thing because a lot of the way you may do something has to do with what you have to work with.

[@monit111]

Edge Precision thanks Not sure how to send you stuff here but my email is [e-mail] The machine is a leadwell with 5axis trunnion I have done some models of how i think it will work but i have a feeling im going to need more adjustability then i currently have as the castings could drastically vary from one another Thank you for this

[@EdgePrecision]

My e-mail is [e-mail]

[@tj9382]

Yeah awesome stuff.

[@johnthayjr4237]

Good job . Old Tool Maker JT Hay Fort Worth Texas

[@EdgePrecision]

Thanks! Hey your not far from me. In the great state of Texas.

[@johnthayjr4237]

Yes sr just down the I-45 . You have yourself a fine machine there . And the best part is you no what to do with it .It blows anything I’ve ran and programmed out of the water . Keep up the good work .

[@bobanjovanovic8377]

Why you never use the Tooleye?

[@EdgePrecision]

The simple answer is it’s easer to do manually than with the tooleye. Where they mounted it is so high on the machine it’s hard to jog the machine up to it and reach the handle jog on the control.

[@bobanjovanovic8377]

Edge Precision Thank you. I have worked on a Integrex 1060V, IG 60, IG 40, Quickturn 350,... and i always use the Tooleye. So i didn‘t understand why you don‘t use it. Thanks for answering. 👍

[@billcorrigan8456]

Did you have vibration in these parts

[@EdgePrecision]

No with the fixture everything went pretty well. It was a while ago I don’t remember any such problem.

[@eTower365]

Hi, what is 1 revolution?

[@EdgePrecision]

I think the answer to you question is one complete 360 deg. turn.

[@akfarmboy49]

what that brand is that boring head?

[@EdgePrecision]

It’s a Iscar ITS boring head but they are built by Deandria.

[@akfarmboy49]

thank you I'll track it down.

[@Ujeb08]

it seems to be super accurate. one rev = .004", wow!

[@hdheuejhzbsnnaj]

Bravo.

[@sergio15637]

Excelente

[@leichen5474]

皮特 厉害！！

[@grafixbyjorj]

Whatever they saved by getting those horrible castings they must have spent twice over getting the finish work within tolerance. Did you check for any warp after taking them off the fixtures? I would expect some residual internal stress, and you milled the skin off them.

[@EdgePrecision]

As bad as the castings look the material machines quite nicely and there appears to be no or very little warp age after machining.

[@сашапашп]

Wow, nice!)

[@ahmedcengiz9784]

Maşallah

[@xmaswitguns]

Where are you located?

[@EdgePrecision]

I am located in Houston, Texas USA.

[@miles32323]

It's gotta suck working with shitty castings and stay in tolerance