Distortion From Machining and Setup

[@StefanGotteswinter]

I find these videos kinda more entertaining and interesting than pure machining videos. Making chips is all nice and fine, but getting there and getting a good part out is what makes me way more excited. Love to see these, thank you!

[@troy11144]

Agree!

[@nicocastillo500]

You have no idea how much we appreciate your years of knowledge

[@PatrickHoodDaniel]

I believe you should make more detailed videos on these because clamping and fixturing seems to be the foundation of machining. The detailed videos could be where you start before you start machining. I would definitely watch it.

[@gwharton68]

Enjoy your videos, when ever you post. Wish I was about 30 years younger so that I could benefit from your knowledge.

[@Razehell42]

That's why I came to watch, knowledge from the experienced is too good to pass up.

[@PatrickHoodDaniel]

I'm not a machinist, but I still find your explanation and this subject fascinating! Keep making videos no matter how pretty they are. You are an expert in your field and sharing this will enlighten others. I often think of the times where machininst were making everything without the aid of CNC and a lot of those skills may be forgotten. Now we have CNC, it is still important to keep this education going. I've been making videos for 16 years on KZbin, you will get a lot of hate, but don't worry about those people. It used to affect me, seriously, but I don't think twice about mean comments anymore. In most cases, I will look at the commenter's KZbin channel and see if they have made anything that helps others, or at least demonstrates what they are saying, but I have yet to see an example of this.

[@PatrickHoodDaniel]

@@EdgePrecision Absolutely! I will send you an email. Just sent a test email so you can remove your comment if you wish.

[@codypayton168]

This is what I deal with Daily. I work at a job shop & mainly operate 3 diff VTL’s + 2 Horizontals. I’ve experienced pretty much everything you’ve talked about today. Another way to hold wacky materials or thin walled parts is to use table clamps. You could either have holes drilled in your chuck or put an actual table on top of your chuck. Also, if it’s tight tolerance I always rough out the part, then release it to relieve pressure before finishing. (Lower chuck pressure before releasing/re clamping). Thank you for making this video, I really hope you make more of these!

[@carsonp.7009]

Thank you for posting all of your videos you are very good at explaining these complex topics of machining

[@Gabriel-bk1hk]

I've been working in this field for a few years now and you're video have been so helpful! Truly appreciate everything you have shown me in your video. Thank you

[@moeszyslack4676]

Anyone who gets offended or otherwise cries about the content or style of your videos is a fool, ingrate, or both. The fact that very experienced, highly talented, and extremely skilled people like you share their wisdom is a gift. I am not a machinist, though I wish I had a hobby machine shop along with my wood shop, but quite a lot of your topics and content carry over to wood work also so I still benefit. Keep posting whatever you like, however you like Peter. I know I'm not the only one who appreciates it and gets giddy seeing a new upload.

[@Jay9999]

Important and interesting topic

[@guywihn1658]

I appreciate anything you are willing to share with us. Thank you for everything I've learned from your videos..

[@NikColyerMachineWorks]

love your videos. Hey, whatever subject you talk about applies to what I do and each bit of information you give me helps me be a better machinist. Keep em' coming!

[@pgbcredneck]

videos like this are awesome! very few people will address this with this level of honesty, experience and knowledge love your videos! I usually just lurk in the background 🤣

[@9voltprojects]

Your channel with all the great videos, is a real treasure for everyone who loves metal and machine work.

[@michaelschwartz9485]

I wish I could go back to the days of working in a machine shop. You're the next best thing. Thank you for your hard, great work!

[@michaelpiotrowicz6100]

All killer, no filler. Could listen and learn all day. Thanks.

[@HDisNotSmart]

I really enjoy your explanation of what my first real engineering instructor taught me in 1995. "You cannot have stress without strain. You cannot have strain without a stress." Your description of how "simply" holding a part causes unexpected stresses (and strains) was on-point. I'm an engineer, but my scope of practice has nothing to do with machining parts, but material science and physics are unchanging across industries. Thank you for talking to us with acumen and the spirit of teaching.

[@timodell7706]

Thanks Peter. This is so important and becomes really significant as the material gets bigger and more exotic. I would love to see a video on how to approach facing heavy plates top and bottom in your horizontal mill.

[@kilosierraalpha]

Peter, this is one of the best videos you've done! It made me thing about so many things I've encountered. You've explained it perfectly and I understood you really well. Thank you!!! And please, more vids like this!!!

[@trolliran]

I’m an educated machinist and working as a workshop manager at a workshop where we make our own tools for in situ machining of primarily large two stroke marine engines. Going back to my education, I only worked with manual machines, an me coming into the workshop that we have where i work now, your videos are a fantastic source of information. I truly enjoy every single video you put out there, Peter. You are an inspiration to new machinists as well as experienced ones. I am overly thrilled, every time a video is released from you. Thani you for your time and effort 🙏🏻

[@dav1dsm1th]

Thanks for the videos. I've never watched any of your content without learning something new (usually several things per video). Never hesitate to turn on the camera and ramble. I don't come here for instagram shots. I come for your explanations. And to watch big CNC machines turning expensive stock material into expensive parts and expensive chips. Stay safe out there.

[@rupunzel6299]

Understanding part distortion due to internal stress in the raw material is basic to making parts. There is no escape from this reality of raw materials and how the internal stresses from and during the raw material manufacturing process happens. The amount and kind of internal stresses for any given piece of raw material to be worked on by a machine tool is often unpredictable and will only reveal once the material removal process happens. This is a complex topic, yet absolutely essential to making parts using the subtractive machine tool process. It would be excellent to do a series of videos on this topic as it is so very important to properly understanding what happens as parts are being made. Distortion due to work holding is another given. This is why work holding fixtures can be extremely complex and at times far more complex than the part to be made. There can be very complex design work related to fixtures and how work holding fixtures impact the part to be made. Again, an excellent topic for video content. Other process factors that impact the finished part, heat treatments, aging post process, environmental conditions, storage conditions, corrosion, surface finishing. Another worthy video topic would be how surface finish impacts measurements and tolerances. There are many machinist on KZbin, Pete at Edge Precision is one of the best for sharing useful information and experience with little to no KZbin content stuffing, simply excellent in many ways.

[@Tezza120]

My nephew runs a waterjet cutter. He was cutting slots in RHS and saw it distort. He thought it was the heat of the cut but I thought it was the stress from being folded and seam welded being relieved - maybe both? I suppose the waterjet is not far off a sandblaster distortion. Using a slitting saw on aluminium stock made me aware of how much material can move. When it split the bore the block closed up and shattered the slitting saw. I think the people that follow and watch your videos do so because of the detail you put into them and it is appreciated. I clicked on this as soon as I saw it and not disappointed.

[@innominatum9906]

You are so far above my level of expertise and youre making parts that I will most likely never get to machine. I simply dont have the skills or dare to even try 😅 The simplest thing I tell our apprentices in relation to this topic, is that if you clamp down a piece of raw material in a vice - dont start hammering on it like youre insane just to get it to touch the parallels. Ive seen people do this a lot with aluminum and the result is that the part will warp back once you unclamp it. You know what - Ill have them all watch this video. Thank you, Peter 🤗

[@davidmexicotte9862]

Love yr videos. I always learn something.

[@ahfreebird]

Thank you for this, Peter. This type of knowledge is usually impossible to get without scrapping parts. When these things start making the difference between a good part and scrap, the line between engineer and machinist becomes very thin. I would love to see as much of this as you would like to show.

[@dennyskerb4992]

Started watching your channel before you went gray. Luv everything you post.

[@billlee5307]

I thank you for all that you share with us. I always valve the time spent watching your videos. The distortion issue is a very important area when doing precision work, please continue.

[@travisr1718]

Yes I would like more videos like this. It is very educational,I learnd a lot from you. I am from Serbia I got my own cnc shop but I’m nowhere near as knowledge as you. This is the best channel I follow. As many videos as possible please!! Thanks for passing on the knowledge.

[@marximus508]

The only machinist I watch. So many videos of guys ramming a vendor supplied tool through a chunk of soft material for views. It's nice to have some confirmation that I'm not the only one dealing with material stress and work holding distortion trying to hold a final tolerance possibly four or six setups down the road. I personally would like to see you show this in a video. These are the tips and tricks that can take years of experience to learn. Thanks for sharing.

[@slavikmarinovski2249]

This is gold. having such an expert discuss these topics is precious, and usually will not be shared with such detail in a jobshop by senior machinists. I particularly remember the titanium plate you machined with the custom toe clamps, very relevant to this topic. please do make more videos! been following you for about 7 years now! thank you for sharing your knowledge!

[@timwood3455]

I'd like to see more. Awesome as always thank you

[@paulhammond7489]

I come here to listen to you sharing your experiences by watching how you plan and execute your activities, much if not all of your planning and execution is based on your personal experiences, most of those were good, so you repeat those processes. Others were less than optimal or end up scrapping material (like the examples you shared). We are all capable of learning from our mistakes, that's a part of how we grow and gain experience. Or if we're smart, we can learn from the experience / mistakes of others who are kind enough to share their experiences, and honest enough to share their mistakes. Please keep making this stuff, I know I'm not alone in enjoying every video you put out there...

[@jasonhull5712]

All great information. I enjoyed this little chat. Thanks for taking the time to share this experience.

[@hermit.shed.]

I really appreciate that you take the time to share your experience. I would love more of this type of video

[@fredflintstone8048]

I'm a hobby machinist making parts and tools mostly for myself, friends, neighbors, family. I want to be able to do the best job I can with good precision. Some of the things you mentioned regarding using a Kurt vice in the milling machines I've been practicing (centering a part, or putting in a part to counter on the other end the same size. I don't make large parts like you do so I'm fortunate in that regard with being able to hold to tighter tolerances. I watch a lot of Machinists on KZbin some professionals, some hobbyists. I'm glad I found your channel because I consider your videos among the best most educational videos in the field. Please keep doing what you're doing as long as you feel motivated to do so. I always learn something from your videos even if it's something well beyond my level of work in the field. I'm always about wanting to learn principals. Thank you again.

[@PeregrineBF]

I'm in the same boat, and I agree. Even if I'll never use it, it's *interesting*.

[@jimforsyth2.]

I enjoy any video you make . For me the more the better . I even just enjoy watching a complex part being made

[@riderthewake02]

These are some of the most important videos for new people to machining. I have 4 years in the field and i understand alot but there's still soo much i dont even think about when i program or even run a part. Im always thinking of part distortion,just finished an 1/8 304 shim cut down to .051 +/-. 002 1.5 in long almost 5/8 wide with 5 holes and 2 countersink. The part was within dimensions and a flatness wasn't called out but had 5thou of bow. Had to control bend them all. Please keep posting videos like this. I truly help new guys atleast keep in consideration some of the problems thst arise when quoting/programming/running

[@parnellpollioni]

You’re a great resource for machinist it’s always fantastic to watch someone do something and learn from it. If anyone complains they should shut up.

[@davidcashin9194]

Peter I watch your videos for your experience and skill in machining not so much for video skills not that they are bad. The knowledge that you transfer is priceless I have learned so many things even that I am not into CNC but a huge amount transfers directly to manual machining which is where I sit. I am very interested in material distortion and how to counter it so keep them coming.

[@XxLeCaptainxX]

Ive been enjoying your recent "purely informational" videos, such as this one and the one covering typical trig problems for a machinist. I just began an apprenticeship 2 months ago (and was 'operating' for 3 months before I began that) - a lot of this information is like gold to me!

[@davestrong6472]

Hi Peter..great video, I’m pretty new at this and my company supplies fixtures plates that are 40” dia with flatness of -+002 in hot rolled….also 6061 rings same size with dia of +-.005….. I can’t tell what a challenge this has been. We had a 38” inside dia on a .5 plate out of round by .023 after milling out of the center…machined a second one and it was perfect! Keep up the video they really help. Dave

[@rextransformation7418]

Yessir, whenever you can and may, please do more videos of this nature. Highly educational!

[@DudleyToolwright]

I always love your videos. Thanks for your significant contribution to the available knowledge base.

[@lachlantr5589]

I’m a self taught CNC machinist in Australia with no real mentor in my workshop. I’m desperate to learn more but often find that books and information online is too general. What makes someone a professional in their craft is the small details, particularly in machining. For me this attention to detail and teaching is extremely beneficial. Although English speaking machinists are a dying breed. So it may only be beneficial for less than 1% of KZbin viewers. I love your videos and wish I had time to watch more. I watch your videos at x2 speed.

[@warrenjones744]

I find nearly everything you post interesting and a lot of time helpful. Since I do not do any CNC machine work the programing stuff is over my head and no use to me personally but I learn stuff regardless. However realize I am very much in the minority here and don't mind it at all. You keep doing as you do Peter

[@hullygully-3599]

Yes Peter, setups and a practical demo would be very interesting to me. Thanks for sharing your great experience.

[@levitated-pit]

Peter, you are the best machinist ive ever seen! Im a 63yr old Brit, apprentice trained/engineer/manual machinist fitter/service dude, and the poor machining ive seen in my 42 yrs of work due to basic ignorance/lethargy is shocking! the apprentice system these days does not train the guys,

[@johannglaser]

These not-so-obvious topics are really interesting! I especially like your drawings where you exaggerate how parts bend, and when you draw the arrows how forces act.

[@andrewmillyard3162]

Please Peter. I'd love more content on this side of machining. I am only young but always pay attention to your wisdom.

[@Autosolutions-p6h]

Dear sir Every time i see a new video for you i cant skip it. I wish you all the best

[@BigglesFlysAgain]

Yep, I'm interested in this topic. Look forward to more videos.

[@waynepegram3262]

Thanks for taking time to make this video, looking forward to more!

[@ryanbaker6059]

We regularly grind a hardened steel cylindrical part between centres on a Studer universal grinding machine. It is 6.5mm diameter and has a counter bore in one end, with a wall thickness of around 0.75mm. The diameter at the counterbore end has a 0.001mm roundness requirement. We could not use a standard driver as even the lightest finger tightness on the m3 screw would cause distortion. We got around it by initially 3D printing some drivers with a light interference fit on the OD and another time by friction driving from the counterbore with a mandrel with a couple of small o rings. Distortion is an ass kicker! Great video as usual.

[@Partcision]

Please make more of these videos if you can, I really love the practical information and the stories of your previous jobs!

[@spikeypineapple552]

Love your videos peter, worth 1000s of $. I just milled a 6mm keyway into a 20mm dia piece of 303, 2m long. I told them it wouldn't work, but they said they'd straighten it themselves. The ends must have jumped 20mm when I opened the vice. I even asked them if I could put a key in the other side to balance it out, but that wouldn't work for them.

[@Neils995]

Thank you for sharing your knowledge. I'm 5 years into the trade and super enjoy the constant learning.

[@jobkneppers]

Peter, really interesting stuff. I had my fair share of banana parts in the past too. Especially cold rolled but also hot rolled stainless 316 challenged me to get out right parts. Roughing, releasing, finishing is one of most valid strategies for me cutting accurate parts. Thank you Peter! Good to see you in action again! Best! Job Suggestion?; thin long parts in the lathe with tight tolerances.

[@bcbloc02]

I love these kinds of videos. I oftentimes wonder if people ever check the parts they make after they take them off the machine. Also if the tolerance is tight temperature is a Huge deal but it seems rarely discussed.

[@coorexz]

Honestly appreciate someone talking about distortion of the workpieces, it's not something you see around KZbin in general. There's just, "oh we scrapped that part, we just make a new one.." Like an example from work, aerospace parts, thin walls (1.50 mm / 3.00 mm thick etc.) and it's a large product (largest diameter is in the ballpark of 1300-1400 mm, while the smallest is about 700 mm) And the distortion is insane on those kind of parts. We machine a couple of features +0.20 to +0.30 mm from the nominal measurement all because once everything is machined (it's quite the long operation, around 70 hours) those features have grown into/calmed down into close to being nominal at that point.

[@theessexhunter1305]

All of your videos are interesting Peter.

[@donmathias1705]

I started my apprenticeship in 1975. We were taught about stress relieving material. Often we had to release chuck pressure over night on larger turning jobs. Complete roughing all over was normal practice and centre's often had to be recut to achieve straightness again. Some steels are more like green wood than most people ever imagine. Bright cold rolled square and flat bar is amongst the worst.

[@НиколайРянзин]

Very usefull video I mainly machine small parts like 2-30 mm size and havn't noticed these distortions. Heard only from u. I'm glad u made an explanation video. I'll repeat another guy in comments: Such type of videos I do like the most

[@joebauer3874]

We absolutely want some demonstration, thank you awesome instruction

[@ryebis]

Packed with practical experience and wisdom. Machinists should watch this over and over again until they understand that everything distorts, expands and contracts - all of that needs to be factored into the machining process and setup.

[@paulmace7910]

I for one would like to hear your experiences with distortions, workholding, etc. Keep going. It’s all interesting.

[@strykerjones8842]

Interesting subject, hearing from a very experienced machinist is pure gold for me. I’ve experienced some of these issues and clearly didn’t understand what was causing them. I would particularly like to see demonstrations of what you described.

[@deemybutt]

Fantastic topic, please continue to share your knowledge on topic, wood love to hear more.

[@drummerhammar]

Ignore the haters Peter, love your skills and channel! greetings from The Netherlands.

[@Petertje94]

I like all your videos. I'm working in the plastic cnc machining industrie on a b-axis millturn. Distortion in my last name. Still every day try to balance between clamping pressure and distortion in parts. A lot of the time on my machine the clamping pressure doesn't even read on the pressure gauge and still distort my parts out of tolerance. And on moment like that the centrifugal force from the jaws comes around the corner. The time the chuck needs to close the jaws takes like 30sec.

[@SerenityMae11]

I would definitely like for you to demonstrate these scenarios, this issue has bit me more times than i want to admit

[@Geebuv]

100% would be interesting to see subsequent videos on this subject.

[@jamesreed6121]

I'm all for more video on this subject. Don't forget to include the fix after the "failure". This subject just might be one that we all should see and learn from. KOKO!

[@Wmbhill]

I’m interested in this topic. Your vid’s are great, thank you.

[@curroz7689]

Yes more please) My personal preference, the more obscure information, the better) As you said, everybody can throw a piece of material in a machine, not everyone can take a part out|)

[@petark1933]

Super video as always ! :) I would really appreciate more videos on this topic.

[@wacomtexas]

Inciteful as usual. Only experience teaches you never have enough experience. I'm machining hardwoods atm (massive internal stresses, massively sloppy tolerances lol). I'm learning that ideally I should sneak-up on the finished dimensions over several weeks, add drying cycles, manage the repeatability of work-holding setups and work-offsets more carefully, and lower my expectations. I hope to graduate to metal one day..

[@93Martin]

I think you have an immense amount of experience on the subject, and understand it in a way that lets you explain it well. That said, this is kinda all over the place. I don't thing there's a WHOLE lot missing to make this a comprehensive source of information for 95% of us. I think if you were to take the contents of this video, pull the major talking points and organize them as you would a written essay, then shoot this again following it as a guide(maybe even write a script?), you could create a proper video essay. Explain the problem, the theory, the nuances, the solutions, and then give some general guidelines for others to follow. What I'm saying is that, I don't think you need to make a series of videos. I think with a little thought put into how you organize and present the information in this video, you could do something pretty special in a single 30 minute video. If you wanted to, of course. Always interesting to see and hear what you've got going on, Peter. Looking forward to the next installment of the new spindle build!

[@algerc.5492]

Outstanding video and topic Peter. Watched a lot of YT machining vids over the years, never seen one go into depth on distortions like this. Felt marker might help with illustration sketches, keep it up.

[@K_Shea]

This is absolutly interesting!

[@sambrose1]

I always learn something from your videos. Thank you for sharing your knowledge.

[@philbert006]

I think it's safe to say you are qualified as an expert, and have a whole career of experience to support that. Everything you do is interesting and there are multiple opportunities to learn for anyone.

[@mikemarriam]

I once worked in an optics lab. It had a laser interferometer set up on a giant granite table floating on air bearings. It was about 3 feet thick. I put my hand on the table for about 10 seconds, and you could see the expansion in it in the laser pattern. As Robrenz says, everything is rubber.

[@braxtonec]

Always glad to learn from you sir. Thank you for sharing your experience and love of machining.

[@d1nks83]

Thanks Peter. Great video.

[@oohookoo]

Yes Peter please keep it coming .. and thank you.

[@TrPrecisionMachining]

very good video peter,,thanks for your time

[@gonzalovandamme5846]

Great content, keep uploading! Cheers from Argentina!

[@TheJaws399]

These kinds of videos are excellent.

[@urbancarvers8974]

This kind of detail and experience is so helpful.

[@joshmonroe2562]

Keep doing you Peter!! Love your videos

[@cammccauley]

Nah you’re videos on stuff like this and math are excellent

[@processagent5095]

Great video. I've seen where you've touched on this in a previous video. I was aware of temperature effects, but had no knowledge about the stress relief and input in materials during machining operations. I love the root cause analysis of what might otherwise be mysterious dimensional outcomes. A video on inserts would be cool as well. Which types for which material and how they might affect the material. It kind of feels like a shot in the dark when trying to pick the correct insert with a million choices out there.

[@paulshouse524]

Thanks again for sharing your experience and erudition.

[@HDisNotSmart]

Agreed. A confident professional is not afraid to share knowledge. A truly confident person loves to share knowledge; we know we increase, rather than decrease, our personal value by helping others learn.

[@productionmiel1447]

Yes Make video please Thanks for your knowledge friends

[@DonDyarprecision]

The best plan for close tolerances is to avoid vises altogether, but people are addicted to vises. Even a 6" Kurt will shift a part toward the fixed jaw over.001" with moderate tightening. Often that is not noticed and does not matter. The Jig Boring machines and CNC jig centers mostly use clamps. The subplate systems with two piece subplate vises is the best of both worlds where a combination of clamps with the vises can be used. The craziest thing I have seen on YT is a miniature sub plate made to be held in a vise. One problem I had was holding castings with minimum distortion for repairs. Another problem some materials are damaged stressing them is vices or chucks, the damage shows up in X-ray. Everyone has a table clamp kit but avoid using because it will disturb the vise. Now that is funny!

[@caploader111]

I would be interested in the fixtures you've made to avoid distorting parts. Also if you could explain how to machine soft jaws or fixtures taking into account how the work holding will distort and deflect as it is tightened. Also interested in order of operation for lathe parts. Thank you I think this is the most important subject to learn for machinist

[@d1nks83]

Great video Peter. Really interesting topic, hope to learn more from you.

[@joshualange3645]

Thanks!

[@EdgePrecision]

Thank you!!

[@danielwerger5641]

Peter, I would like to see a number of videos on this subject, especially with examples if possible. Cheers from Canada...!