Endmill chatter at 20,000 Frames-per-Second

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What does it look like when an endmill starts chattering? How about at 20,000 frames-per-second? I'm in the shop playing with a high speed camera, filming Online Carbide 1/4" 4FL variable helix end mill on mild steel with my AvidCNC Benchtop Pro.
Really amazing footage, pretty impressive to see the workpiece, vice and spindle/endmill moving around so much!
0:00 Intro
0:56 Test setup
1:17 Stable cut at 19000 FPS
2:06 Chattering cut
3:52 Motion detection (frame differencing)
4:22 Deflection analysis
5:03 Head-on shot
5:29 More chatter
6:03 Aggressive cutting
6:34 Breaking endmills
8:41 Four minutes of 20,000 FPS Footage :)

[@WinstonMakes]

YES! It's so rare to see good footage this slow of machining, and such a fascinating analysis.

[@BreakingTaps]

Thanks Winston, really appreciate it!

[@dimasroy5040]

@@BreakingTaps 200 IPM.......😂😂😂,MILD STEEL When i Use Max 100 IPM, but thats Aluminum Materials ,KOR 5 Thanks for the Video

[@BreakingTaps]

🙂 Figured if the goal was to make it chatter.... might as well really give it the juice and chatter :) To be fair, the WOC is still pretty light which makes the IPM look a little less ridiculous... still very high though :)

[@dimasroy5040]

@@BreakingTaps Looks the Titans CNC Academy, Thats 1600 IPM KOR 5 1/2 Endmill Aluminum Material Not Break

[@Zizie_sc]

This fast, you mean 😁

[@StuffMadeHere]

Awesome. I've always wondered what chatter looks like. It would be cool to see a macro shot of any of the shop tools that move really fast like an air nibbler or something. I also wondered what it looks like when you accidentally run a lathe spindle in reverse (or mill). Not that I would have ever done anything like that, I'm purely asking for a friend that removed a substantial amount of material wondering why the knobs were so hard to turn...

[@BreakingTaps]

Yay thanks for stopping by! So funnily enough, I think my first milling video on YT I was running the endmill in reverse and really struggling to turn the handles, not understanding what was happening. Doh :) I just might have to investigate that, yunno, for science.

[@HuskyMachining]

@@BreakingTaps I'm pretty much convinced that all the channels I like also like watching the same channels I like... P.S. I feel like this totally changes my perspective on chatter..... had no clue a rigid looking set up like that would oscillate so much! I mean I could see the endmill and or tool holder and entire head of the machine deflecting that much during chatter but had no idea the work and entire machine table and vise would... crazy

[@combin8or]

Heck yeah! BTW, Steve Mould did an interesting video on video motion enhancement algorithms that modify the contrast of videos to accentuate motion using lower speed cameras. You guys could experiment with that for some good high speed footage.

[@portlandscott]

@@BreakingTaps I'm so relieved to know I'm not the only one. haha

[@benwinter2420]

Why helicopter's self destruct

[@pragmax]

I think it's been said lots of other places (AvE comes to mind): "everything is a spring." It didn't make any sense to me until I thought through what makes a spring-pass even possible. This video really drives the point home.

[@bogdan_n]

Robrenz: "You must think like everything is made of rubber". And he was lapping a granite surface plate.

[@gufbrindleback]

Not only a spring, but a spring-a-ma-thing

[@zuthalsoraniz6764]

The three fundamental truths of engineering: Everything is a spring, everything leaks, and there is no such thing as a sharp inside corner

[@technikchaot]

@@zuthalsoraniz6764 sharp corner not only sharp inside corner. At the sharp side of every knive it is just a radius, they may only be measured in nanometers or so but they are there.

[@akren2482]

Such an underrated channel. Pushing home-manufacturing to a new level with every video. Your editing has improved massively as well over time. Best of luck on your KZbin journey

[@BreakingTaps]

[@BreakingTaps]

Also appreciate the note about editing... it's so hard! I'm humbled everytime I watch a really good video with editing. Slowly getting better, trying to spend more time on it since it makes such a big difference imo.

[@mailleweaver]

I really like your "reading the tea leaves" metaphor. It very well encapsulates what it feels like to look at something that most people would see as nothing but noise and try to find patterns and meaning in it. Troubleshooting seems to be intuition as much as logic sometimes when our brains manage to find patterns learned from lots of experience while our conscious minds can't quite grasp them.

[@olmanoutlaw]

33 year machining vet. Loved this. Keep up the great videos.

[@Hawk013]

As an actual CNC machinst, I can tell you that even the biggest and heaviest machines move around like this. Not as much, and not as fast, but your regular Haas mill is a limp noodle compared to dedicated heavy iron for HSM production machining. "Everything is a spring" is indeed correct, and everything that has clearance, has slop to move around. The second thing I want to mention is that your best stepover for "less than ridged enough" tooling is usually 33% and 66%, where the cutting forces want to pull the cutter parallel with the direction of feed, instead of into or away from the work. This tends to give you a more perpendicular cut, because the tool isn't flexing to one side, and can give you a more stable cut because the direction of the cutting forces is countered by the feeding forces of the machine and should have less backlash to move around in.

[@NoDude]

This was amazing, I thought I'll be fast forwarding through this but I was glued to my monitor the entire time!

[@michaelcerkez3895]

Still watching this video 3 years later. There's a wealth of knowledge to gain from it, both about your machine and the effects it has on machines in general. Once again thank you.

[@frankbonsignore.RochesterNY]

One of the best things that has happened to me today is discovering this channel. I sat there with my mouth open at being able to see and understand chatter. Thank you!!

[@fasteddie4107]

This is one of the most unique and informative videos I have ever seen on machining. Clearly, the average machinist does not have the equipment nor ability to do this depth of analysis. Thank you very much for sharing it.

[@rogerroberts1310]

Finally have an answer for the problems I had during the 25 years I worked as a Tool Maker/Machinist. I was too busy dodging chips to see the cutter "dance" about. I hope this video will be seen by all the younger people coming into the trade. THANK YOU!

[@JakeBiddlecome]

Wow, I always cringe when I hear chatter and in my head I'm just imagining that super hardened metal against metal, but actually seeing what it's doing is crazy. Really great analysis, too. Haven't seen this channel before but I'm glad I stumbled across it.

[@80lab38]

I've seen quite a bit of machine porn but this shit is just gorgeous! And also educational. Very well done! Keep it coming! ...and nice choice of music, too!

[@virt1one]

"what NOT to do with an endmill", great high-speed footage! I assumed chatter was just bouncing *off* the part, creating just a lateral vibration - it never occurred to me that it would be a circular oscillation. But considering the bit is spinning, I suppose I should have expected that. Thanks for the vid!

[@tylerhensley2312]

That was fantastic!!!! Thank you! I went into this thinking 'oh cool a slow mo video of an endmill' and ended with a whole new perspective on what the cutting edge requires.

[@latentdiscourse4357]

That is amazing. I’ve made my fair share of mistakes and have seen the movement of the machine like that at the end. It’s pretty cool seeing it in slo mo

[@christianblack2916]

I ve been running a cnc router tor 11 years and this video made me feel like a virgin, touched for the very first time

[@tkzsfen]

This is the stuff of universities and institutes. Very educational! I think that the factor , which additionally plays a big role, but is hard to estimate for yourself is the effect of temperature. It isn't constant throughout, but we all know how it could worsen a metals property. Great video!

[@MAACotton]

This is just some crazy video analysis. KZbin's algorithm sent me your way somehow and I am so glad they did. I've always been looking for someone who knew machining AND All this slow mo videography stuff. The way you can measure certain things like how much the spindle moved is extremely helpful. Subbed.

[@bobbyshaftoe45]

Absolutely fantastic work. Your play by play is super useful. Regarding cut depth... insight + (slowmo) sight is a 10 outta 10! More of this kind of skoolin for desktop amateurs PLEASE!

[@xxxxxx-rm2pn]

Breaking that tool was so worth it for the footage. Absolutely amazing. Thank you

[@operator8014]

Wow, this is great information! Watching the setup move into a resonant frequency range before blowing apart makes a lot of things suddenly make more sense.

[@mattfleming86]

WOW. I think you are the first person I have subscribed to after only 1 video. Fantastic footage and crazy from a physics/material perspective.

[@rosswagner3021]

This is AWESOME! It’s so cool to be able to see what you hear! Thank you for investing in this.

[@kerrykrishna]

This was so inCREDIBLY cool to watch... Subscribed!

[@butterbagelgaming3654]

This is honestly intriguing, I always thought the contrary to what you said in this video about chatter. I always figured that less heavy of a cut would cause less chatter and a lighter cut would cause less chatter. Awesome video.

[@ray-charc3131]

Heavy cut creates a greater cutting force which bends the endmill tool and ultimately breaks it. Light cut won't but allows it to just oscillate that leaves lines on surface.

[@4dirt2racer0]

awesome video man!! this was so cool i love high speed footage of machining and i was also curious about chatter ur conclusions really interesting i cant say i woulda guessed it was because of too small of a cut...

[@CaptBeanerzzz]

I would LOVE to see this done with all different types of tool holders to see the difference between them. Do ER collet, hydraulic holder, slim fit, shrink fit, rego fit, etc.

[@Sam_Handwitch]

Cool to see whats happening when my co-workers are breaking endmills every week.

[@SonoranAstro]

Day*

[@huvrr1]

As a cutting tool maker, this video is fantastic. I love it. You're talking about things that are so fast we'd never see it without a camera like this and therefore remains a "black magic"/"voodoo" area for most machinists. As a first time viewer, I'm off to see what else your channel has!

[@HSMAdvisor]

Great video! I just have to correct you. It is not really the endmill deflection, but the whole gantry vibrating and moving all over the place.

[@BreakingTaps]

Very good point, I should have been a bit more precise in my wording! Actually want to do a followup showing the table and gantry moving around, maybe with tracking points or something. Still trying to figure out the best way to quantify it.

[@Ryan_Manthe]

I was thinking a solid carbide endmill deflecting .022” would break lol

[@JF32304]

Bingo. It's just not rigid enough.

[@igorozegovic9977]

Wow!! Did not expect such a good video!! Great job man!! Loved it

[@justinmoritz6543]

This! This is golden content. When you had asked earlier what we wanted to see, this is exactly it. Great content!

[@BreakingTaps]

Great to hear, thanks! Appreciate the feedback here and in those polls, definitely helps me :)

[@michaelcerkez3895]

BT, very nice. I've been running machines since the1970's and this is the first time I've ever seen this. Thanks for the video and yes I will show this around.

[@AndyN1357]

This is fascinating stuff, thank you for your efforts.

[@chongsiu7893]

Thanks for this great video. It would be cool to see a slow-mo comparison between conventional milling and climb milling, and to see how the differences in surface finish are formed.

[@glenj.taylor2938]

I was thinking the same thing. At this FPS and with the measuring tools in the editing it would be awesome to see.

[@arsanzic2161]

I LOVE this channel! You're gonna go places and thank you!

[@bjorn5209]

Instantly subbed. Good shit my dude. I'm showing this to everyone at work tomorrow

[@KoenigseggMan24]

Great footage! Really gives a greater understanding of what is really going on

[@I.no.ah.guy57]

Dude that's so awesome all the slo-mo footage was gold 😭

[@LukeAquilina]

I just discovered your channel, but I must say I'm highly impressed by your work.

[@ego73]

New subscriber. My name's Ian. Great to take a good hard focused look at tool behaviour in duress. It's a nicely curated painstakingly assembled presentation of informative photography. When we break tools, we gain more experiential information and this video serves to catalogue and label some of that otherwise experientially gained information. Useful! It'll keep me from going through so many end mills...that is if I ever get the bloody thing built. You've got some interesting titles...

[@airgliderz]

Awesome video, seeing chatter explains a lot. Seen it on large machines also not using right tool for the job. Amazing how much the mill, spindle and vice move.

[@gregmead007]

Dude, you should have a LOT more subscribers! I’d subscribe more than once if I could. I’ve been CNCing for a while and this video showed me why I’ve seen some of the issues I have in the past that were a mystery before! Keep up the amazing content! If you build it, they will come. 😆

[@wayneshephard]

Great quality video and information, subscribed

[@reubenhenderson5368]

I loved seeing the endmill shatter and the chattering in slow motion. Very nice.

[@bigmotter001]

Fantastic analysis! A picture is worth a thousand end mills " well maybe not" but at least a couple. I have wanted to see chatter for a long time to heighten my awareness of the circumstances that create it. All kidding aside thanks a million for posting this video and take care!

[@cncmachinistcnc3276]

Were have this channel been🤯 this is gold😳😳😳😃

[@alexanderjamesINC]

This is beyond educational. I hope you realize the service you have done here. It makes the science behind machining visible. Thank you.

[@alexanderjamesINC]

I also wanted to ask, when your spindle bogged down and the VFD eventually shut off, if you had a more powerful spindle (5kw), that cut would of then been possible, no?

[@BreakingTaps]

Thanks! I think a more powerful spindle might have done the trick, although I suspect there might be a configuration issue with my VFD too. Someone else in the comments ran the numbers and the spindle should have been pulling under the 2.2kW limit... so there might be a threshold on my VFD that isn't configured correctly, or maybe I tripped the thermal cutout. Not sure :)

[@rideordie295]

All about finding the happy medium and making sure your fixture doesn’t move. And good quality tool. I used to be a CNC operator. I could tell when a tool was about to go from the sound, any burn marks the tool made, and the quality of the cut. It is fascinating to see it in slow motion.

[@1495978707]

The production value is just so great

[@aSpyIntheHaus]

That is spectacular! Great and very informative vid mate

[@EricDalgetty]

Really great video! I'm always babying my lathe because I thought I was helping the machine, but from this it looks like I'm actually making the surface finish worse! Time to try some new feeds and speeds.

[@BreakingTaps]

Thanks! And yeah, totally agree... I'm thinking back to prior projects and wondering if things would have gone smoother had I just given it a bit more juice, instead of dialing it back 🤔

[@gregmead007]

Same here! Seeing this I feel like I was fighting fire with gasoline in retrospect. 😬😂

[@3Hose]

When I was machining I didn't have that problem. I was always pushing the tool/machine to its limit. It's a lot easier to do that when it's someone else's equipment 😁

[@bethfaulkner4907]

When machining long shafts it’s often common in industry to increase the roughing feed rate to the point where it almost looks like you’re screw cutting the shaft to reduce chatter 😊. Higher engagement usually stops the job rattling around and makes the work quicker!

[@harmlesscreationsofthegree1248]

Cool vid man, subbed, look forward to more

[@danielabbey7726]

Wow, very eye-opening video! Nice to see what's really going on with chatter.

[@danielrodrigobarreto]

Really amazing video! Learned something today

[@bjoern.molinari]

Really cool footage! Cutting process vibrations is a really interesting topic. Solving a chatter problem is not easy to solve without good knowledge of the dynamic stiffness and damping (of the tool side and the fixture side).

[@Andrey222ful]

Great video analysis, It does clearly show that the router is not rigid enough for those cutting parameters, and the climb cutting is making it even worse. It was cool to see how whole setup is moving during the cut. I was amazed to see that end mill didn't snap right away on such machine/setup shifts.

[@TheMadMagician87]

Fascinating stuff, thanks!

[@ircsmith]

great images. Had a Fadal at my last job that no one knew how to use so I learned how so I am familiar with feed and depth parameters. I also did some high speed vid of a fluids so I know how hard it is to get good footage. What you did is really good and informative to watch. The oscillation of the material took my by surprise.

[@mechmotion]

This is great footage. I’m a professional CNC machinist, and I train the new guys. One of the demonstrations I do is take a 1/2” steel rod and a 1/2” carbide end mill and hit them both with a 2 lb sledge hammer while held vertically in a vise. The steel bends and bends on each hit and the carbide snaps right off, usually on the first hit. It is always shocking to see. It’s interesting to me that .050” or more step over was too much, that’s where we get good finish passes on our machines. Fun note, more tool length engaged usually is “free” when considering horsepower and will normally result in a better finish and longer tool life.

[@xpndblhero5170]

I could watch that for a long time.... That's oddly satisfying. LoL

[@taogotos]

Just found. Subscribed immediately. Wonderful job.

[@dmyers9230]

This stuff is more complex than I would have imagined. I always thought that less is more on a finishing pass, but clearly this is not true and there is a scientific optimal setting. Thank goodness wood is forgiving. But now I have more knowledge when I try can cut aluminum (6061) on my StepCraft CNC router. Thank you for sharing this knowledge! I would love to see the aluminum welding video as this is the exact issue I had last time I tried to mill some aluminum. It was a 4 flute endmill that previously worked well and I figured it was just dull. Now I think it was simple 2 many flutes, the wrong settings, chips not clearing fast enough, and the endmill was probably dull. Thanks

[@briceviolette8415]

The fancy editing was awesome

[@Ataraxia_Atom]

Wow simply amazing content. You have a new subscriber haha

[@phillipmitchell2254]

This is extremely relevant information, thanks for doing the research!

[@trophbrwntrouthunter]

So cool to see!

[@zedex1226]

In a "proper" cnc machine all you do is shift the failure point around to different places. Care and maintenance of tool holders and spindle taper. Pull studs. Draw bar springs. Collets or whatever tool holding. Tool balance/runout. Thrust bearing maintenance. Work holding. That's all right off the top of my head. Good cut parameters are exactly as important. The ragged edge of max productivity is every bit as razor thin, the bar is just set a tiny bit higher.

[@dbturbonub2536]

Great footage!!! Also, we usually say machine "rigidity" instead of "stiffness".

[@ilikaplayhopscotch]

I clicked on this because Breaking Taps is such a good name for a machinist channel. Stayed for the whole video.

[@Bigman74066]

Chatter has always been kind of a mystery to me. Great video!

[@markosabic2250]

Here's a little bit of dopamine, nice work man ! New subscriber here.

[@mathuetax]

NEAT footage! Rather wild how much deflection is going on.

[@AsmodeusMictian]

Thanks for the vid!

[@Ccccccccccsssssssssss]

Woah, this is so cool! I love KZbin! Thanks for posting!

[@OriginalJetForMe]

This was great! I am very grateful to YT's algorithm today. If you're in the LA area I'd love to see what my 4x9' AvidCNC and Tormach look like at high speed. Great video!

[@joshualange3645]

Good work. Good content. Good gracious i just subscribed!

[@TheRainHarvester]

This video circles around the point. Great job.

[@ColinTimmins]

That was fascinating to watch, very cool. =]

[@Barabbas7798]

That's awesome man.

[@MidgetBarmaid]

Pretty much everyone here is a machinist nerd like me. Awesome video!

[@AccidentalScience]

Really interesting. Thanks for posting.

[@christianlewis7055]

Fantastic video man! I love it.

[@knutroald5332]

Good nerdy stuff👌🏼😀

[@5x535]

Great video! I love the tune! Subbed.

[@FloweringElbow]

Hey, awesome footage, really interesting to see. Thanks for sharing. :)

[@ammerudgrenda]

Great job! 👍

[@johnantliff]

I really appreciate the trouble you have gone to in this video. I operate a small turret mill which has been fitted out with ball screws and stepper motors and I have been using it to cut aluminium with mixed success. Using HSS 4 mm or 6mm 3 and 4 flute cutters I have had problems with chips sticking to the cutters. Whilst using compressed air to move the chips out of the toolpath I have had some end mill failures when aluminium has become welded to one of the flutes. This causes deflection and drag sometimes enough to break the HSS endmill. It would be interesting to see in slow motion how many times an edge picks up material and how many times it is shed before causing breakage. I suspect that it happens more than I can see at normal speed.

[@WobbleMatic]

Great footage and explanation.

[@brianjones866]

Sweet tool dig my old shop would have been excited 😅😂

[@Jonnydeerhunter]

Fascinating!

[@FilterYT]

Awesome, thanks!

[@ninjanoj666]

Great footage! You could try some video amplification techniques to see some of the oscillations even clearer

[@speeddemon1774]

Stellar video. The editing and production quality on this is incredible. This is honestly one of my favorite machining channels now. I do wonder what that high speed setup is, more details in a future video?

[@BreakingTaps]

[@darranedmundson1505]

Kudos on making a video that is both visually stunning and laced with technical detail. What's the music at the end?

[@tszabon]

awsome video, thank you.

[@JoshStLouis314]

Very interesting, you've got a new subscriber.

[@power-max]

I just getting started in CNC with my 3018 "pro" I got on amazon, it's most definitely a toy. The easy-bake oven of CNC routers 🤣 But its interesting to know this, that shallow cuts are not without their disadvantages.