How to Machine the PERFECT BALL in a BOX | DN Solutions DNM 5700L Mill

[@Kardos55]

The importance of a foundation. Making a perfect cube is a challenge to many experienced machinists. Nicely done Barry!

[@TheyForcedMyHandLE]

Right! Folks think the ball is hard, then realize 2/3 of the video is just making the cube.

[@majorva2653]

leave 2mm to clamp on the bottom, machine the plane on top and around with a endmill, 5 perfect to each other faces if your endmill doesnt flex, which doesnt happen with a sharp good tool saves you like 1.5 hours in his case

[@mrfinder18]

Basic AF. If making a cube was hard, you came into the wrong field then.

[@mgk1397]

@@majorva2653 Only if you can get an endmill long enough to side cut the entire block, so it depends on how big you want the cube. Either way you are right, it is much faster.

[@JohnBlaze505]

Making a square cube is day one stuff.

[@machocamacho9544]

When I did my ball I used two bottle caps to hold on to the last side. It wasn't the best, but it was the only thing I could think of as a 19 year old machinist.

[@barrysetzer]

Hahaha that's actually pretty smart!

[@haydenberndt4835]

I used a flat piece of hardwood that I cut to the correct square size, rounded the corners, and used a large drill to make a pocket in the centre. It wasn't the most stable, to be sure, but it did the job. Now that I have a 3d printer, I'll have to give this method a go.

[@andyloney777]

I was just wondering how an apprentice was supposed to do it if you didn't have a 3D printer.

[@barrysetzer]

You can also machine these exact jaws out of aluminum!

[@tylerchiu7065]

@@andyloney777 i mean, he did say that you could mill a holder too

[@gofirst501]

This guy’s presentation and teaching skills equals his engineering skills. Impressive guy.

[@allentastic]

Both are somewhat rare talents, I was thinking the same thing.

[@blaynheimann3423]

Barry is such a trip. I loved the years i got to work with this guy, he was by far one of the best Programmers i had the pleasure of working with and before he came along my company had never run anything high speed. also his singing about everything he did was classic and his sayings were top notch.

[@unclelar53]

Cool stuff. I'm retired now, but was a machinist/toolmaker/CNC programmer for 50 years and still a bit surprised at the simplicity of this project, yet the final product looks very complicated. It reminds me that it is always best to, first, look for the simplest way. Back in the 1970s, it was just "NC" not CNC, and we ran on punched paper tapes. We would refer to it as "no control", lol. Fun, fun.

[@mount.sinai.5295]

Man its something else watching this as an european.. Your AMERICAN energy is something else. I dont know why but i have huge respect for this guy and i dont even know him :D I love the accent, makes me want to listen more

[@barrysetzer]

Hahaha glad you liked the video, brother! Thanks for watching!

[@mount.sinai.5295]

@@barrysetzer Amazing content bro! Its just what this industry needs, content like this

[@lsfloro]

Namaste! I'm a retired (primarily manual) machinist and really enjoy your videos. The perfect ball in a box is a classic.

[@elliottanderson9507]

the heretical part of me just thought "shrug cut box in half, insert ball, weld box back together, mill welds flush..." but this is much more technically impressive

[@NegativeROG]

That 3D fixture was BRILLIANT!

[@MrScienceMaths]

Barry your a genius. Excellent work, another great example of the integration of subtractive and additive machining. Love you Barry!

[@barrysetzer]

Hahaha thanks, this is one of my favorite projects, glad you liked it too!

[@ricosuave3565]

Barry. I dont know anything about machine ing. But I know you're a Genius. LoL 😅😆🤣

[@thebeverageman2982]

Who edited this video? I really enjoyed all the little things sprinkled all over it, like the MLG hitmarker. Excellent

[@JoshBelowKnee]

Whoever is doing the sound effects is doing a bang up job!

[@TheExplosiveGuy]

I've always loved doing tight tolerance work, everyone else always seems to hate it or aren't very good at it but I think it's rather fun. I've always dialed my vises in as tight as possible until my .0001" gauge dial stops moving, if I had a dial indicator that read in .00001" increments I would use that instead lol. My boss always gave me the stuff that we couldn't afford to mess up and had extremely tight tolerances but wasn't in a hurry either, he knew I took my time dialing things in as tight as possible even when I had a mile of tolerance, I was never the super fast get it done in 20 minutes kind of setup guy but he appreciated my attention to tolerance all the same, I even set all my tool height offsets down to the tenth, and would also run every new cutter through a piece of test material to establish my diameter offsets down to the .0001" as well. Takes a lot longer to set up but when your first part buyoff comes around and you've nailed every single dimension down to one or two tenths, it's a pretty good feeling and it impresses the hell out of the inspectors as well.

[@xl000]

Meh. Machinist is an easy job. Why do you think it's taught to kids in trade schools, I think it's a cool hobby though. With a CNC, some woodworking and 3d printing skills, I can repair almost anything

[@Joshua-YeetRat]

@@xl000 it's not easy man

[@CaskStrength777]

​@@xl000it's taught to kids in trade schools because it takes a very long time to get truly good at it, and the people who make things like space shuttles and parts to crazy tight tolerances in millionths of an inch, microns, like I'm doing, you don't pull that off just coming out of school. For someone to say it's an easy job you obviously have no understanding of anything related to machining or how difficult it actually is to make something complex let alone this properly. Some of the most brilliant people in the world are really skilled machinists. This guy was fine with a thousandth of an inch variance in the cube and I laugh at that. I would have made this 10 times better, and I would be splitting tenths. Because when you get good at it it's not difficult to do that rather quickly. But it takes a long time to get to that point where you understand all the intricacies of variance that can come into the setup. He was fine with 0.0002" variance on his paralellism, I would have quickly had the vice parallel to millionths. The hard part is getting the vice bottom perfectly flat because there are always micro burs on the table, slight imperfections on the vice that you use precision ground flat stones to take off and clean meticulously before you even put the vice down. If you do it correctly you can do much better than this much quicker. There are people who can do tight tolerance work but take forever and they don't make money, the key is being able to do very high accuracy quickly and efficiently. Machining is the only career I can think of that develops a hands-on experience with geometry and physics when you get to the high levels, and it promotes a comprehensive understanding of physical natures of force. There's nothing easy about it, your conception is shallow at best

[@levihoff7923]

Video quality is through the roof today. Love seeing machining on KZbin!!

[@onepairofhands]

that surface finish when you were squaring the stock is amazing

[@OlsonKustomWorks]

we used to just freeze the cube in water, or dip it in wax, then hit the 6th side. we didnt have 3d printed jaws 20 years ago lol

[@paulkraus4799]

That’s one of the coolest parts I’ve seen made in quite a while. One of these years I’ll have to try that . Great job Berry

[@barrysetzer]

Hey thanks Paul! This is one of those projects that I always liked because it keeps the new guys interested in machining. Everyone likes having a conversation piece for their toolbox or desk!

[@mrbmp09]

bArry not bErry were not fruits.

[@Sara-TOC]

@@mrbmp09 Good ole' auto correct...will get some every time ;)

[@horseshoe_nc]

@@Sara-TOC or as I like to call it, Auto Incorrect. 😜

[@johndennis3181]

I use this method for getting some very square (no such thing as perfect) but when I need the best I can get I clamp the part to an angle block, this always yields better perpendicularity.

[@shaniegust1225]

Great video Barry! And I love how the editors are getting HUGE credit on this one! BOOM!

[@barrysetzer]

Thanks Shanie! And yeah those guys deserve way more credit than they usually get!

[@BrilliantDesignOnline]

Awesome editing and use of AfterEffects, like where he says in X and In Z and the screen labels track his hand.

[@peterchindove7146]

How much would this cost? The ball in the box?

[@ascobie22]

Great demonstration on squaring a block

[@beckoningjinx1119]

This reminds me of a production part that I used to run. Milled all six sides, starting the saw cut up and rotating the fresh faces toward the stop. On the fourth side, there were 1.25" drilled holes with less than .050" wall left from the previous milled ends. If you didn't get it squared good enough on the first side, those holes would be out of tolerance. Then, rotated forward and back to finish the block out. The last side had milled ports that intersected those 1.25" holes and 1/8" holes with about .040" walls that went through over 2" of material. Being a production part, we didn't have the luxury of getting it all square before features were added, but they weren't bad if you got it square to begin with and kept a handle on it.

[@Atlas.Brooklyn]

Ok

[@maikel371]

all hail to the video editors! what a great video y'all

[@barrysetzer]

Yeah those guys do a fantastic job!!

[@maikel371]

@@barrysetzer you also did a amazing job :) i just found another use for my army of 3D printers. thanks barry! what a great job you have

[@STUNRICK]

I might be slightly drunk and have nothing to do with CNC machining... but I admire technology and the art of it. Thumbs up, great vid.

[@cgdrider]

Nice work. As a retired 50 year CNC Machinist, Once I saw the project I immediately knew how it was done. The only thing I would have done different would be to make the Ball capture fixture aluminum soft jaws and as a former GibbsCam Sales engineer/application engineer, I would have used GibbCam to program the CNC and Solidworks to create the part model.

[@SameerKhan-xn9gn]

I need to try to make one of these before I die, Thanks

[@EdTube444]

I have never done machining, which now makes me realize I wasted my life because it looks cool AF, but as a carpenter and builder I see the same methodology applied. Achieving "squareness" and approaching a build with "forethought" like "okay my 6th side was holding the ball so how do I get the 6th side without goofing it up". I get crap from other workers I have worked with for being OCD. And when its all said and done their product is, in their words, "good enough". I've been hearing this for 30 years. I see I should have been a machinist. You all seem to understand perfection is a worthy goal.

[@bensonburner42zero]

I've done Turner's cubes where for the final side you tape up the cube with tinfoil tape and then fill it with melted paraffin wax. Let the wax harden then machine the final side. Use a heat gun or low temp oven to melt out the wax. Perhaps not nearly as accurate but definitely still a great result. This video was great and I want to try and make one of these now! Also wondering if two pieces of round stock and a counter sunk set of holes in the ends would maybe work ok for holding the sphere on the final side. 🤔

[@tommasu5391]

Awesome video guys! Is it possible to share the steps done in master cam for people to follow along and Try to make it as well?

[@moodberry]

Dude!. Oh how I wish I had a teacher like you in high school!

[@tdg911]

You guys are badass, period. Just saying. Much love and gratitude.

[@marcabrams6087]

Have to remark on how much has changed and how much IDK since my programming and CNC (G & M code) and operation days in the 80s on an Ikigai 3 axes. So far above what I learned. Know JUST ENOUGH to be amazed! I so love seeing how technology and hardware has so advanced. waent the dark ages, lol, Still had inserts.

[@joewoods9909]

Fantastic video, I like the longer and more educational ones!

[@arturmelniczenko3611]

It's a great thing to try to do it at home at the physics institute, but in the metric system we'll see if it will work. Well done

[@Make-Asylums-Great-Again]

Ok

[@Вертющыч]

Barry!! I NEED MORE BARRY!!!

[@barrysetzer]

Hahaha thanks for watching, brother! 💪

[@MoonSystem1111]

We did this in a Traub TNS-30/42 about 1993-1995 in brass...

[@hansjanko7966]

Yes, i remember, but i really think it was in the late 80ies, because i worked for Traub then and saw it there. It was a sensation at a industrial fair and the programmers etc. were incredible proud of it. And you are also correct with the material, i also remember that thing made out of brass! The lathe had a revolver and a C- Axe and Mitsubishi control? Traub is now owned by Index the other manufacturer for CNC lathes at that area in the east of Stuttgart (Esslingen/Reichenbach)

[@MoonSystem1111]

@@hansjanko7966 kzbin.info5I5uyFWavVw?feature=share

[@kylebatdorff1217]

Saw this video this morning and new I had to show my students ASAP! They loved it and immediately said we're making that!! Thanks so much for making the video and look forward to seeing more of this content in the academy. Thanks again!!

[@TITANSofCNC]

WOW! That’s Awesome… Thanks Kyle😁🤙 Please say hi to your students for me! Titan

[@duffmanmark]

Stepping it up a notch would you do a ball in an octagon that would be cool to see

[@ChristianZenker]

Long time agao i learned to use this machines, but i never had an project awesome like this. Thanks for showing

[@mohammedalbattal77]

Ohhhhhh man we have a ton of new information here I like that one when you check the square with v block it so fine and we can save alot ov time with this way Thank you Mr Barry for this video and thank you for your time 🔥🔥🔥🌷🌷🌷 Boom

[@Jatsekusama]

Great work!!! Next video on CNC turners cube plz!!! :D

[@KeithAlumbaugh]

I use a ball bearing instead of a half round rod to square up stock.

[@e2jw]

Sure, you can do it THAT way - but I just get a large ball bearing and cut the cage, soak them both in vinegar overnight, push them together in the morning, rinse and dry. Works about like you'd expect... not at all LOL! But Seriously - Great job with this! (i did put an egg in a milk bottle once in a similar way)

[@ekremtalha5468]

What is the real benefit of using a "half cut"? It connects on the part by one point due to it's geometry but what kind of benefit does it have? I haven't seen it before.

[@patpalermo7629]

I never clamp anything offset that much in a vice - it will not be square - at least not in the vices I have. The fixed jaw is fine, but the moveable one will cock. Putting it near the center of the vice, or using a spacer on the other side of the vice will fix it. Evrey vice I have does this. Check yours. If it is still within .002 when clamped this way, then I want one. Been machining for 30 years.

[@Bruhaustindavis]

"Using nothing but a 3 axis mill" What a humble and lowly piece of equipment you're using ;)

[@frankensteincreations4740]

Absolutely nuts! Crazy where technology has taken us…

[@iamtyzed]

From Switzerland I first learned that in my first year on a conventional mill 2:40

[@Szcza04]

I'm having trouble programming this part. I wish you guys offered a cam tutorial with this.

[@lidarman2]

I'm an optomechanical engineer and I giggle when machinists equate spotless clean with rubbing surfaces with their fingers. It's an interesting relative perspective. :)

[@trevorgoforth8963]

I gotta say Barry, you really know how to put the FUN in fundamentals 😂 #dadjokes

[@christophervillalpando5865]

Awesome Video Barry! Very informative!

[@VikingRul3s]

Well done!!! I don't think I've ever made a box that perfect, old school style, but frankly I'm too lazy and would just include the "squarness" as a part of the first 2 CAM programs

[@TommiHonkonen]

We did one with a cross inside at school 10 years ago. Wanted to do one with a ball inside for years. You should have had Travis cmm that block for squareness.

[@atlas7309]

I absolutely love your editors style!

[@jtrent3960]

Great fundamentals video, and Barry is the fn best.... Cheers

[@barrysetzer]

Why thank you! I will make sure that I rub this in Jessie's face HAHAHA! Seriously though, thanks for watching, and for the feedback brother!

[@MagnetOnlyMotors]

If you had your vice a few degrees out of alignment, you would have a wonky looking cube, which would also look very interesting.

[@markhill2489]

great stuff guys ! i really appreciated this. thank you

[@stevebell5231]

Now that was bloody cool

[@bobbymelehes732]

Loved the editing! Keep it up!

[@bjmckay3]

Good job👏 pred straight forward for experienced cnc lads

[@reidklassen5096]

I can't wait to try this!

[@DJKrEyVa]

here's a kinda dumb request, do you think you could do the same on a 5 axis mill, doing all 5 sides of the ball in one op then last doing the 6th side, and to compare with the 3axis ball please? (not the cubing part mainly the ball part)

[@mariusschubert4737]

One of the most informative and fun videos about cnc- fundamentals plus a cool project I'm goonna keep in mind for once I'll be a cnc- instructor. Cheers from a German machinist & keep up the awesome work promoting this beautiful trade!

[@barrysetzer]

Prost, brother! Thanks for watching!

[@mariusschubert4737]

@@barrysetzer Always! Prost :)

[@Carminebonzo]

wonderfull wrok !!! a long time ago i have seen a 6 arms star made in a aluminium Ball (diam 60mm).i always search one of them ...

[@sjorsangevare]

I found the edits quite hectic. I wouldve loved to see more of how the machine machined the ball, I didnt know you could make perfect spheres like that!

[@timbaer8525]

Best practice would definitely be using more of the fixed jaws and reference surfaces for keeping square. If you have more surface easily available to use, use it. Only going to make better square easier.

[@countlessmansions7735]

How do you make the solid model and tool path in solid works??

[@orioltr8387]

Its posible to machining a complete sphere in 3axis without the box? Maybe drilling the center and using screw for fix the sphere at second step?

[@ericmatthews7652]

Did mine on a manual lathe after seeing another video.

[@davidsnyder2000]

Super cool teaching 👍🙂

[@tonyl2941]

The one thing i would love is if you guys had a discord server so we could share info about machining, ask questions, and chat/ hangout. I love the forums boards that are available but my problem is that as new machinist (just about 2 years now) when I post on a forum asking for help I tend to need help as fast as possible. While discord can send notifications directly to your phone if you have the app installed versus going to your email to see whether some replied to you on one of the many forums.

[@barrysetzer]

Well, in our FB group, we are all there, and regularly answer PMs and forum questions. ;)

[@johnhumphreys2365]

Is there anywhere to find the model for the cube and the jaws, great project for students to practice setting up

[@TITANSofCNC]

I will talk to the team about adding it to the Academy.

[@johnhumphreys2365]

Great stuff, I will keep an eye for it, students would love to take something like this away from class i’d say .

[@barrysetzer]

Also, at 9:56 I made sure to include the dimensions on screen for anyone that wanted to model one up!

[@johnhumphreys2365]

@@barrysetzer thanks Barry

[@lucasluiz8735]

Looks cool, not gona lie.

[@ELITEWELDER1]

Thanks for the entertainment I’d love to come be an apprentice and learn how to operate and maintenance all these amazing Rocket creating machines! So cool how I feel watching this amazing skill. U guys rock’.

[@JGV_IX]

Insane!! Great work!!

[@travisj.3994]

Solid video brother. Really enjoyed the tutorial embedded in a super cool project.

[@brianw572]

That is very cool and would make a great conversation piece. Thanks for showing how to do this.

[@barrysetzer]

Yeah i always like having people guess how I got the ball in there 😂

[@buiucgiau2664]

That's great! What is your this tools of rough operation?

[@joels4208]

Nice Video. DO you know what material Trevor used to 3D print the soft jaws?

[@bruderschwester903]

New Videos editing is awesome!!!

[@DiegoLopez-sg5bs]

Very very very bright 👍

[@DELACARS]

Cool. What was the depths of cut on the ball? feed and speed?

[@alegermani1981]

La lavorazione in trocoidale per fare la gabbia è eccezionale... complimenti veramente

[@satyajeetsahoo1073]

Ohh man... it was really amazing 👏

[@Beaches_south_of_L.A.]

That was really cool and I like this guy he's really cool too.

[@duyle7031]

I'm try this on the weekend

[@funnyanimalworld7579]

Probably most people learn this in companies because of high cost of equipment but either way this looks like a great profesional video👍

[@ProjectShopFl]

That was Awesome! 😎 I want to make that out of copper.

[@DumfriesDik]

That was a great video, thank you.

[@dirmaworks]

Barry, Can you tell us what diameter ball mill you are using, and what is your final Z depth for the surfacing operation. Thanks, Rob

[@barrysetzer]

Sorry for the late reply, but it was a .375 ball going .85" deep

[@hunlee7521]

오~이런식으로 해야 하는군. ㅋㅋ 저도 한 번 도전 해봐야 겠네여 ㅎ

[@aaronczarnecki1403]

Great stuff! What Ball End Mill are you using? Thanks

[@philipp__5106]

Thats verry nice🙏🏼

[@markmanning2921]

did you see how your co-worker came by to check your work and make sure you arent fuscking up on youtoobe? thats teamwork! Question: when cutting the sphere from the second and subsequent faces do you need to take account of the cuts made to previous faces?

[@air3dp]

I like how 3d printers can save a job :)

[@Metaldetectiontubeworldwide]

" MAGICO THE MACHINIST " AWESOME ☆☆☆☆☆

[@Pointern]

Cool video ! how hard is this to actually get completely round and nice end finish ?

[@funnyanimalworld7579]

You have whole door covering you from hot metal scraps ,in my time working with some ancient equipment i had only my skin covering me from them😅

[@KimbrellBrad]

I've done that in wood before on my PowerMatic lathe but wow in metal! Super cool idea on those vise jaws! I need to get a 3D printer anyway...great reason just thinking about not having to machine soft jaws on my manual metal lathe!

[@coyleboyd4882]

I wanna try this so badly