Machining fluxcapacitor covers out of PEEK

[@matttradie1341]

Wow. I didn’t think the supports for keeping the top of the box from touching the pizza needed to be so sophisticated. 😲 Happy new year Stephan.

[@kylejacobs1247]

that's a crazy amount of PEEK shown at the end, and way bigger than any part I've seen made of PEEK before. I'm curious what the customer's specs were that led them to spend the $$$ on this, especially as a monolithic part with so much material removal.

[@googleuser859]

I've been looking forward to a new video so thank you for sharing it.

[@elanjacobs1]

OMG those are the most adorable quick change tool holders I've ever seen!!

[@jimsvideos7201]

This was worth watching for that fixture alone never mind everything else!

[@GlaserOUT]

Excellent video Stefan. You know just how much detail to show and haven't fallen into the trap of milking each one into more than one part like some other machinists. A happy and prosperous New Year to you Sir.

[@StefanGotteswinter]

I try not to do multi-part videos anymore. Its very demanding from the viewer to dedicate that much time on a project and one can show a lot in 30..40 minutes if things are edited tight.

[@Ryan-dz3jo]

Fantastic video with something for everybody and the workflow belies the skill and experience. This content is why the internet is great, thanks Stefan.

[@zzzgz5]

PEEK - Polly Ether Ether Keyton, two Ether molecules in there :-). It's amazing stuff. I worked with an engineering project for a small drive system where we used PEEK for a worm gear that engaged with a powdered metal gear. The initial design had both gears in steel but they couldn't handle the heat. Never saw any of the PEEK gears fail. ATF was the lubricant.

[@AlexCNC]

Smart way to clamp the part for op 2! And also a very neat height gauge.

[@ROBRENZ]

I am not tired of saying this, really nice work Stefan! ATB, Robin

[@StefanGotteswinter]

Thank you Robin!

[@woodscreekworkshop9939]

I enjoyed this one a lot. You’re a very smart man, thanks for sharing

[@bcbloc02]

Really like that height gauge! Well thought thru process as always.

[@StefanGotteswinter]

Thank you!

[@Legendinium]

Yes, that height gauge is an absolute beauty!

[@risfutile]

I'm so glad to notice you're using a 3d space navigator! This confirms my view of them not being a toy or gadget, since you would never use those :)

[@StefanGotteswinter]

Yep, Using them for a few months now, after a friend showed me how he uses it and I was hooked. Got a second hand one (The most basic one thats just the puck with two buttons, not the crazy starfighter control panel) and love it.

[@StefanGotteswinter]

(And zoom/pan/rotate looks so much smoother in videorecordings with them)

[@petergoose8164]

Absorbing video about an interesting plastic. Suitable for higher temperatures than most thermoplastics and also high vacuum. Extreme material with a price to match.

[@josephmagedanz4070]

Nice height gauge...seems to work well and have lots of great features. Nice episode; thanks for sharing.

[@logancompton3923]

Very clever setup! I like the fancy flexure fixture and chamfering the annular bosses prior to machining the bulk of the material. Thanks for sharing!

[@2lefThumbs]

Great video as always👍👍 Great to see that you're still working on flux capacitors, and finally Happy (but belated) New Year

[@KravchenkoAudioPerth]

Always enjoy your videos Stefan. Thanks for taking the time to make them. And for sharing them. Mark

[@joepie221]

Nice job. I loved the displacement fixture for the 2nd side. Finally subscribed. Sorry, I thought I did that a while back.

[@Rustinox]

That clamping system is brilliant. Thanks Stefan.

[@drawbar217]

Add a couple of drive lugs to the outside and a keyway and it would fit on a turbo encabulator!!

[@unionse7en]

FINALLY a height setting video that doesn't jog DOWN INTO the gauge block! lol ( a pet peeve of mine)

[@StefanGotteswinter]

I ruined to much endmills that way ;)

[@kleinesmaenchen]

@@StefanGotteswinter I hope that is some old gage block that is only used for this purpose. I ruined one setting my tools with it in my younger years, ground myself an accurate, hardened block just for setting tools after that.

[@bulletproofpepper2]

Super fixture very smart and order of operations stellar, super hard super sharp tooling. Thanks for sharing.

[@ehamster]

Fantastic work as always. Your English is nearly perfect, unlike my German, but as a native English speaker, I would call the ‘domes’ pillars.

[@ade63dug]

Coolest height gauge i have ever seen , you have the best toys . Cheers Ade,

[@robertwatsonbath]

Thanks Stefan, neat fixture. Milling in a Winter Wonderland! Belated Happy New Year.

[@adrianu5481]

Thanks Stefan, fascinating as always. I agree with wayne, we don't see enough of you.

[@brucewilliams6292]

Very good use of the flexture to clamp the part. In my arsenal. Thank you for the video!

[@janisdobelis932]

Nothing more satisfying than a chamfer mill doing it's job 20:36

[@1ton4god]

Love the video. It was suggested by Chris Stevens, that I subscribe to you. I'm just now getting into Machining. So I look forward to seeing a bunch of your videos thank you so much for what you do.

[@ksaweryszykiedans5839]

Thank You very much for another example of so fine machining. From the title I assume that these are the spares for "time travelling lathe" of some Old Tony :). Best Regards

[@imagineaworld]

Been a while!! Good to see you sir!

[@misterfixit1952]

Why do you do manual tool changes? With the power drawbar, I would think that adding a tool holder rack at the back of the machine would make it easy to add a g code routine to pick and change tools automatically. Also, I highly recommend a cyclone vacuum attachment, when cutting plastic. It really keeps the mess down. I have a cheap cyclone push-type vacuum cleaner that I rescued from a dumpster and after removing excess parts I hung it on the wall next to my mill and lathe and it works wonders picking up chips and the cyclone keeps the filter from clogging up due to fine particles.

[@seeigecannon]

Great video. Something you might want to consider for a 2 part operation like what you have been doing with your fixtures is to use a secondary work offset and do both operations in a single run. To state it differently as I don't like my current explanation: edit your program so you have both fixtures populated, then do all of the operations you can with tool 1, then the same for tool 2. This would reduce the number of tool changes you need to do. A drawback though is that you might have a harder time with any mid-part QC you do.

[@loukola5353]

I don't see how that would save any time. Machine time will still be the same and he still has to manually move the parts from one fixture to the other.

[@turningpoint6643]

A great object lesson on how an experienced and real machinist can still produce a short run of fairly accurate and no doubt costly parts on a lower end CNC against how one of us hobbyist's might Stefan. I'd go broke trying to make 25 of those on my manual mill.And that was a really clever holding method. That plastic type seems to allow a pretty nice surface finish even with such an awkward part shape. I'm curious though, since drilling is more efficient at bulk material removal than end mill machining, would the job not have gone slightly faster and a bit easier on your expensive end mills to use fairly large drills and step drill the part under size where ever it was possible to do so to remove the majority of material while still leaving enough to support those posts for final end milling to finished size? It's not a criticism of how you chose to do it, just an honest question. A most impressive height gauge and not one I've ever seen before. I really like that constant down force feature. I'd assume it can also be used for checking a parts vertical squareness like a Squaremaster? If so then it's even more impressive.

[@StefanGotteswinter]

I considered boring out most material on the lathe, but I have other projects that I need the lathe and my workforce for, so I let the cnc cut on its own. As for drilling it out on the cnc, plunge-drilling/milling for stock removal is a thing, but i suspect the router might be to light duty to do that well. The height gage can do squareness checking, yes, but its not crazy accurate. They spec it out with 0,03mm squareness over 600mm.

[@turningpoint6643]

@@StefanGotteswinter Thanks, I figured you'd have a more than valid and logical reason for just letting the cnc do all the cutting. .03 mm is about .000118" or call it 1.2 10ths over 600mm / 23.6" still not too shabby at all. I'm of course envious. :-)

[@wayneacaron8744]

i have worked many plastics. mostly i wanted "hard" because soft is crap. tool breakage was from plastic fusing to the tool. but one that wears out carbide? contraintuitive a bit. however; i watch utube to see NEW things. thank you stefan!!! poppy

[@TY1979KA]

gefällt mir was du da machst!

[@jhbonarius]

Very impressive! I cannot imagine me making something like this in my home shop... ever. But you're a professional, so figures ;)

[@StefanGotteswinter]

I just play a professional on the internet :)

[@davestambaugh7282]

The first time that I was required to make parts out of peek I can remember my boss telling me that the customer told him that the material is extremely difficult to machine. Boy was I ever surprised as it machined easier than any screw machine alloy that I had ever cut. What they don't know can cost them a lot.

[@SuperMapupa]

I think he mixed up "extremely difficult to machine" with "extremely expensive"

[@davestambaugh7282]

The customer supplied the material and I had to tell my boss how expensive it is. So you are probably right.@@SuperMapupa

[@TomMakeHere]

Those parts look really good. The CNC chamfer was a nice touch Out of interest what was the CNC run time per part?

[@StefanGotteswinter]

Runtime in total was about 1hour 40. You could reduce that by about a factor of 5..10 on a more rigid machine ;)

[@akosbuzogany2752]

Peek haftet auch tierisch. Hatte mal die Schmierung vergessen und mein 10 mm Bohrer wurde schön reingeklemmt, konnte nie wieder rauskriegen.

[@TomChame]

Very neat! The software is beautiful. All the best for 2020 to you.

[@patwicker1358]

Very nice coverage from beginning to end.

[@SamEEE12]

The ISO20 holders are super-cute. What is the three pin connector on the height gauge for - is that a data out connector, if so it could make a fun Arduino mechatronics project

[@andash123]

Wow that stuff really machines well! I don't know much about CNC, but is it necessary to raise the tool that much between cuts?

[@StefanGotteswinter]

No, I just used the default 25-something mm retract. Normaly I would use way less, but I still learn BobCad and run it a bit on the safer side ;)

[@xenonram]

@@StefanGotteswinter BobCAD is located right by my house. (In Clearwater, FL.) You don't really ever hear people talk about it, esp people in other countries.

[@Speedy2222]

Normally you would want a micro-lift retract of .002-.010 as raising fully adds alot of extra time, though adaptive machining in general is reliant on a machine that has servo speeds with the ability to quickly ramp up and down in speed. IE not typically router tables or smaller diy cnc machines.

[@RambozoClown]

Great video as always. I'll have to remember that chamfer first tip. But all those unnecessary retracts during the pocketing would have bugged me to the point of editing the code or the post. I know for 25 parts it hardly matters, but if I'm in the same room, I would go crazy. ;)

[@anderskarlsson9881]

Nice and simple way of clamping in the fixture. Precision must be really good using those posts for centering. That will be remembered :-) Those parts can not be cheap. Lots of money just for the material.

[@brucewilliams6292]

The Trimos in so sexy! I'd be envious but I couldn't make good use of it so will stick with have to make due with what I have. Love seeing the high end tools.

[@arnljotseem8794]

Great video and som smart tricks. liked the chamfer op before any other operations to solve the vibration problem. I usually don't watch through cad/cam parts of videos, since I'm not into CNC, but in this case I watched the hole thing.

[@bobuk5722]

That height guage is very neat. Originally very expensive too I would guess. And then there's Stefan's sense of humour. Going up, going up .... BobUK

[@StefanGotteswinter]

Craaaaazy expensive new, about 2500eur. Thanks for watching :D

[@romo4301]

Hammer Video und geniale Bauteile! Beeindruckender Werkstoff! Wieder viel neues gelernt! :-) Gruß Robin

[@P8ntbaLLA56]

Why didn't you also mill the outer diameter on the router instead of the lathe? You would still have to face it on the lathe, but it would have saved a lot of time indicating.

[@StefanGotteswinter]

The PEEK Rod in its extruded form is very uneven and out-of-round, to clean it completely up to final diameter I had to be very carefull and I didnt want to take any chances, so I did it manually on the lathe (The stock was about 800eur).

[@NH3rrm4nn]

Rad. Thanks for sharing the cad cam. What's your step down/ depth of cut? Maybe I missed it but didn't hear you say.. percent of mill width? In plastics I assume you can push it quite hard.. awesome 2nd op fixture. Using the thin wall flex. Thanks again!

[@cronos1.2_sqrt5.2]

PEEK is priced not in Euros but in arms and legs. Those parts are +90% waste. Just wondering...could it be possible to remelt the powder and use it for more parts ? +400 Celsius > hollow cylinder > hydraulic press...you figure it out.

[@wayneacaron8744]

you dont post enough! poppy"s workshop says HI

[@kannznichkaufen]

I like the fixture and thought a little. Does the part rest on the outer rim or on the studs? I shortly considered if rotating the part by 45 ° and bringing the studs in axis with the clamping areas would make a difference or even be of some advantage. But thinking more thoroughly brings me to the conclusion that You made the best choice. If there is clamping tension that leads to successive deformation along material being removed, that effect would be stronger along the lines between the clamping points. Compliments. Tolerance is impressive.

[@SailingYachtDreamcatcher]

Excellent content!

[@mealex303]

Peek is a very good insulator

[@pgs8597]

G’day Stefan. Well thought out fixture it worked well. I understand this was a low part count therefore the production method used but it produced an awful amount of swarf and was time consuming. Excellent presentation as always, cheers. Peter

[@JustinAlexanderBell]

That's a nifty fixture.

[@riesmoos]

I needed a clean pair of pants after watching you playing with that height gauge.

[@StefanGotteswinter]

Youre welcome ;)

[@touchgo7281]

I will be listening to Blind Guardian in the shop tomorrow. never heard of them before...

[@StefanGotteswinter]

Awesome, awesome powermetal band!

[@rayeaglenz]

Great video, Stefan! Thank you :)

[@TheElderlyBiker]

Stefan, you really need to get some sort of extraction on the router. Love the ISO tooling....

[@StefanGotteswinter]

Dust extraction is a problem - That would mean a blower or a dustextractor running for hours.

[@DavidtheSwarfer]

@@StefanGotteswinter - have a look at the dust extractors that Matthias Wandel makes. simple and cheap and Quiet!

[@GrafRucola]

Stefan Gotteswinter don’t know if it makes sense in an non video environment, but you can Duty cycle the dust collection to not have it on all the time :P

[@patheron7812]

I might have hogged out the center of the cylinder using a boring bar since the stock was already on the lathe.

[@StefanGotteswinter]

I considered that, but that would have increased the time I would have to spend on the lathe - And I needed the lathe for a different project.

[@sunside79334]

not only PEEK is high end, its ridiculously expensive as well at around 100 euros/kg. in fact it's the most expensive stuff we've got in our shop, far ahead of M390 MC, W720 and even titanium.

[@joehackenberg30]

You would think that they would have had them 3d printed though maybe they needed the strength ? But hey I'm glad you got the job and amazing work as always

[@EmmaRitson]

thats very interesting. thanks stefan

[@StefanGotteswinter]

Thanks Emma!

[@Smallathe]

Awesome! Thanks for sharing. Love the new tool... :)

[@unpopular_mechanics]

Hi, how does the isel machine compare to the fixed gantry router that you just got, in terms of accuracy? Any reason you did not use that machine?

[@StefanGotteswinter]

Accuracy is about the same, its less rigid thou. But it has the toolchanger spindle ;)

[@howesinc]

Great video, Stefan! Thank you for sharing.

[@Joelsfilmer]

Hi Stefan. You talked about the fixture being overconstrained. I don't have any education in the field so the whole concept of overconstrained mechanisms is a bit hard for me to understand. Could you explain what makes this fixture overconstrained and what the practical implication of it are?

[@wernerberry7800]

Great video Buddy thanks for sharing! Am surprised your using Bobcad!

[@StefanGotteswinter]

Not much options in my price range if one does not want to use Fusion360

[@wernerberry7800]

@@StefanGotteswinter Yeah I understand. Bobcad drove me crazy but that was many years back I think V22. Fusion did have some growing pains however I am loving it more and more. Have a good one Brother!

[@bradthayer6782]

Did the customer think about instead making the 4 tubes separately and gluing them in place in predrilled holes in the larger piece? Seems like that would have been MUCH simpler as it could have been almost entirely lathe work.

[@priitmolder6475]

PEEK= polyether ether ketone. That extra ether makes it special

[@aronjanssen5702]

Nice! But i think it would be easier to 3d print these? Peek can be printed really nicely

[@Strothy2]

Um meinen alt Meister zu zitieren "nen Meter von dem Zeug kostet mehr als du in einem Monat Verdienst, also pass auf das du nicht zu viel versaust" Ich weiß nicht mehr genau welches peek es war aber zerspanen mit hm Platten für Alu war immer eine Wohltat wenn man die Späne zum brechen bekam, meistens endete man damit das man den laufenden span mit dem Sauger auffing oder per Hand aus der Maschine führte, das Zeug wurde für high End Laufkufen für die Medizintechnik, ich glaube in Desinfektionsmaschinen verwendet. Und as alawys nice video!

[@hries57]

Stefan ,, did you ever consider 3D printing in PEEK the unfinished shapes .. and machining them from there? This is a material I plan on using with my printers (I have fancy one that is more or less an oven .. and my Raise 3D N2 PLUS should also do well with this material). GREAT SUBTRACTIVE MANUFACTURE video!! Best ,, Harry

[@wmcrash]

I've seen that Blind Guardian poster enough times to where I gotta ask: what's the story with it?

[@StefanGotteswinter]

Not much of a story - We where at a live show in Lichtenfels and as we where leaving the concert hall, I asked our driver to stop the car (on a much used road, no less), I jumped out the car, ripped the poster off a handrail and got back in the car. Since then its in my shop as a reminder for an awesome liveshow..

[@TandaMadison]

Nice looking parts. I can only assume, with them being the covers, you have already manufactured 25 flux capacitors. ;-) I paused the video and went back a few times to look when the popup appeared on the screen. I think it may have been your screen capture software but considering when it popped up I thought it was some kind of amazing high tech vibration analysis tool!

[@jozefvindis4926]

Really nice video the fixture, height gauge and problem solving, love it. One question on those cnc toolpaths, why so shallow stepdowns? Wouldnt it be better to do full depth of tool cutting edges with small stepover ? Is it more precise or reliable to do it this way?

[@samcoote9653]

"just to get an idea of how large a 600mm height gauge is" yeah yeah Stefan, we know you want to show off that Blind Guardian poster, and I won't complain haha

[@danf6070]

Hey, great video as always. Just curious about recutting chips that stay in the bore. Is that not a problem? Are you planning on installing some sort of chip extraction method? At work, if we don't have the coolant set up to blast chips out of a pocket we'll notice a difference in finish and dimensions.

[@mpetersen6]

Was there any option for making the parts from multiple pieces where the posts would be cemented in with a high end solvent. That or 3D print. Always more than one way to skin the cat. Hope Doc Brown and Marty, er the customer is happy

[@StefanGotteswinter]

Are there any solvent based glues for PEEK? I don't know ;)

[@mpetersen6]

@@StefanGotteswinter I don't know either. But if the customer specified a solid part, that's that. If these are prototypes for production parts i suspect that they would be injection molded. PEEK should be weldable with a PEEK rod and a high temp plastic welder. Did find this though. www.masterbond.com/applications/bonding-polyetheretherketone-peek. If that worked the posts could be made in two pieces expoxyed into from both sides. All of the assembly stresses should be transferred through the tapped holes. That's probably why the 4mm tapped holes are so deep. They get a fastener from each side. I suspect that this is for a di-electric field switch that mounts on the framinstat of the turbo-encapulator sub-assembly of the Flux Capacitor.

[@davestambaugh7282]

I would like to see how you would make this part with out using any computers. It would take a little longer.

[@Hoaxer51]

That’s the dirtiest I’ve ever seen one of his machines! Great video!

[@ronpeck3226]

As per always "You give good Demo"

[@MattOGormanSmith]

With the price of PEEK, I'm wondering if it would be worth injection moulding these parts, even for a run of 25.

[@nikond90ful1]

Thanks for the video.

[@Stefan_Van_pellicom]

27:01 Who else was blowing at his screen ? :)

[@giorgiocanal1659]

Hi Stefan. Great job, as usual. What's the fixture clamp material?

[@StefanGotteswinter]

The fixture is PVC. Not for any other reason that it was the only chunk of plastic that size I had at hand :D

[@wayneacaron8744]

just about to see the machineing

[@iaahner]

Purely curiosity: are there no good adhesives that would have been suitable for the application? This geometry seems to lend itself better to being an assembly than a solid part. I'm curious what requirements drove it to require 1 piece construction?

[@curtisvonepp4335]

One thing you might add to the machineing process is a vacium hose some materials would vacium quite nicely . 🐤🐤🐤.

[@dizzolve]

those are some polished lookin widgets. Nice. How long did it take to mill the parts

[@felixxavier6870]

probably already asked but what is the material of your grey fixture ? PVC ?

[@StefanGotteswinter]

Yep, PVC.

[@willi-fg2dh]

so . . . do you think you can sneak one of the finished flux capacitors out of your customer's shop? if you do, don't let Old Tony near it . . . that could get dangerous.

[@wktodd]

Nice Stefan. so how long before you make a tool changer? oh and Happy new year :-)

[@TrPrecisionMachining]

very ggod video..thanks for your time

[@Etna.]

Thank you for this video, Stefan! It was a perfect watch while cooking chicken broth for my girlfriend. (She has the flu.) Regards, Etna.

[@StefanGotteswinter]

Thanks! Quick recovery for your GF :)