Machining Our Own Brake Rotor on SMX 3100ST 9 Axis | DN Solutions

Tyson Makes a Brake Rotor on our SMX 3100ST from DN Solutions. We use our Schunk claw jaws to hold a 100 Lb piece of Cast Iron Material, and Kennametal Tooling to make this amazing part.
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#CNC #Machining #Machinist

[@automan1223]

I turn brake rotors & drums for a living. Our speeds are very docile compared to what you are using but one thing remains. The shape of the part is a BELL. It generates harmonics which effects the surface finish. We always use an elastic strap and wrap the rotor or drum to help absorb the harmonics. Without it you get fish tails in the finish. You also have an interrupted cut which has to be murder on the tooling as well. You might consider hole ops on the rotor face last. As a last op a non directional finish with a flex hone type tool is advised.

[@tracesellsyourplace1745]

How many machines do you have at your shop?

[@TheDandyMann]

Do you make your rotors and drums from solid stock like Tyson is doing or do you get them preformed and then finish machine the parts?

[@brianrhubbard]

Order of operations, drilling and chamfering last could leave burrs on an otherwise smooth face. These machines are way more ridged than the average Ammco lathe, making interrupted cuts on these machines is child's play. Not all manufacturers recommend non-directional finishes. The OEM of these rotors only provide coated rotors. Most European OEM's use coated rotors. Now in the aftermarket world, you do what you have to do.

[@cryptoldya6229]

I also make rotors for a living and agree with you. Drilling should always be last and you would want to balance it before using. Also to save alot of time, kennametal has drill that would do your top and bottom chamfers as it drills each hole.

[@automan1223]

@@cryptoldya6229 oh yeah ! totally forgot about balance !!

[@VR6NAVYVW]

First the holes are to help with heat yes but actually it's more to release the gasses that attribute to brake fade that build up between the rotor and pad. The gasses literally create a barrier from the metals touching eachother. Also those rotors are useless without veins which are actually the major cooling component of the rotor.

[@hazy-hf5od]

Also without the vanes gases cannot escape correctly.

[@rayp.454]

You guys broke a record! The worlds most expensive brake rotor. Well done video Tyson!

[@BigWill3855]

*most expensive cast iron rotor

[@Jon-O.]

@@BigWill3855 all drums and rotors are cast iron.

[@BigWill3855]

@@Jon-O. ever heard of carbon ceramic?

[@Jon-O.]

@@BigWill3855 brake pads yeah

[@8bits955]

@@BigWill3855 or even carbon carbon bec if you watch F1 you will know how much they cost 🤣

[@leonschumann2361]

love the "boom" when titan shows up (the machine is so cool. so versatile with the amount of axes ... compaired to a machine with a revolver you probably save hours every week)

[@joesmith2465]

I always enjoy Tyson videos they are always a complete project. this is something I would do if I had a machine large enough I'm always making custom car parts for our builds. Keep up the great content.

[@chrism4008]

Always super chill too, very relaxing imo

[@wannabecarguy]

FYI, my customer owns the machine schedule. I could make anything I want. At the end of the day they call the shots. I wish I had the time to make all this stuff.

[@grizz865]

What all do you make?

[@MrMBinder]

I've never really enjoyed machining cast iron. The surfaces are fine and it's fairly easy to deal with for tolerances and heat, but that's where the good bits end. The smell is the least weird thing about it. The chips are more like granulate that gets everywhere - the bottom of my coolant reservoir was covered in a black sludge which was due to the composition of the metal. My small drills started breaking because the particles clogged the pumps for the through-spindle cooling 👀

[@changblonk4089]

Exactly lol, but what about those fine ass brass chips that find a way into every corner of the machine

[@ericburns8697]

yea, piece is a beaut, but we have turned down jobs simply by the fact that Cast Iron sucks when you machine it.

[@MrChevelle83]

cast iron lends it self to good old fashion open lathes without coolant. I can totally concur on the mess with castiron, I cut brake rotors a lot on my brake lathe and turn mill rolls for a living and the mess is indeed terrible

[@AlChemicalLife]

Better than the splinters I get from grinding super alloys

[@MrChevelle83]

@@AlChemicalLife PPE anyone??

[@mobilePCreviews]

I've always wanted to do this but I always thought "oh but how are you going to do the cooling vanes?" so it's really cool that you guys tried it out.

[@AlphaEngineer2022]

Always wondered this too, that’s why they are generally cast and then skimmed. I wonder how much the veins matter🤔

[@Stasiek_Zabojca]

@@AlphaEngineer2022 They do matter, a lot. You have around 2 times more surface for cooling so brake disc takes longer to overheat and loses heat way faster.

[@Dane33781]

Without the venting the rotors are also heavier than they need to be.

[@nathanchalecki4842]

@@Stasiek_Zabojca perplexed as to why they showed a race car. Without venting, this disc is just plain bad

[@yanicktanguay2746]

Exactly. I think they only made a rotor for the "show" because those rotor will be horrible. They are heavy, will over heat very fast, take for ever to cold down and high performance rotor use a specific alloy to match the pad.

[@olegvinichenko6831]

I'm really confused, where is venting channels on this disc? without good air flow it is suitable only for low perfomance applications.

[@whatzituya55]

I thought something was missing. While the veins could technically still be added it just proves why parts like rotors are something better when cast then just surfaced

[@clapanse]

@@kingofkings600 They aren't mandatory, but if you're spending what I'm sure this cost to manufacture, they're definitely expected.

[@gt40f]

This is just an educational exercise. Without internal venting this part is not performance-oriented

[@brahtrumpwonbigly7309]

"Solid brake rotors are usually machined from a single piece of raw material, like cast iron. Although more exotic materials are available particularly when it involves racing or street performance requirements. Solid discs usually appear at the rear of the vehicle."

[@whatzituya55]

@@gt40f bro they literally showed the car they were going to put it on and it sure wasn't my grandpa's Corolla.

[@tmr626]

Since you guys have the best machines in the business it would be really neat to see what you can do when machining custom wheels for motorcycles, cars and trucks, be it, 1 piece, 2 piece, 3 piece or 3d custom aluminum billet styles.

[@kleini3]

The most suited for stuff like titan alloy yes, maybe not the best. But some 5 axis machining of a rim would be fun

[@tmr626]

@@kleini3 They could make the most amazing looking billet wheels with their new multi-axis machines. Hopefully Titan thinks about making a video one of these days.

[@trevorgoforth8963]

You’re a beast Tyson, beautiful part man!

[@Jessie_Smith]

Great video Tyson. Those ceramic inserts are a beast!

[@adammiller4879]

Tysons videos are always the most informative and we really get to see what’s going on.

[@Desertmoto]

I’ve seen this video a couple of times now and Tyson killed this part! I bet it was very intimidating standing next to that piece of cast iron with only the large door between them. 👍🔥

[@akronimm862]

Tysons of CNC

[@seththomas2490]

Keep these videos this length. 15 minutes is perfect

[@AlphaSierra375]

Exceptional video! You know it's a good sign when I can't help but watch these complete project runs just because it's fascinating. Makes me glad to be getting into the industry despite what a few manual machinists have been saying about CNC. Keep killing it ya'll. Would love to come for a tour in a few years!

[@MakeItWithCalvin]

I love how Tyson explains things in simple terms, with no excess drama, and is honest about his fears running things too. This shows people the true side of machining, things get scary at times but it is about managing risk.

[@krusher74]

Yes! I hope he leads the other to less shouting and atempted drama. I dont wanna watch orange county choppers

[@rezloh9141]

love the content from the lathe side we need more!

[@gitpusher2400]

That machine is insane. Must be fun being able to use it everyday!

[@soundspark]

OSHA must freak out at 0:41. Also good to know you can trust your life to something you made.

[@strengthcoachlondon]

Would love to see you guys machining a pair of 50lb, old school deep dish weight plates. Rogue made a beautiful set out of billets of stainless steel for the Arnold Strongman classic.

[@jestonporter5049]

Tyson is a BEAST!!! Freaking awesome job, dude!

[@compt3ck]

Drilled or slotted rotors are for venting gases created by the pads, cleaning of the pads and additional cooling. The issue with drilling is they are prone to cracking. With that small chamfer I would guess those wont last long if its in a high heat application.

[@mikemcmullin149]

Love the idea of lights out, it's machining at a master's level. Would lie to see this after the automation is installed and tuned.

[@gvi341984]

We need more videos like this for this channel. Now I want this channel to make a YoYo thats perfect

[@christophervillalpando5865]

Nice work! What a beautiful part!

[@byczektm1373]

Very satisfying and amazing job, but can you machine a vented rotor just to see what sort of challenges part like this makes?

[@skiinggator]

Like that Doosan. Impressive machine.

[@tubosolinas]

Those rapids first at X and then at Z are spookyyy

[@kdenyer1]

Production wise have a look at Cogsdill deburring tools you can deburr both sides of the hole at one operation.

[@Zerspanerkino]

i guess, your nc-control or at least your cam-soft could handle it: for facing give your boring bar a 45° rake angel, than you can face your parts at first op. and as a bonus you can raise/double your feeds too!💪

[@RealNotallGaming]

MMPR 0.08 is always the best for finishing a "rough" piece ^^

[@jonbravo9278]

I'm an auto detailer. Not sure how I even got here. But this is f-ing awesome

[@Jack-yl7cc]

I don't think I have ever seen a solid brake rotor that was drilled before, normally that is only done on vented brake rotors. Perhaps adding some custom designed "slots" to aid in brake pad cleaning would have been a better choice on a solid brake rotor.

[@nieljones6181]

so what happens when you resurface them? the holes are there.

[@MrChevelle83]

@@nieljones6181 you dont typically resurface drilled rotors, they are crack prone and usually 1 time use with any abuse. slotted can be resurface but you loose the slots performance so its basically pointless too.

[@nieljones6181]

@@MrChevelle83 ah. I see. Didn’t know that

[@Jatsekusama]

Great work as always! :D

[@hippie-io7225]

What machine uses this brake rotor ?

[@accumulator4825]

Just a car haha

[@mikehoncho5389]

It’s called a “KZbin” machine because that’s all it’s good for.

[@AATopFuel]

Cool! 130 lbs. starting weight. What is the finished weight? Thank You.

[@harry-eto]

Nice, but standard rotors are hollow for ventilation and less weight. Unsprung mass is relevant. 3D metal printing would have been my choice. Bugatti made the calipers of the Chiron that way.

[@SE4RCHING]

beautiful part!

[@rosewhite---]

I used to trepan the centres out of big stainless blanks to 15 inch diameter which was interesting. Then I threaded them and checked the thread size using three bits of 1/16 wire.

[@unholyorders8239]

That was awesome Tyson!

[@mohammedalbattal77]

The first one here .... like usual 🔥🔥 boom

[@XtermanboyX]

Question, how would you vent these rotors ?

[@wigglyworm4652]

Longer videos 😍finally

[@legggl8648]

I was once standing by a lathe with a 4 ton (around 8800pounds) part, which was spinning at around 700rpm, and i was scared in the beginning. i instantly took a few steps back as the spindle accelerated.

[@MrChevelle83]

I work around 15 ton parts spinning 125rpm and its still intimidating standing there even after years of doing it! I always think (what if the quill cone failed and this thing came sailing out of the lathe)

[@D3kKromb0x]

@@MrChevelle83 I kind of think anything that a lathe throws while spinning at 2700 SFM is going be terrifying regardless of how big it is.

[@jackimo22]

Can you finish the rotor and machine out the vented slots between the braking surfaces? This was some pretty simple machining otherwise

[@АлехаШахматист]

awesome

[@marmyofdeath]

Most cars these days have an internally ventilated brake disc. Are you going to put it on like that or are you going to put some internal ventilation in there too?

[@ВладимирСабиров-ж4й]

That's a badass music and sfx used in this video. Can i please ask add links to them, so I can listen it in full versions?

[@daveyt4802]

Can you use compressed air as a coolant?

[@bengrogan9710]

Depends on the material, a lot of the time coolant is also a tool life increasing lubricant

[@derekcook499]

Great video but just curious, why do you drill your holes before finishing turning and risk chipping a ceramic insert?

[@davidschnabel1304]

How did you deburr the backside of the holes? Do Cogsdill spring loaded chamfer bits work?

[@davegill8634]

Awesome Content As Always Tyson 👍

[@gadgetdeez7069]

While it's a very cool looking part, it's not a very functional one. Cross drilling rotors is actually for evacuation of off-gassing from heating the pads. As the pads heat up, they give off gas. This causes the pad to float on the rotor similar to air hockey. If the pad's not touching the rotor, doesn't do you very much good. Crossdrilled rotors also have a little bit of a shaving effect on the pad which will remove some of the material from the pad to prevent glazing. This adds to pad wear. Another thing to consider, there's no ventilation drilling in that rotor. So really the cross drilling is ineffective almost entirely. It is definitely ineffective at allowing gases to escape simply because both ends of the drill are plugged by pads. This is why a ventilated rotor is required for cross drilling as the gases will leave through the vents in the rotor. So hopefully this break fade waiting to happen doesn't get installed on someone's car. Regardless though, it's a cool looking part.

[@deamonengineer6107]

Is there any specific reason why the holes were drilled before the finish pass over the diameters, was the intermittent cut a preferred option over any potential swarf marks from the drilling op. or is this just down to personal preference

[@cuprakol]

Would have been better doing disc with a hub would have looked a lot better and would have been cool to see you vent it as no car has a solid disc where I live .

[@nobodyelse-h6h]

For that matter wouldn't be stainless steel a nice alternative?

[@NoName-bf6ty]

I love working wiithh cast iron (said noone ever)

[@ChrisBrown-dy8ts]

Horrible stuff, makes a right mess of machine and operator. Always rough out on old machine then finish on newer lathe.

[@xCaptainKlutch97]

Now do a 24 inch aluminum rim with a cool milled out design!

[@MasterKozuko]

Wondering if you chamfered the thru holes back side of that rotor?

[@brandonlittle6444]

Who's S13? No venting, or rear chamfer? What model is this for?

[@kleini3]

Dat spirals after the drill goes out of the bore 😬

[@crissrivera9560]

Please Some Videos for A2 Tools Steel and SS420 We use a lot of this material on our shop for plastic Injection Molds Thanks!! Nice video!

[@teemuronkainen]

Next time make this with milling machine!

[@wannabecarguy]

FYI. The big boys run full float rotors.

[@elliottwhatley7365]

can you make disk break rotors for my 1972 ford pinto front.

[@sHpAaKu316]

no vents in the rotor?

[@MillTurn4Life]

I cant see much of a geometry on the rough turning tips almost look like diamond tipped inserts lol

[@georgeowen2083]

Don’t you have to worry about distressing cast iron because it will warp?

[@TheOutbackIndustries]

Just asking why would you drill before your finish pass? Does the interrupted cut not have a chance to damage you ceramics or cause bad finish? It obviously worked just thought about that when I was watching and wondering if there is a reason behind it.

[@soundspark]

It was only .010" wasn't it?

[@BrilliantDesignOnline]

Backside hole chamfers?

[@darikmatters8866]

What is the total run time if you just hit start and let it run all the way through without stopping??

[@Fale222]

BEAAAUUUUTIFUUUUL

[@andrewbeaton3302]

Haha shittttin my pants over here ! Mind blowing

[@wilclark2562]

My guy, I love the quality and information of the video, but for the love of god please blink when talking to the audience, it’s a little unnerving. Other than that great video and fantastic show of all tools used.👍

[@rmorris3722]

I thought there were more brake rotor makers. Any were super expensive.

[@ohlangford]

Can you compete with OEMs ? Is it cost effective?

[@brandons9138]

No, and no.

[@johnlocke617]

Isn’t cast iron self lubricating? Wouldn’t be my first option for brake disks, just saying. Cool video though

[@philelliott2685]

What are your disks made of? unless you're pushing an awesome car with ceramic disks then they're very likely cast iron like they've always been.

[@iamtyzed]

This is so cool

[@oneiros1401]

Final weight? Test on an actual car?

[@Mrdubomb]

what does something like this cost?

[@declanwilson4230]

So why run this without coolant? I’d like to know bc I’m curious about this part and cast iron machining

[@nerd1000ify]

Cast iron is full of little graphite flakes or nodules (depending on the type of iron) so it basically self lubricates when being cut. It also makes a fair bit of dust while being machined, when the dust mixes with coolant it makes a kind of sludge that is a big pain to clean up.

[@MegaEmmanuel09]

Wow, I wonder how many grams were shaved off during the finishing and deburring stages

[@bobski1151]

Next up, titanium dinner plates. ;D

[@Jessie_Smith]

OOooo that is interesting 🤔 unless I forget and put it in the microwave 🤣

[@michaeltuckerman6983]

You're a beast

[@SprDrumio64]

the safe start rapiding gives me a heart attack every time, going straight down to the z first and then going x just makes me go dizzy

[@Jon-O.]

Nice work but the vanes need to be in there should've drilled them and step milled them.

[@Turboy65]

There may actually be a market for these as a premium grade brake rotor. Chinese made cast rotors are such garbage that usually warp pretty quickly. If you can make these at a competitive price, there's a business model.

[@darikmatters8866]

Actually, most rotors are actually made of cast steel, not cast iron.. That being said, a rotor for my MAXIMA runs about $80 and "high Performance" 180-350 retail ... All of them are internally vented so they are complicated castings and most are coated.. These are high volume production items that are very hard to make a profit on

[@MrChevelle83]

No way they could be cost affective at their shop hr rate. 1 hr would easily eat the cost of a part store rotor. and they work pretty good but you gotta turn them after they get seasoned because they dont add enough iron to cheap ones now days.

[@mikehoncho5389]

The rotor they made might look nice but it’s 💩 engineered without venting and it probably weighs a ton. Nobody would buy a “solid” rotor for a performance application.

[@peterdouglas4073]

Your going to have to make a second rotor now. Can't run odd rotors.

[@alishihade4751]

Good job but how you will debur the othere side, because you need to relocat the part.

[@whtkngofc]

Dial indicator

[@gungan5822]

I've never seen an un-vented rotor on a front brake before.

[@itaco8066]

Cool

[@sjorsnabben3832]

Listen at 6:25 he said the wrong thing and they put the correct insert name in afterwards😂

[@sundarAKintelart]

What's the weight of the finished part 🤔

[@peterismyfirstname2872]

Memorial Day in America. Life has it's ups and downs. Just for something different. Completely different but related. Same same but different. Interesting topic. Interesting dramatic 'just the facts mame' old school news delivery. Non-emotional, clean, clear, effective and efficient Ward Carroll is all that. He landed airplanes on boats for a living, a Retired US Navy Top Gun Pilot. The story of service members is related. Link not included but the search word is: 'THIS FIGHTER PILOT EJECTED INTO A THUNDERSTORM AND LITERALLY RODE THE LIGHTNING' ⚡WARD CARROLL YT CHANNEL 🇺🇲 Vets👍♥️🥇 Happy Memorial Day.

[@guisado1002]

Boom

[@MrArray1967]

Bet, you can't make *Dannebrog* even though it's graphically way more simple ... 😉 🇩🇰

[@steveanderson4768]

What I’d like to see your knees is you spend X amount of time writing the program and we spend X amount of time on the machine just so that we have an idea of time and effort because you guys make it look so easy a damn good job though

[@djsmola1]

Beautiful machining. I always watch, but this brake disc is unfortunately useless.

[@NSResponder]

We are living in the future. It won't be too long before your neighborhood mechanic won't need to keep any inventory besides steel and aluminum bar stock and billets. Need a rotor? Look it up and make it. Need a brake cylinder? Same thing.