Making a part: Flux capacitor bushings

Adam the machinist, Low profile V-Block:
• Hard Milling a V Block
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#practitioner_of_the_mechanical_arts

[@hashgeek929]

I strive for everything I do to meet Stefan’s definition of “not too bad.”

[@siegfriedkettlitz6529]

You should set realistic goals.

[@timoruohomaki]

If I understood it correctly, "not too bad" equals about 5 microns. Should be ok for most.

[@Hoaxer51]

@@siegfriedkettlitz6529, Lol!

[@georgehelliar]

It's akin to Clickspring's 'presentable'

[@thebonermaker]

Don’t we all?

[@Cookie-cn2jc]

Between you, Adam and Robin the world is very different in an interesting way. Thanks.

[@StefanGotteswinter]

Thank you!

[@crichtonbruce4329]

Good Morning from Canada. You are quite a gifted presenter: Clear, concise, and articulate. I also admire your editing skills: that was quite a number of processes condensed into that time frame, but nothing left out. Thank you again.

[@peterhadfield873]

I'm a little surprised that the flux capacitor isn't finished yet. Still, I'm enjoying the build series :-)

[@simonhopkins3867]

It was finished. Just not yet! 🤯

[@robertpearson8798]

He’s still waiting on the Mr. Fusion to arrive from Amazon to power it up.

[@iteerrex8166]

We’d know it’s finished, when there’s no more content, cause he’d probably leave this time period. Lol

[@spitefulwar]

@@robertpearson8798I fear Elon's got his hands in this holdup

[@StefanGotteswinter]

No Musk in my projects.

[@FZ1nbiker]

The line "not too difficult" was where I lost hope in my ability. another great Vid!

[@durkee8713]

Nothing better than Saturday morning cup of coffee and a new Stefan video 👍🏻

[@russellforrest1730]

Fascinating to see your strategies for dealing with carbide. I know what you show depends upon the jobs you get in and the if you get permission to film, but really enjoy seeing more exotic materials.

[@spitefulwar]

Even packaging material is prepared to close tolerances by the master!

[@jrkorman]

I never realized that "Flux capacitors" had so many parts. Well done and yet again interesting.

[@EdgePrecision]

You know the best day in a wire EDM owners life. When he sells his machine. Your right running a wire EDM was one of the most aggravating machines I have ever run. Also there are a lot of cosumable supplies that cost money. By the time you pay for all that there is no money in it. Unless you have many machines running all at the same time and you’re running all of them by yourself. That is possible. I know a guy that runs 8 of them by himself. Only then can you make your labor cost.

[@StefanGotteswinter]

Sounds like owning a boat :D Thanks for chiming in on that topic, Peter!

[@billdoodson4232]

I love this channel, the precision, attention to detail and finish is so impressive. I suspect the tolerances on my parts in my home workshop are similar to the actual sizes of your parts. Well they are better than that, but you know what I mean.

[@Rustinox]

I didn't know it was possible to polish carbide that nice. It looks great.

[@ROBRENZ]

Very nicely done! ATB, Robin

[@campbellmorrison8540]

Ha, 3 days and they are back! in New Zealand they wouldnt have even got to the EDM shop let alone be finished. Love your work, even your packaging is precision!

[@thigtsquare950]

Those bushings remind me of my job at my dad’s. I used to polish similar materials for the wire drawing machines. They have a similar radius on one end, a conical shape at the “exit” of the wire and a cylindrical section, which created the diameter of the wire. We sized the steel wire to produce bolts, screws, nails etc. I was involved in all the steps of production: wire sizing, rod cutting, head and thread forming, heat treatment and electroplating. You know apprentice of all, master of none. 😁

[@thigtsquare950]

BTW short before CNC machines arrived to my country.

[@StefanGotteswinter]

Interesting, thanks for telling!

[@gregfeneis609]

I was thinking along the similar lines, like these might be guides for wire into some machine that works with wire. Perhaps straightening wire that comes off a spool, or winding straight wire into a round shape as for a coil or spring.

[@thigtsquare950]

@@gregfeneis609 they wouldn’t work for straightening wire. For that you need to break the elastic point in the wire’s bends. You do that by offsetting pulleys or rotating a die system. The rotating offset die system is the most used because you break the elasticity in every direction, not only in one. It’s hard for me to explain it better, I’m not that articulated.

[@gregfeneis609]

@@thigtsquare950 yes I'm familiar with the roller mechanism that you describe. I was thinking this part would be the entry nozzle to that roller mechanism you're describing. I wasn't thinking this nozzle would be the only thing required for wire straightening

[@perrypark8485]

Always get excited when you post, super cool

[@RookieLock]

Beautiful ! I love seeing these carbide parts !

[@jimsvideos7201]

You don't make it look easy but you do make it look _possible._

[@stephenlesbos6208]

Thank you for sharing your skills, knowledge and experience

[@dittagecoeco2738]

Once again I have loved the process and the reasoning. Thakyou Stefan ✌️

[@angelramos-2005]

Great detail work,Stefan.Thank you.

[@kevinkohler2750]

Watching you explain the order of operations you follow and the thinking behind that order is always interesting!

[@bobluthier3031]

thank you stefan, the knowledge and experience you offer is priceless.

[@CRUZER1800]

You always make your videos so interesting.. and this one is no exception. Well done! Russ

[@andrewh2341]

You never cease to amaze me with the cool things you come up with

[@garysgarage101]

Amazing macro shots Stephan. I know how small 1.85mm is. You capture these details amazingly well in your shots so we can all see very clearly what you’re doing on those tiny parts.

[@brianmccusker3852]

Well, that was fun to watch, particularly on a new project. Very rewarding to see the use of parts you've acquired and made over the years that I've also been able to watch. Thanks Stefan, best to your cat and cheers.

[@noberet]

Really nice work. Thank you Stefan!

[@warrenjones744]

Always informative you are Stefan. I really enjoy the tool descriptions and your thought process of why you use the methods you choose. cheers

[@nicklimuti5186]

Great video, as always. That ID surface finish could most likely be improved even without polishing by finishing with a resin-bond mandrel, or by slowing the part rpm slightly and the traverse fairly considerably on the finish pass. Though you'd still be left with some of the artficating from that one crystal on the plated mandrel that's proud of the rest in the latter case. Also, the bell-mouthing of the part isn't due to the pressure decreasing, that would actually do the opposite. It's because the total pressure remains pretty close to the same, but the contact area is considerably reduced, resulting in a higher pressure per unit of surface area contact. At least, that's how it's always been explained to me over the last two years in a precision grinding shop.

[@Gottenhimfella]

Remembering than English is not his first language (and taking into account his considerable grasp of issues related to accurate work) I think what Stephan probably meant is that as the mandrel is stroked out of the bore, the centering "pressure" (really, the proper word is force) on the diamond mandrel drops eventually to zero, so that the mandrel will nutate (wobble) due to geometrical and balance imperfections in the rotational movement. Because of the high rotational speed, centrifugal forces will make the nutation self reinforcing. When it is in the bore, it becomes somewhat constrained from that wobble, as the hole acts like a steady. Consequently on re-entry to the bore, bell mouthing is inevitable, because initially it is easier for the mandrel to cut the work rather than be deflected, (because of the higher "pressure per surface of unit area" you mention - again, it's really *force per unit of area* . Which is what "Pressure" actually means, technically speaking). This progressively changes until it enters far enough that there is enough contact with the mandrel for deflection to be easier (produce less bending moment) than cutting, so as to largely eliminate that nutation. But in the meantime, a subtle bell or trumpet mouth is being formed at each end. Nutation only predominates when the cutting portion of the mandrel exits and then re-enters the work. The effect you describe (which does not involve nutation) also happens, but it's much more subtle.

[@Gottenhimfella]

I re-listened to Stefan to make sure I had not misunderstood his intent. He says it's important not to stroke too far out, or completely, because you will "suddenly lose pressure on the diamond tool". So it seems clear to me that he's talking about the steadying pressure [by which he clearly means force] (which is lost altogether when you exit the hole, and compromised as you get near to the exits). It is not plausible that he would not know that a loss of CUTTING pressure involves LESS material removal, not more.

[@StefanGotteswinter]

Thanks! Agree on the reson bond mandrel. As for the bellmouthing - What you describe is what I tried to say :D

[@nicklimuti5186]

@StefanGotteswinter I figured as much, it just seemed like a useful clarification to make. Thanks for all your work and teaching, Stefan. I've learned a lot from your channel. Looking forward to the next one!

[@nicklimuti5186]

@Gottenhimfella Yeah, I didn't mean to imply that he wasn't aware of the mechanics of the situation, I was mostly just trying to clarify for anyone who would not have understood what he was trying to say, as the intent of the message and the actual words just didn't seem to line up. Stefan is on a whole different level than most of us, and I have a world of respect for the man's talent and willingness/ability to teach. On another note, thank you for continuing to clarify the topic, as your input on the scenario of fully withdrawing the tool means the whole situation is described here pretty well.

[@TheTacktishion]

Good Content... ! Well presented.... As always, great camera work.... Thanks for bringing us along....!!!

[@robertfontaine3650]

Always worth watching. Thanks

[@williammills5111]

Very nice. An interesting challenge, well met. Thank you for sharing. Love the low-profile tag team of your indicator holder and Adam’s workholder 👍🏻👍🏻!

[@StamD65]

Outstanding attention to detail,great explanations,keep it that way,maestro!

[@DudleyToolwright]

Great video as always. Be aware that the binder in Carbide blanks is usually Cobalt, which is moderately toxic. I am speaking about the residual dust that you are wiping off of the dovetail ways, etc.

[@StefanGotteswinter]

Yep, very aware, thanks! The dust extractor is rated for "it will kill you slowly and painful"-materials and I wear a mask when doing major carbide work.

[@jdmccorful]

Wow, A + for details and content. Always enjoy!

[@LikeFactoryMade]

Thanks for this great video! Happy to see that so many people are appreciating your content! Cheers! 🍻

[@StefanGotteswinter]

Thank you!

[@elluisito000]

What would do the flux capacitor industry without Stefan? 😊

[@StefanGotteswinter]

They would be OUTATIME.

[@HP_rep_mek]

Fantastic finishes, as always Stefan👏

[@cylosgarage]

Superb, Stefan!

[@StefanGotteswinter]

Thank you very much!

[@ashreid20]

we have some parts at my work that we currently send out for manufacturing elsewhere that i am figuring out if we can do them in-house. very interesting video and lots of good information to consider, thankyou. oh, the dust extraction through the spindle of the lathe is top tier. we have a dedicated lathe to turn parts from carbon also, so i am definitely implementing that on it.

[@FireandFrostHVAC]

“My friend has a wire EDM in his barn “… 🤣🤣🤣 Only a German could say something like that.

[@wambsganz8]

I really love your dust extractor on the Lathe.

[@bclare2544]

Nice work Stefan.

[@rexmundi8154]

Excellent. I learn something every time

[@user-wx4oy6yi9s]

Hi Stephan, these bushes look like the bushes we use on our gundrill to guide the drill into the face of the barrel.You can get any size you like made from TBT in Germany.

[@richardmorton1310]

Stefan always makes what to me seems not possible, possible and as always it's amazing.

[@wktodd]

Great work as usual. Good macros too.

[@adhawk5632]

Gotta work that algorithm😉, thanks again for sharing 👍👌🇦🇺

[@shawnhuk]

Stephan has finished his bushings, and here I am still reorienting my Cincinnati T&C grinder….

[@Jimmeh_B]

P Horn. I wake up with one of those every morning. I know... I'm a child. Great vid!

[@StefanGotteswinter]

Sir, this is a R-rated channel :D (Also if you leave the "h" out of phorn, you end up in the deep hole drilling section of the internet.)

[@Jimmeh_B]

@@StefanGotteswinter 🤣

[@Andrew_Fernie]

@@StefanGotteswinterthat's dependant on the aspect ratio of the tool you're using

[@Agnemons]

And the Dioptic of the viewing tool @@Andrew_Fernie

[@kusler67]

Thanks for the video!

[@alungiggs]

Fascinating. Really informative and enjoyable. 🙂. Thank you 👍🇳🇱

[@briandobrich1513]

These would be perfect for my ultimate thread guide setup.

[@adamthemachinist]

The cnc did a great job in those radii

[@StefanGotteswinter]

Yeah, way better than I would have expected, going into that project.

[@Watchyn_Yarwood]

I am mathematically challenged, just so you know, I am totally amazed at the radius' you produced! For the life of me, and it tried to learn on my own, I cannot imagine how you calculated those so perfectly. As with everything you do, perfection! Thanks for sharing with us!

[@Maskinservice]

I knew it! I knew it already in the eighties when I saw the films that there must have been a Gotteswinter somewhere in the making of the special time travelling variant of the DeLorean! 🙂 As always, a fantastic film of a fantastic job. Thumbs up!

[@user-pd5ot4zd4b]

Wow, beauty parts!

[@troyam6607]

23.04 the noise made when Stefan dropped the grinding bit is the tolerance noise reaction i aim for in my work if he was to inspect it. 🤣

[@pipikr]

Love these noise canceling cutting discs and sawbands :D

[@clintchapman4319]

Nice work! You're a clever fellow! I didn't know you sold products... I'm going to get a set of those stones as soon as I figure out how to order it. Keep up the good work!

[@ElixirCNC]

You mentioned struggling to get Fusion 360 to climb from top to bottom, at around 24:00, under the passes to, find pass direction and input 180°, then it will start from the top.

[@dragosmates]

Very nice!

[@MrMojolinux]

Impressive work! I used to run a Moore Jig Grinder "back in the day" and hated grinding carbide.

[@StefanGotteswinter]

Thanks! Interesting, i prefer grinding carbide a bit, because i find material removal way quicker than on steel. But it comes with its own challenges.

[@paulsto6516]

Impressive. 👍

[@TrPrecisionMachining]

good video stefan

[@klugkluk]

Posted 19 seconds ago, already liked 😂

[@Michel-Uphoff]

Schön gemacht, Stefan! Emmett Brown wird mit diesem neuen Teil sehr zufrieden sein.

[@HexenzirkelZuluhed]

Spannend!

[@flyingjeep911]

Wish I had a friend with a edm in his barn.

[@miguelangelsimonfernandez5498]

If you polish the interior you are preventing any lubricant from working properly and it could cause premature wear of whatever turns inside those "Flux" caps.

[@advil000]

"Friend has a wire EDM in his BARN."... sounds like something I'd do.

[@globalrezzanate9399]

I was under the impression the through hole was part of the sintering process.... The same way they produce the helical coolant holes....?

[@StefanGotteswinter]

Usualy yes, but on that blank it was definetly burned.

[@simonhopkins3867]

33 minutes of goodness.

[@jobkneppers]

Stefan, a tip; if you ever used a woodcutting saw at a piece of cardboard you'll notice that the saw gets blunt really fast... Same goes for a bandsaw I discovered too... Best, Job

[@StefanGotteswinter]

Damn, yeah - Cardboard and Paper is realy good at dulling cutting tools. I find it less critical with bandsaws, but knife blades and circular saw blades realy take a beating. Another brutal things for blades is Rubber.

[@heighRick]

I'm not jiggly, you're jiggly ...thanks for the video Stefan, helps a lot!

[@bigbird2100]

Great video 👍 This customer sounds like he needs drill bushes,one day you will have your own EDM machine 😊

[@phillipyannone3195]

Reminds me of bushings for wire drawing machine.😊

[@StefanGotteswinter]

Very similar, yeah. As far as I know, these are not for drawing.

[@supatipannobhagavato]

Thanks Stefan, I'm always wonder how diamond bur will act in CNC milll/router.

[@donteeple6124]

As I was watching, I was about to comment and ask....What no diamond paste and polishing.....I should have known better.....lol.....Great work, outstanding presentation. Loved it.

[@ryebis]

Good demonstration. I see you still have the emco around :)

[@StefanGotteswinter]

Nope, its gone :-) Thats old footage from January.

[@user-bg8bz4uf8s]

I wish you could give a ballpark number for the cost to the customer for some of these small parts sometime. I worked in a R and D company in my younger years working with machines to smooth out workflow on production lines in the bottling industry. The amount of cost that goes into small and single run items can be staggering.

[@StefanGotteswinter]

Imagine a 100ish price tag for an individual part on this order. It was on the cheap side, because I also took it as an learning opportunity.

[@kepamurray1845]

Nice to see you using cardboard for your packaging. We use far too much plastic for my liking.

[@StefanGotteswinter]

Yeah, I try to use almost only paper and cardboard for stuffing material. Unfortunately theres no substitute for small plastic bags and some plastic foil.

[@iiredeyeiiredeye1569]

A very nice little project Stefan. I'm wondering if you considered having the bores and radius spark eroded?

[@StefanGotteswinter]

Yep! But then I would only have cutting them to length left to be done by myself ;)

[@JohnChuprun]

Awesome job! I always pick something up from your videos. Also, I'm impressed by your English skills.

[@notsonominal]

Not too difficult and okay results. The bar has been set!

[@Stan_in_Shelton_WA]

You have more than surface finish concerns. The EDM does not remove all constituent metals equally. Think of a sponge. It is important to use grinding or lapping of some sort to get the final dimension. The carbide will wear rapidly if you rely on the EDM produced surface. I experienced this at a place I worked.

[@sylvaingervais247]

SALUT MERCI

[@R.Daneel]

Just had a weird thought. Could you use a camera to center-find? Have fixed feducials on the machine as reference, a perminently mounted 4K cam, and use something like OpenCV to find the center of a mounted part and pass that to the DRO? Basically adding Pick&Place location finding to machining? Probably already available in a box from Wish ;-)

[@ydonl]

Shiny!

[@ryanjordan7113]

Did you try to reverse the chain to climb up and out?

[@greglaroche1753]

Thanks for another interesting and informative video. I didn’t recognize your D bit grinder. What ever happened with the Asian import one you were remaking ?

[@StefanGotteswinter]

Thats still beeing remade :) The machine used is my Deckel S1 tool&cutter grinder.

[@windrk_6754]

@@StefanGotteswinterI was wondering if it would make sense to grind these bores on the S1.. I guess it depends on how well one can eliminate runout & taper in the workhead, & the ease of mounting the high speed head. Great content! Thanks.

[@stevensmart8868]

Awesome work once again. I might have to use some of these techniques soon, as i have to try to improve the surface finish of some small blind 4.5dia14d deep tantalum parts. I might make a lap(never done this before)Any thoughts?

[@StefanGotteswinter]

lapping a blind bore is rather painful, I have to say. You might need multiple laps, maybe even one, that is only a narrow band with nominal diameter on the front, so you can work the end of the bore, without bellmouting/wideing the remaining bore. If its only for surface finish, I would try polishing wood, cut with a nice, crisp sharp end, and some diamond compound to polish the bore that way.

[@MarkW321]

Well done. Do you like your digital Mitutoyo micrometer? Is it better than an analog micrometer?

[@StefanGotteswinter]

Yes! Its the Quantumike with 2mm pitch. Love them, would recommend them 10/10. Just bought the 25-50.

[@MarkW321]

Cool.@@StefanGotteswinter

[@aserta]

9:04 careful, that's some high grade cardboard. Might dull the blade. :))

[@SELG88]

Last emco Vid 🥺

[@bcbloc02]

Ever machined zirconia?

[@jamesdrake2378]

I heard that Abom 79 taught you Fusion 360. He did a fine job.

[@StefanGotteswinter]

He is doing well.

[@matttradie1341]

Looking at what it takes to machine carbide, i have a dress ring (to wear on my finger) that is supposedly carbide. Was about 300 AUD 🇦🇺 but im kinda suspect now what sort of carbide or whether its carbide at all. Its certainly shiny and tapered conically after years of wear. Seems kind of cheap for the work. Even has a pattern etched into it and is laser engraved on the inside with branding etc.

[@Gottenhimfella]

Stefan - Did you try wire drawing dies or extrusion dies as a possible source ?

[@StefanGotteswinter]

Yes