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.

[@CameronMcCreary]

When I worked for a broaching shop when I was younger, I made the electrodes for the Sodick wire EDM machine. One has to know what their doing and have plenty of patience. It would take me about 3 hours a piece to make one electrode. The hole was the most precise area of the part. I used to grind inside bores with a Precise high speed air driven and liquid cooled head. High speed heads do a wonderful job on bores. Stefan does very nice and precise work on carbide. I can really appreciate watching him work the carbide in real time.

[@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.

[@iTeerRex]

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.

[@graveneyshipright]

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

[@apache16492]

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

[@apache16492]

@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!

[@apache16492]

@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.

[@ROBRENZ]

Very nicely done! ATB, Robin

[@durkee8713]

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

[@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

[@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.

[@Rustinox]

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

[@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.

[@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.

[@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.

[@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!

[@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!

[@jrkorman]

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

[@TheTacktishion]

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

[@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!

[@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.

[@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!

[@adamthemachinist]

The cnc did a great job in those radii

[@StefanGotteswinter]

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

[@richardmorton1310]

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

[@cylosgarage]

Superb, Stefan!

[@StefanGotteswinter]

Thank you very much!

[@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 👍🏻👍🏻!

[@spitefulwar]

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

[@jimsvideos7201]

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

[@briandobrich1513]

These would be perfect for my ultimate thread guide setup.

[@andrewh2341]

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

[@wambsganz8]

I really love your dust extractor on the Lathe.

[@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.

[@CRUZER1800]

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

[@RookieLock]

Beautiful ! I love seeing these carbide parts !

[@nigelcole-hawkins]

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.

[@kevinkohler2750]

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

[@perrypark8485]

Always get excited when you post, super cool

[@LikeFactoryMade]

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

[@StefanGotteswinter]

Thank you!

[@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.

[@stephenlesbos6208]

Thank you for sharing your skills, knowledge and experience

[@bobluthier3031]

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

[@Michel-Uphoff]

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

[@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.

[@dittagecoeco2738]

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

[@StamD65]

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

[@HP_rep_mek]

Fantastic finishes, as always Stefan👏

[@adhawk5632]

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

[@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.

[@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. 🤣

[@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!

[@pipikr]

Love these noise canceling cutting discs and sawbands :D

[@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

[@robertfontaine3650]

Always worth watching. Thanks

[@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.

[@bclare2544]

Nice work Stefan.

[@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.

[@noberet]

Really nice work. Thank you Stefan!

[@angelramos-2005]

Great detail work,Stefan.Thank you.

[@rexmundi8154]

Excellent. I learn something every time

[@kusler67]

Thanks for the video!

[@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.

[@paulsto6516]

Impressive. 👍

[@wktodd]

Great work as usual. Good macros too.

[@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

[@alungiggs]

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

[@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.

[@user-pd5ot4zd4b]

Wow, beauty parts!

[@ryebis]

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

[@StefanGotteswinter]

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

[@TrPrecisionMachining]

good video stefan

[@JFirn86Q]

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

[@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 ;-)

[@elluisito000]

What would do the flux capacitor industry without Stefan? 😊

[@StefanGotteswinter]

They would be OUTATIME.

[@dragosmates]

Very nice!

[@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.

[@heighRick]

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

[@RodneyHayes-d3y]

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.

[@klugkluk]

Posted 19 seconds ago, already liked 😂

[@HexenzirkelZuluhed]

Spannend!

[@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.

[@flyingjeep911]

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

[@notsonominal]

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

[@shawnhuk]

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

[@bigbird2100]

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

[@bcbloc02]

Ever machined zirconia?

[@ikkiiiieee]

what compressor do you use to be able to continously run that spindle?

[@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.

[@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 ;)

[@advil000]

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

[@KerseyKyle]

What guidelines do you have for using the proper Erowa pallet size? how heavy of a cut can you take with the ITS 50 pallets vs the ITS 100? am I being overly cautious by wanting to use 148 PowerChuck for most fixtures? It appears that you use ITS 50 size.

[@simonhopkins3867]

33 minutes of goodness.

[@ryanjordan7113]

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

[@Cancun771]

So why is it necessary to first avoid any bellmouthing when you then go on to flare the bores anyway?

[@StefanGotteswinter]

The Bore has a backside too ;) I dont want that to bellmouth either. Also its easier to determine the bore diameter if its not all weirdly shaped. Also: Its good training to learn how to grind a bore without bellmouthing. And I take every opportunity to hone my skills :)

[@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

[@flikflak24]

Hmm. Wondering if you had a low profile chuck with a motor under it standing up on your mill wouldn't you be able to do the movement in one go where you don't wear that much on the axis's on the mill ( kinda useing the mill as a lathe with live tooling ) ? Only asking since that's one of the few things I haven't tried myself

[@StefanGotteswinter]

Yep! Thats what one would do on a machine with a C-Axis (5-axis cnc).

[@flikflak24]

@@StefanGotteswinter or just a slow simultanius 2D action/movement ( X and Z ) and a moter with a chock spinning independed of the machine it self we just used it at work a few weeks ago and it worked perfectly or haveing the part in tool holder and diegrindr standing up in a vise ( that way the mill will pretty much become a lathe with live tooling in. did that back as a apprentis with flarless resoult's. good precision. stable process. good serface finish and fast )

[@DylanEdmiston]

Do you recall your step over?

[@marclevitt8191]

What kind of carbide is that? I am curious about getting carbide like that in different sizes and shapes. Could a water jet produce those cylindrical blanks from a solid brick? I don't know if one could create the hole feature with a waterjet, although an undersized one seems possible. I believe its accuracy is around .001 inch. I recently acquired a Flow Mach 200c that is five-axis so that it can do bevels. I think that the radius you made would be impossible with a Waterjet. I was told when cutting carbide, I need to use aluminum oxide instead of garnet for the grit, which wears out the jet tip more quickly. I think that the tip is made from carbide.

[@StefanGotteswinter]

Thaths the carbide blank used: horn-eshop.us/en-US/product/wos080-330-00-08-0-hk1f The OD is already ground very precisely, that would be an additional step when doing waterjet cut blanks. But I imagine for cutting general blanks it would be a cool tool.

[@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.

[@FireandFrostHVAC]

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

[@jtambor1]

Can you share the make and model of the grinding spindle? Thx!

[@StefanGotteswinter]

The Air spindle? Its most likely a WG USF, but thats only by pictures and what people told me about it, it has no markings.

[@StefanGotteswinter]

A NSK Planetor 700 would be very similar and easier to obtain.

[@jtambor1]

@@StefanGotteswinter Thanks! Been looking for something like this.

[@Gottenhimfella]

@@StefanGotteswinter Google cannot provide a single hit (in verbatim mode) for NSK Planetor 700. Is there a typo?

[@StefanGotteswinter]

Ah, mixed up my spindle names. NSK Planet 550 NSK Planet 400