Mazak Integrex Machining NASCAR Crankshaft from Solid - Addy Machinery

[@punishmentforall]

It's beautiful and sophisticated equipment - but hats off to the thousands of machinists who used to make crankshafts on MANUAL mills.

[@addymachinery]

Let me try to explain again a few things... First, this video is approximately 15 years old, and it shows how one of the earliest Mazak Integrex machines could make a crankshaft from solid material in a don-in-one process. Our customer here was a major (MAJOR) racing team who challenged us to make cranks from three different types of stock: (1) solid billet, (2) casting, and (3) forging. Each type of stock taught them, and us, something we were both looking to learn. This particular demo ran dry purposely so that the camera could "see" everything that was going on. Once we showed that the Integrex could make all of these various cuts, including the gun drill, we proved that we could produce just about any kind of crank from about any kind of material. This video's purpose is to open your mind and to allow your imagination run a bit wild.

[@hrbestalkinme3690]

This video was intriguing to me. I am a mechanical engineering student, I work for a big name motorcycle engine manufacturer. I desperately want a lathe and mill of my own. Even crappy ones would do!

[@jordanloveless8647]

You guys sell my employer machines. I'm curious why a machine similar to this wasn't sold to us for our crankshaft machining processes.

[@jordanloveless8647]

Also, do the journals on the crankshaft need to be polished post machining or is the surface finish good enough for immediate installation?

[@jitendarsaroj366]

Fppp

[@wernerdanler2742]

I saw your comment that the part was run dry so the camera could capture the action but I am surprised the tools held up at all. I used to run all kinds of NC, CNC lathes and mills in the 70s and 80s. It would never have occured to us to try that. I ran parts on an electronic tracer mill that had tolerances of +0.0/-0.005 on a 6 inch span on a titanium part. Amazing what these machines can do. It's all in the setup.

[@F22xSTEALTHx]

aww man that first cut just sounds beautiful

[@ranyothman5211]

The people who write the code for these CNC machines are legends now.

[@MrHeatscore94]

and replaced with master cam lol

[@ranyothman5211]

haha, this is true.

[@koolbeenzbro]

This by no means is an easy accomplishment even with mastercam.

[@scottgolden2766]

koolbeenzbro My old boss did not like doing holes. Drilling the oil hole on a angle like that must have been tough to get right

[@if66was99]

And just saying... Math ALWAYS works. Interpolation, Cartesian coordinates, Trig, Geometry. Math will NEVER lie.

[@Fujibayashi50]

What are you even trying to say? Are you trying to feel smart by throwing around words from High School?

[@if66was99]

​ @Distropital Be nice nice man. Just because you're on the internet doesn't mean you have to be a "richard" I've forgotten more college math than most people ever heard of. Math ALWAYS works. There's always 3 or 4 different ways to prove out a theory. COMPLETELY different ways and they all come to the exact same conclusion.

[@pootinplays]

be sure to turn your headphones up before playing

[@Boerje69]

Was this filmed with a crankshaft?

[@Mr.Saephan503]

Boerje69 - it was filmed with a potato sitting on a crankshaft lol

[@addymachinery]

Notice at 5:00 how the endmill creates a flat on an angle to prepare a flat entry surface for the forthcoming gundrill. 1000 psi is a very affordable option on the Mazak Integrex.

[@fredrezfield1629]

what about the chamfering part ? or is that chamfering which operation is that and do you recall how you modied your turning holder or boring bar?

[@vaidhyanathk.a.6439]

Beautiful utilization of a TURN MILL Centre, great video and great work.

[@forrestaddy9644]

Funny thing: I'm an Addy too. There are few of our family name in the US and those I've contacted descended from a few families who immigrated from England about 1880 to eventually settle in coal country in Wyoming and Utah where my dad was born 1911. Another funny thing: I'm a machinist too. I started my apprenticeship in 1961.

[@shamu3838]

The video resolution on is truly amazing.

[@macroevolve]

I was a CNC tool grinder for ten years, and just made the switch to (Mazak) CNC Lathe. It's a big learning curve on the program language, and that type of machining.... for me. I was expert on the Okuma grinder.

[@guygaric940]

i love the way the shredds twirl around

[@mikemai8568]

Hello Steve Addy, I can't wait to see your new videos with today technology.

[@twlvhrs]

The Precision is what facenates Me

[@MadsWorld34]

I love stuff like this thanks for the video. I was surprised at how much cutting they did dry.

[@lurch1e]

Most milling of steel and cast iron is recommended to run dry. I have seen massive improvements in tool life by just switching off the coolant. The reason for this is that the new TiAlN coatings like to run at higher temperatures and no thermal cracking occurs. The reason for the lubrication on the oil hole drill is to get the swarf out of the hole. On a drill this size, around 5mm, high pressure coolant of around 80 bar or MQL is recommended and definitely no pecking.

[@RomeoRomeo5000]

Steve, Thanks a lot for that video but obviously it wasn't really a NASCAR c/s because it was a 4-cylinder c/s machined in the video? And was AS 1045 the number of the steel, as opposed to 4340, etc.? After the crankshafts are roughed out in the CNC, do you guys finish grind them? I was surprised at that long drill with it's own coolant holes. That was trick! I loved the video; just wished there was more intricate info.

[@OstazFarid]

thanks...very nice work to make crank from solid metal...

[@NIGHTLAMP12345678]

I don't know which noise is worse the tool cutting or drawing your finger nails down a chalk board.

[@dmbadcat]

1:10 music to my ears

[@Obelus_OG]

this beat kinda hit, damn

[@1Plebeian]

that tool change is badass

[@danielhoffman2299]

One awesome piece of equipment ya got there my boy.....

[@freddietz96]

Makes me wish I studied engineering instead of art in college. Something either works or it doesn’t-no politics, no complaining.

[@headfirst6227]

Working where I work might make you change your mind. We make palletizers for the canning and bottling plants and we have plenty of complaining and politics. This company claims to be "people-centric". It's just a way of saying they are going to involve themselves in every aspect of our personal lives whether we like it or not. The jury is still out on the legality of this.

[@freddietz96]

Sorry, couldn't help but laugh. But that's actually a pretty serious injustice. I can't count the number of times I've heard "people centric"--just another political football. Usually comes with lots of lawyerly small-print your micro-managing employer fails to show you. I'll spend the rest of my life trying to keep away from that, if I can.

[@DieselRamcharger]

***** first time I've heard of this. crazy stuff. so glad i don't work in big business any longer.

[@freddietz96]

***** Funny, how my comment got me less responses about engineering and more about the greed and chauvinism of today’s employers. And though I still don’t think anybody wants to switch over to traditional Marxism, you can’t help thinking this was never such a widespread issue in our country. At least not through most of the 20th century. You used to be able to go to your job, get paid a living wage (here in the Mid-Atlantic that’s a little more than $20/hour), and you were known mostly through your participation in “community organizations”-church, AA, Moose Lodge, spiritualist group, self-improvement group-whatever. But it wasn’t this case where your employer pays you squat, then keeps tabs of your personal life as though you were a specimen in a jar. But we also didn’t used to have a “permanent war economy”-or a permanent war mindset. WWI was our first overseas war, one which proved immensely profitable for everyone besides the men who fought it and the civilians they bombed. Unfortunately, it seems the men who profited were in a position to start buying up our news media-which they then did (AP is largely under the duress/oversight of Reuters, and has been since...sometime around WWI). And so, a few short years later, instead of still hearing horror stories from WWI vets, these were replaced with calls for yet another expedition to Europe. Then one to Korea, and another to Vietnam. In the process, we “fought” the cold war-a state of constant readiness (along w/ constant expenditures on lots & lots of bombs). Then, cold war over, suddenly in the mid-1990’s we’re bombing Osama bin Laden in the middle of a desolate region nobody knows about (except for it being the world’s supplier of opium-if not also a highly strategic area for both possible oil pipelines, as well as for launching still more wars against oil-rich nations). So, my point is we no focus on anything within our own camp. Instead, there is now this ever-constant “unseen foe” lurking...somewhere...and it’s supposedly our sworn duty to go off and fight him. And so nobody gives a damn about American community-“It’s a Wonderful Life” has gone from being a chronicle of American existence to a very long-ago and distant dream. And I know I’m oversimplifying a lot, glossing over a lot, but I think if you get down to the primary essence of what’s wrong, that wrong lies in the fact that in the early part of the 20th century we ceased having leaders who cared so much about America and began having leaders who cared mostly about war profiteering. Everything else-the private central banking system, the lobbying of congress, the erosion of our cultural mores, porous border policies, dumbing down of all our institutions-if these didn’t specifically grow out of a new policy of “imperialism”, then they were made possible by it. And I’m not a pacifist-but that’s also not what I’m talking about. I wholly believe in fighting a war of defense. But that’s not what I’m seeing. Instead, I’m seeing a constant, never-ending “us versus them” politic, with the actual immediate threat of the “them” never being fully proven, always kept semi-shadowy, and the actual spoils of the consequential war never getting evenly divided to the “us”, but rather, only to our leaders and corporate leaders. And that’s not democracy. That’s empire. And we’re not set-up as a nation to be an empire-you look at our constitution and that’s quite specifically for a democratically-elected republic that is constantly monitored by the public. But...I’m not in a position to do much right now. I have legal problems of my own, money problems of my own. But I am making a mental folder of all that I see, and what I see is an American people which doesn’t want to be made an empire compelled to be made into one. Americans seem to be compelled to these ends through “economics of scarcity”-however, the thing I notice most often about scarcities is they are artificially created. And that is what I, myself, would war against. This, just for the sake of eventually living in a community that resembles “Bedford Falls”, rather than always having to live in a place that resembles “Pottersville”. In Pottersville, everyone is exploited and all the better resources are grabbed by the slumlord; the people follow his example and grab all they can for themselves. In Bedford Falls, the leadership is more just and altruistic, and the people follow suit.

[@freddietz96]

***** Beyond all that, I always found Perry Bible Fellowship cartoons help (although they have nothing to do with any Bible fellowship--I don't even know why they were given that name): comicsidontunderstand.com/wordpress/wp-content/uploads/2011/06/shrink.png

[@if66was99]

Mazaks are some of the best machines I've ever run. 4 or 5 of them. The Integrex and Mazatrol controls are amazing the things they can control, and incredibly simply. Intuitively. Mori Seikis would be a somewhat distant second. Those Mazaks are a bad mother SHUT YO MOUTH!

[@joe8388]

Oh I love working on this machine :)

[@derick3482]

hey joe are you a mazak operator? which software do you work with is your Integrex 640MT fusion also?

[@masseyfergusonfan5837]

Great video and great share good work...Noel.

[@digiacomtech5589]

A question just occurred to me ... State of the art computer controlled machines can spin the shaft and easily coordinate the movement of the cutter up & down to produce offset circular parts of the shafts (where the pistons connect). Old school machining (on a lathe) offset the shaft to produce the circular part of the shaft (where the pistons connect). The question is which technique produces more accuracy? I assume the tolerances achieved by todays computer controlled machines are better, (plus they are easier to setup). Your thoughts?

[@anonanonme2463]

So was a whole magazine of tool bits killed cutting all this with no lub/coolant?

[@eleazarbaldeonhuamani7461]

muy buen video de fabricación de un cigueñal felicitaciones por la oportunidad de compartir

[@umeshkumaryadav9077]

very nice and good finishing

[@danielhoffman2299]

This is true but you can lessen or eliminate the chipping problem by adjusting the program to slow the feed at the start of yer secondary cuts. also a pause at the withdrawal point will lessen the tendency of the tool to grab a chip at the start of the second cut.

[@chrischalabi]

How does the indexable endmill compare to the traditional ones?

[@douro20]

They can also integrate surface hardening using a fiber-coupled Nd:YAG laser (a $20,000 option, mind you).

[@SgtStedenko1]

The coolant depends upon what type of tooling is being used such as CBN,,Carbide,,or Steel

[@waynep343]

just curious.. is billet steel forged and hot worked to increase strength like the videos showing the hot forge shaping of train axles.. how much stronger could it be... i recall an article where they are running fully counter weighted cranks in TopFuel classes as they spread the counter weights along the length of the shaft.. instead of just having the ends heavier to complete the balance.. stops the middle of the shaft from whipping

[@ArmyCop]

They turned off the lubricant cooling so they would be able to film clearly. Notice how messy it got when they were drilling the long lubrication flow holes. I'd be surprised if that piece ended up anywhere but a display item or the scrap pile. I'd also guess that the bits that were doing most of the cutting got scrapped as well.

[@jackbelk8527]

StressPruf (1044) has been used for many years. 1045 is essentially the same.

[@clemwyo]

Aluminum that leaves dark blue chips? Maybe the no coolant is so we can see what's going on?

[@Mega32roadster]

Amazing, I had now Idea how they made them, COOL!

[@themainproblem]

Anyone know the end cost of a crankshaft produced by this machine? That was amazing to watch.

[@douro20]

Where I am going to work they have ten Integrex machines!

[@OneCupOfCoffee204]

In my humble opinion, if you can't see it clearly, it's not worth watching. However, I do appreciate the effort.

[@leneanderthalien]

No coolant to let the work visible, but normaly they use oil in water emulsion to lubricate and cooling (indispensable to hold high precision)

[@OmahcronOmni]

This is the same machine that milled the T-1000.

[@Dave-vu4sx]

The T-1000 is a "memetic poly alloy", thus not requiring machining. The T-600 and T-800 maybe. But in all honestly, Turn mills aren't great for large complex profiled parts, better for rotating components.

[@OmahcronOmni]

I have been corrected... I feel soo humble now I didnt even know that fact. :)

[@wernerdanler2742]

@@Dave-vu4sx Hey Dave. I have not worked as a machinist since the 80s. What is memetic poly alloy and the T-1000?

[@Dave-vu4sx]

@@wernerdanler2742 kzbin.info/www/bejne/fJKXe6RtnK-pkJI - This should answer all your questions, in the 80's we only had T-800's, but around 1991 we had the T-1000. :)

[@Thundarr995]

That 1st cut sounds like some major electric guitar feedback. Reminds me of No Sleep Till Brooklyn by the Beastie Boys. LOL!

[@josemiranda1407]

Impressionante o trabalho dessa máquina muita tecnologia

[@sdvten]

Good luck having a crank made of 1045 bar stock hold up to the sustained high rpm a Nascar engine sees.

[@ChinesehammersAnYang]

Thanks your share. Nice video

[@genemartin6962]

My question is: Why did they use 1045 mild carbon steel for a billet crank? Why not a 4140 or 4340 Chrome Moly Billet?

[@devildogmarine6681]

I would assume no cutting fluid so the camera can see the cuts?

[@vtecnegro85]

True this is a flat crank used in the Ferrari motors.

[@danielhoffman2299]

Haven't ever seen a V8 crank before have you home slice..All American V8s have 4 rod Journals..That is two rods to a journal for a total of 8..Damn kids, have to explain everything to ya..

[@vanthoinguyen2364]

Công nghệ Việt nam bao giờ mới có nổi em này??? Mình mới có 1 em phay CNC 4th axis mà đã thấy quá hay và hiệu quả rồi.

[@vanthoinguyen2364]

Rất nhiều người trong đó có tôi đã từng rơi vào trạng thái : nhiều lúc muốn làm nhưng lại thấy không được làm, nhiều cái được làm nhưng lại không làm được. Ở đời, "làm được" và "được làm" là 2 thái cực khác nhau. Ai đó đã thành công thì chắc hẳn phải là người kết hợp được hài hòa 2 thái cực đó!

[@sandroalves490]

É um trabalho muito bonito e bem feito.

[@ThePriapus23]

Despite all the love for metal, you can use cooling emulsion for machining, because it hurts when you watch. But otherwise it's still a great achievement what old Mazak can do

[@benzman-zj7qm]

Check out the one for third eye tactical scope mounts

[@szaki]

Where is the forging process?

[@JamandTheHolograms]

Reminds me of those science videos we used to watch in school back in the 80's. Except there's no guy wearing a sweater and telling lame jokes.

[@MrCSSTRIKS]

damn pretty good quality to me what kinda calculator u talkin about brotha i want one!

[@mikemadsak4454]

im just getting into live tooling and i love it

[@derick3482]

hey Mike are you a mazak operator? which software do you like with the Integrex is it for 640MT?

[@Xenony100]

Прикольно, конечно.. ))) Такой станок с 5-ю степенями свободы многое может... ))) Но на самом деле коленвалы на производстве просто отливают... ))) Это настолько проще, насколько и дешевле!.. ))) А побаловаться на станке с ЧПУ - это здорово!.. )))

[@josedominguez6783]

IMPECABLE TRABAJO DE MECANIZADO .

[@josedominguez6783]

¿SABES DE MECANICA?

[@josedominguez6783]

Algo

[@rkellyonu]

Looks like a 4cyl Crankshaft to me...dont know why nobody has had said anything

[@sknife9629]

Two rods per journal.

[@ThePaulv12]

And, if its a V8 then it would be a flat plane crank so you're absolutely correct! Thing that puzzles me though, if it is a V8, then why is there only one oil hole on each throw journal?? Might be because they use a single V shaped connecting rod (I doubt), or a master and slave rod, or conventional setup where both rods overlap the oil hole , or ever a fork and blade design. I'm puzzled.

[@cstavro]

ThePaulv12 because it is, in fact, a four cylinder crank! I noticed they use a 0.984" end mill to machine the rod journals, which is SBC sized rod bearing width. That explains the single oil hole per journal. Is a four cylinder crank still illegal in nascar? ;)

[@JimProng]

+Chris Stavro Thanks for that confirmation. I paused the video, counted the journals and couldn't make sense of it.

[@ericartis6960]

But I wonder what is the stroke & bore it?

[@danielchapin7593]

Pretty sure they used coolant, there was a lot of glitches were they skipped frames, probably just turned the coolant on to blast the work piece ever single or other pass. And they didn't run coolant for viewing purposes. But even if they didn't use coolant, they just want to sell the machine so what's a couple thousand compared to a hundred thousand.

[@billwelter4101]

The rod journals are wide, its a V8 crank. I just wonder if a 1045 billet is stronger than a 4130 forged crank. But , you never hear about a broken cranks, so probably OK. I wonder why NASCAR doesn't use flat cranks - rules require a "stock" style crank?

[@lmeza1983]

I wonder how much the hollow drill alone costs this looks expensive.

[@PabloSosa-t3o]

Me gusta mucho los videos saludos desde cuba l ❤❤

[@beyondthelol]

what was the point of those small drill holes?

[@bjre.wa.8681]

I'm assuming it gets heat treatment of some kind?

[@Squarerig]

How long did this process take,from start to finish?

[@davidallwright3973]

how much of this could be done using mazatroll programming loos like you would have to use iso g code .eia program to do all that off a cad cam package

[@arktikgraywolf]

No coolant on carbon steel? I guess a few inserts are worth the demonstration...

[@frostywahlly5465]

amazing technology

[@FireCrowsWorkshop]

video published in 2012, shot with high tech potato...

[@dmbadcat]

shot with a quad slr multi reflex cmos potato; silver esr edition

[@Shaun.Stephens]

Filmed in 1997 though... Recorded direct to videotape.

[@Icutmetal]

Why would you WANT to use coolant while milling carbon steel?

[@KEEPINITRIL]

I cant recall any nascar teams using single plane cranks

[@RedStapler100]

Agreed. NASCAR doesn't use 180 degree cranks. The internet is full of misinformation.

[@nicksimba8180]

Forged is more durable?

[@miguelfdez712]

Higher resolution, please!

[@zakmitchell3128]

.....And off it goes to finish grind, for the grinders to make everything right

[@budzab]

Which CAM is here used for programing this operation?

[@younesnahiz4884]

e la cima di tutto . bravi

[@kennymiller4428]

1045 medium carbon steel. there is no coolant so you can see the process. typically this wouldn't be done dry unless they use a refrigerated air to cool the tool. definitely not aluminum.

[@georgesnasr7227]

Is it a flat plane crank ?

[@TheGuymox]

How Many Axis' is that?? I ran One before, but not this newer Version. Itergrex 50 with T-Plus 32 controls.

[@DLCaster]

5

[@TheGuymox]

yeah, i noticed when the video started back up it's the first thing they show...i ran an intergrex mazak but it was just 3 axis

[@flaviodominguez5048]

El futuro ya esta entre nosotros ,una sola maquina hace todos los procesos solicitados por el operador (CNC) ,en este caso un cigueñal ,muy buena maquina herramienta , la gente de RECTIMOTOSDINO COM AR

[@TheChinmay3110]

What is the Cycle time ???

[@poofighter3741]

Doesn't seem to be using coolant ?

[@jr540123]

tomte47 I think they just turned it off for that run and slowed down the machine to give the camera a neat view.

[@DivineBetrayal]

I thought crankshafts needed to be forged for strength? Does the material selection allow it be machined and still have the same transverse strength?

[@sidgar1]

+DivineBetrayal The heat treat is done after the cutting is complete.

[@MrJetjoe]

I would add a ruffer that's not sticking out so far

[@mohamedbari7506]

yeah, that's the heart of an engine!

[@christophercolumbus8944]

don't crankshafts need grinding?

[@zairyounes1523]

good djob!!

[@R5H4D0W]

No lube? Last time I tried machining steel without lube I destroyed a few of my carbide tools

[@3nrasandun]

I think they didn't use lube this time otherwise we wouldn't be able to see the process clearly

[@TheNative7th]

U can roll without coolant on roughing and finishing

[@TheNative7th]

But as u can see on the drill with the thru coolant...they were using coolant..so it was probably shut off for demo purposes

[@darthvader4hire]

TheNative7th coolant is needed for that kind of drilling. to cool the tool in such a deep hole and to flush the chips out.

[@jmatthewstewart]

I wonder why he (or she) doesn't use coolant for the turning at the very beginning.

[@dtiydr]

Do you really have to peck drill when using pressurized cooling?

[@Brainmalfuction]

probable more to clear chips then for heat management

[@dtiydr]

Brainmalfuction That exaclty what I meant; peck drilling is just TO clear chips.

[@PencilProper]

How much would a machine like this cost?

[@macroevolve]

Well into six digits for sure. Some multi-wheel ( silicon carbide and diamond ) grinding machines at a shop I used to work at were a million each. Studers.

[@kevinmeupelenberg6938]

€145000 im 16 year old and me and my boss just bought this machine 2 days ago and now we get a 6day cursus to get to handle this machine

[@cyberslick18]

Kevin Meupelenberg Your boss bought it. You didn't.

[@MrReichennek]

I figured it would be 4340 as most of the internals in highend engines seem to be. \

[@nunocruz9730]

i suppose this is how they did it in the 90's