Handmade Making Process of Large Milling Machine Gear | A Huge Industrial Gear Manufacturing Process

Handmade Making Process of Large Milling Machine Gear | A Huge Industrial Gear Manufacturing Process

[@alexpyattaev]

Your steel mark will be "whatever we had in the scrap heap that day", and heat treatment will be "very good", with carbon content of "dont worry about it", tolerances of "very good" and surface finish of "real smooth".

[@mr.t993]

Exactly🤔, the whole Process seems very inefficient as well

[@BrettonFerguson]

Yes. However this is also true for 90% of things bought in the United States these days. Nylon and Polyacetal gears are more durable than "steel" gears made in China. Everything has "Made in China" printed on it. Everything "steel" is made out of recycled printers, refrigerators, and crap. Every made from "steel" likely had a decent percentage of copper, nickle, and other metals. This is why half the office chairs in the USA, the adjustable bolt in the back has stripped threads and almost every chair doesn't work properly. This is why if you try to hammer a nail into hard wood, it will bend. The nails available will barely go into farmed pine. You need a pneumatic nail gun. If you try to drive them in with a hammer and don't get it the first whack, it will bend. It isn't just nails. All hardware is like this. All appliances are like this, microwaves, fans, ovens, washing machines, anything made overseas. Fortunately most important western automotive drive-train, engine and transmission parts, are not made in China yet. Otherwise our engines would explode after 25,000 miles.

[@alexpyattaev]

@@BrettonFerguson maybe that is why it is not made in china? It would explode before warranty is out=)

[@kkon5ti]

@@BrettonFergusonthis one is from Pakistan though

[@kkon5ti]

@@BrettonFergusonAmerica Moment comment

[@jordancoleman1608]

All these people in the comments being impressed at the “skill” with which people make “industrial” gears using “primitive” tools and techniques. All I see is exploited people working in dangerous conditions to create objects of poor quality that only superficially resemble the thing that is actually needed by society. I sure hope these gears aren’t being used for anything important, since they’re made of random, highly-contaminated metal scrap to tolerances so large it defies justification. I don’t know how many workers are seriously injured each year making these things, but I’m sure even more innocent people will suffer as a result of the gears being installed into machinery that subsequently fails with unpredictable consequences.

[@congoballs9725]

💯%

[@nandayane]

Pretty much, although for scrap it looks like they are using all the same component which is possibly the same grade of steel.

[@crackbabystemcell6887]

If you saw where 80% of pharmaceuticals that come into America from India you'd lose faith in our country. We love cheap exploited products. Your shoes were probably made by child slaves.

[@GoatDust]

Who cares? They choose to live like that. And depending on the load, it can function for what it’s needed. Better equipment has historically been made from much simpler or crudely made instruments.

[@woahhbro2906]

These are better working conditions than when I worked at Wendy's

[@Danielrunner100]

After a long day of work, I sit down crack open a beer and watch one of these videos. It reminds me how easy I actually have it.

[@JohnnyCage38]

How easy or not. All kind of work being done at the best is tirely dangerous.

[@lonesomelenny7606]

Have to wonder what the injury % is and life expectancy of these poor workers. No safety glasses and wearing sandals in dangerous working conditions. Have to admire their work ethic.

[@vyacheslavorlovsky506]

100% truth

[@scorps-hl8ue]

Because it's what you call hardworking no looking fancy in colourful clothing that's why they get the job done and for next to nothing pay compared to western living is why companies are hiring such people! And moving over to 3rd world countries...yes

[@teaguejelinek4038]

Yeah and these guys get home and watch a medieval documentary to remind them how easy they have it.

[@StillAliveAndKicking_]

Glad to see that no expense is spared to ensure worker safety. Standard issue safety flip flops, I wouldn’t go near molten metal without them.

[@springplus300]

This looks like dangerous work. Good to see most of those guys wearing safety sandals...

[@jodijaanify]

Saftey is there last concern or worry, they got kids at home to feed, cloth. dont be a prick. if you have even low IQ, you can tell these men are poor. from Pakistan.

[@TranscendentaLobo27]

Woo! Good one. Every time I watch one of these, I can’t wait to see the same exact comment. Really lifts the spirit, ya know? Good job.

[@twiz148]

Their OSHA "competent person" is onsite...sleeping in the office...

[@smk6650]

To be fair, if that shit falls on your steel toe boot, or your sandal shod foot, you’ll be losing that foot either way. That being said, it is dumb for 1 million more reasons.

[@nick_pappagiorgio]

Also safety squints to protect the eyes

[@wojomojo]

For those wondering about the gas step: Gas-cured (“Cold box”). Sand and a gas-reactive resin system based upon phenolic urethanes, acrylics, or sodium silicates; gases include amines (TEA/DMEA), SO2, and CO2. Sand is first mixed with the gas-reactive resin system and deposited into a core box. The mixture is instantly hardened by blowing a specific gas through the core box; thus working time is flexible as it is a function of the delay between molding and gassing. The mold can be used immediately for casting. Sand is removed either by physical methods (shaking/rapping) or via thermal operations that pyrolize the binder.

[@dstockbridge1]

Thanks!

[@fernandoi3389]

Thanks man I was wondering just that !!! What about all the scrap metal they use ? does that make sense ? Looks like a big mix of different stuff.

[@OneExhaustedFather]

Always check the comments, thank you kind person for this info. I was curious what they were doing with that.

[@WwarpfirewW]

get these man a real mold :(

[@Havok135]

For us dumb people, he literally said "The gas they use, is used to harden the sand so it can be used for molds quicker" your welcome lol

[@mzmadmike]

Gears like this are used for bridge mechanisms and such. They don't turn fast, never get a lot of revolutions, and the surface finish will lap in with wear. There are 150 year old mills with gears made in this fashion that are still working.

[@badseednut]

Without heat treatment, and depending on how much they operate, they won't last to see another day

[@Anax100]

@@badseednut I don't think this is their first rodeo. If they just broke, there wouldn't be an entire set up to make them like this.

[@rameezrazzak]

@@Anax100I agree. The focus is different: efficiency in terms of cost. It must be cheap, and it must work.

[@bitrage.]

They engineer the gears so they still have a job next year!!😉

[@brotherowl]

Thanks, I had been thinking for huge ships.....

[@jacobishii6121]

I asked the guy what grade of steel this gear was made of and he replied "yes"

[@daveh9755]

Very good, very good, the best we can find.

[@user-ls1fz7tb6q]

He replied, “What grade of steel do you want me to write on it?”

[@df71091]

Tin cans 😂

[@BurkhardusX]

It’s still steel and that is what counts.

[@BurkhardusX]

Pakistani society is so primal, so natural, completely original. Very impressive. We observe humans at their development we had in Europe in the 19th century.

[@FourRulesRacing]

When civilization collapses I want these dudes in my corner. They can make you anything out of anything.

[@tipi5586]

Well if you want low quality steel you can buy it from China already, don't need to wait.

[@icykenny92]

Why wouldn't you choose someone with the knowledge beyond medieval time metalwork skills??? These people is stuck in time.

[@commissarkitty3553]

@@icykenny92 they still have more metalworking knowledge than your average joe. Even though the working conditions are horrendous, they are doing what they can with what they have.

[@icykenny92]

@@commissarkitty3553 At this point it's really clear to me that their religion and culture is in their way to grow their industry. Also you can see they don't understand how to implement more efficient production line architecture, probably because their religion doesn't allow them to learn from western society. And the safety is really bad, something tells me they have this Allah protect me mentality.

[@commissarkitty3553]

@@icykenny92 Man that is alot of assumptions there, its likely not religion or culture but poverty, outdated education, and a corrupt government that doesn't enforce regulations in their industry. You could argue that is part of the "culture" but western countries looked much like this during their early industrialization. Most likely its a developing third world country where cheap human labour is used in place of efficient but expensive machines to offset the cost.

[@CLIFFLIX]

These guys are crazy. Working with no protection at all...in flip flops!

[@christopherkarlon4463]

Like in mmorpg, increase the attr whos gave critical and strenght damage, you dont need HP if you dont take any hit hahah

[@odysseyorchids9507]

We in Florida do the same. Flip flops year round for any job big or small.

[@hitler69]

google how much protection gear cost then google pakistan minimum wage now do the math

[@potato9832]

Never tile a floor in flip flops. Learned the hard way. @@odysseyorchids9507

[@Lemarking]

chanclas +100 en protección contra el fuego

[@ARCOFJUPITER]

Ive watched similiar videos of these guys repairing tractor tires...grinding down the rubber, heating and melting it, actually ' sewing ' metal wire around the patch and putting and actual new rubber cast mold into the damaged spot....it comes out new. Comments from American tire experts are astounded at these peoples ingenuity. My dad used to do this sort of thing on his farm in the late 40' into the 1950's. You work with what you have and you make it work....again, like one person said " they wouldn't have a system of making these parts unless they did work and people kept coming back for more " right ? I'll put it to you this way....hands down....if i became rich and wanted something very rare and impossible to find an orignal example of made of metal - i would go to Pakistan and ask these guys to build it. Seriously. I'm into model tanks and planes....the German Tiger 1 tank ? Extremely rare. 7 complete examples left in the world...1 running. Some private collectors are reduced to piecing one together from various old parts called ' Frankentigers ' they dont even have an engine. The amount of money that a German, American or high tech Asian country would charge to build a brand new replica of a Tiger 1 ? Probably twenty million USD. Pakistan ? Maybe 2 million. Im just saying....its the truth....and it would run and work.

[@archstanton1628]

Plenty of bridges here that were built in the 1800's using similar techniques, they are still standing. Brunel didn't have access to CNC either.

[@andychow5509]

You would be surprised how much of a science iron making already was in that time. The products made in the 1800s were of much higher quality than what is done here. Brunel would be embarrassed that 220 years later these people lack the accuracy people expected then.

[@Leningrad_DE]

порадовал точный инструмент в виде сплющенных пробок для калибровки зазоров :) Ну и конечно, впрочем как и всегда в таких видео, это защитная одежда, а главное обувь.

[@ginofregni]

😂

[@kamaz38video]

Наши ТБшники попадали б в обморок ))

[@wadgold956]

ну так это же черновая, потом то все ровно точат. Да и на шестерне такого размера вряд ли нужны зазоры в микронах. А вообще не знаю как вы, но на х я это смотрю трачу время.

[@Dobrya4ok1]

@@wadgold956 ну квалитеты 14-16 точно ыыыы

[@alanalanov4125]

@@Dobrya4ok1 😁 меня убил - обдир эвольвенты на глаз вручника... 39:40

[@wallpurgesnight8209]

This is like taking a step back in time to the 18th/19th century through a modern colour window 👍

[@razberik8320]

I was thinking the same. The process is quite correct in most of manufacturing steps. But they make it like in 18/19s.

[@user-un3oz8pj3p]

Exactly. When you have enough free time and manpower you can do it that way

[@Churchill250267]

Health and safety have yet to be invented...

[@porkey768]

Ya it must be 18 19th century old technology but it is inexpensive way to make things work this is d reason world is running in balance right 😊

[@fizykdupa]

@@porkey768 Typical managment talk. That is not the "inexpensive way to make things". At this point of time in humankind history this is the stupid way to make things.

[@hastyone9048]

Impressed to no end with the exception of harvesting the metals. Looks like they are mixing iron with copper with aluminum with tin with lead etc etc, The casting will ultimately have weaknesses and be prone to failure. The whole process was incredible though.

[@PbPomper]

And what about surface treatment? Surface hardness is extremely important for gears.

[@b0ng420]

bet these dudes can make one hell of a sand castle

[@user-pb9ky3gf2s]

Nice one 😂

[@GiovanniGiorgo]

Much respect to the men getting it done with what they’ve got to work with.

[@matheusfaria7230]

You're talking like they own the thing, they are being abused you dumbo... It's not what they've got to work with it's what they are forced to do without having it.

[@nicolasarkin]

This. Yea there are OSHA violations but all I see are men doing what it takes to provide for their families and teaching their boys to have pride doing so as well.

[@tagman1304]

Looks like they have everything they need

[@bradysmith3024]

@@Dartgame340 Feel lucky you live in a White Western county that has it. All these cats will have cancer from the dust and fumes if injuries don't get them first.

[@StefanoBorini]

@@nicolasarkin That's a great way to defend child labor. Well done.

[@ruudvansteenis]

"What is the metal you use?" "The metal we have the most of!" 🙂

[@charlesballiet7074]

litteral pot metal from cookware

[@damianboj3809]

Thats why they have to do it soo big! With modern technology, this gear would be probably 5-10 times smaller.

[@mikehermesmeglio]

It's 9310 !

[@PbPomper]

@@charlesballiet7074 I'm sure there's some plastic in there as well.

[@vmhanlon]

It would be fun to watch a team of OSHA inspectors view this (and similar) videos. Oh the humanity!

[@theeaskey]

That's why we're going down the tubes.too much oversight.

[@seklerek]

@@theeaskey So you'd rather western factories looked like this?

[@feilox]

OSHA doesn't do much in America though. Toxic dumping by companies. Companies not certified by ISO 9000 standards don't care what their workers do etc.. many factories in midwest with no ventalation system for toxic chemicals etc... why u think America has such a high cancer rate?

[@RiDankulous]

ok, boomer! 😆

[@rukuku]

Child labor is not wasted here. I'm glad they are all wearing safety sandals.

[@acidstar11]

rather my kids work and learn then play and dream, fun FACT the more protected you are the more careless you are

[@bitrage.]

And Safety Squints

[@raydunakin]

This is pretty interesting...it's like looking back 150 years or so to the days before mass production and automated machinery, when everything was made more or less by hand.

[@mi5iu491]

Most of the world lives like this still. Not every region of every nation is like America mam

[@llVIU]

meanwhile in 2023: made in china, no factories here!

[@PetrJandus]

Maybe more : )

[@DrunkenDemon]

Despite the conditions in the Video, the process itself hasnt changed very much.

[@brolike-gw7cw]

@@mi5iu491 you need to get out more, what America has to do with it ? They didnt invented it and they do not have the highest living standart either

[@dieselhead24]

The tooth profile looked better before they scraped them down. That scraper really tore up the surface. Amazing casting skills and so much labor goes into each one. I love the way he forms the sprue from underneath.

[@user-ce6fr1qm3h]

os caras sabe que estar fazendo são bom no que faz abraços

[@giovanni4151]

Whats the sense? out of the fusion it's out of specs and need to be reduced in dimension. first steps must be course, then they will finish it

[@lordkayx]

@@giovanni4151 agreed, Im guessing OP didn't notice the little punch holes and outline draw on the face, There is a lot more left to reduce. Watch some of the other videos and they show the finishing prosses in more detail. they stopped at 80% of the way done

[@trekkie1701e]

They were taking some big boy chips with that scraper.

[@CFox.7]

you mean machining it to spec ? They didnt do it for appearance. lol

[@eugeneskytail1739]

-Какую марку стали вы применяете? -Да!

[@yaroslav2888]

Самую лучшую, отборную!

[@Evgen__B]

Сталь марки КП - какая получилась.

[@user-np9vd5ul9x]

Ракету у них заказал в космос слетать, сказали что под заказ 7 дней ждать))

[@drd1924]

Whats more impressive to me is the fact they have a milling machine large enough to face this part

[@everybodyisanidiot4553]

Looks like a lot of steps are mostly for job creation, government grant perhaps?.. Some people jobs at the mould construction stage seem to be "I spread baking soda where it doesn't matter".

[@ItsMrAssholeToYou]

Lathe.

[@drd1924]

@@ItsMrAssholeToYou Good catch Asshole, that would be a vertical lathe, not a mill.

[@peoplez129]

You don't need a good mill when the part is made of a bunch of scrap metal. It's a big part, it's metal....but it's not durable.

[@gavinjenkins899]

@@peoplez129 It's durable because it's way bigger than what would otherwise be needed if it was tightly graded and controlled. To compensate for exactly that. Same as how when people made bridges out of stone, they made them much heavier than modern steel ones. And they still stood up, because overengineering can make up for a lack of materials for most tasks that need brute strength not super precision.

[@jerrysstories711]

It's fascinating to see how manufacturing like this is done in less industrialized countries. I mean, homie is making a precision part, so he starts by digging a hole in the factory floor! Amazing!

[@BrettonFerguson]

This is how we used to do things in the west. The machining tools they are using were made in the west between the 1930s through the 1960s. Now we have computers control everything.

[@ChadFromSpace]

Someone drink a bunch of soda quick, were out of shims.

[@Jadder88z]

Large item, low volume casting would be done pretty much the same anywhere. Even in Germany.

[@daomingjin]

actually we didn't do it quite like this. We would have put that gear on a 3-axis mill, surface finished both sides flat with some kind of cutting bit on a high speed spindle. Then Take that same gear, change the bit in it to one that's much much longer and then mill the surface of the gear teeth properly. Technically that would have been on a 4 axis Mill. The same cut happens and each time there's a new cut you would rotate the 4th axis by a specific number of degrees. There would be entire booklets written for where each cut should be and which angle it should be at. THAT is how we did it in the west at the turn of the century. @@BrettonFerguson

[@Fran-xu9ic]

For this reason, the site has no floor, everything is very well thought out.

[@pessimisticpenguin]

from 36:10-36:30 you can literally see voids and cracks in the metals after they mill it haha

[@KRtekTM]

27:18 I like that pure smile on the guy's face when those two gears clicked together :D

[@localkiwi9988]

We use to to do this sort of work in New Zealand in the 70s when i started work. All those foundries are gone now. I must admit, our working conditions and safety where a lot better than what these men work in. Patterns and mould making much the same. All the old lathe factories are all gone now too, maybe the odd one around. The lathe factories we have now are all computerised.

[@shashankachoudhury3667]

I agree - this is probably in Afghanistan or Pakistan, going by their dress. And safety of course is non-existant. But kudos to the chaps for their can-do jugad!

[@CurseUppl]

​@@shashankachoudhury3667it's Pakistan.

[@Occupy_pedophilia88]

They make the work like in the 70s but with the safety of the 20s

[@localkiwi9988]

@@Occupy_pedophilia88 Morelike, Industrial revolution days

[@Occupy_pedophilia88]

@@localkiwi9988 nearly the same tbh... I mean factory conditions didn't change much until like 1940 after war. While war they didn't gave a fuck about the workers as long as they worked enough. Before that they didn't eighter/aighteher I don't fuckin know how it's spelled 😭sry English isn't my first language yk so hope yk still what i mean 👌😅

[@Wes12940]

machining all those teeth by eye must take ages. crazy!

[@BlackenedEclipse]

What these people achieve with so little is truly astonishing. For all those people that complain about their methods and way of manufacturing, I can truly tell you that if they had a better way they would do it, but due to their economical situation/supply chain, pretty sure they do the best with what they have. I hope that soon they’re able to build up their PPE and safety gear, and also improve their pay to live a better life.

[@michafrackowiak9379]

Unfortunately, the former Angosa colonies are still far behind Western and American technology. And if the West wanted to sell them technology, they would achieve more than the West, that's probably why the Angossians are blockading Asia and Africa, because these people want to work and are able to make something out of nothing, they would achieve what China has achieved. The West would sooner lose

[@shashankachoudhury3667]

Hear, hear ! - I couldn't agree more. In a world rapidly depleting itself and the general public being led by their noses with the fairy tales of the gaint corporations, it may not be long when the rest of the world follows suit.

[@mcjeebus]

That's right , like we were doing in the west in the 1700s

[@timn4481]

its irresponsible is what it is. There should be no prize for this behaviour. if the manufacturer cant provide safe and controlled manufacturing, then they shouldnt be allowed to manufacture. They are stealing jobs from companies that spend money on keeping workers safe and generating quality product. Most people wouldnt want to be buying products that have humans as part of the consumables.

[@michafrackowiak9379]

Unfortunately, it was Aglosai in Europe and the USA that introduced labor laws to make production expensive and the same Anglo-Saxons buy goods in Asia to make good money on them and at the same time they do not allow these old colonies to develop, this is how filthy rich business works in the world India Vietnam Laos etc. would like to develop technologically@@timn4481

[@serdarcal]

They do everything but they don't make chair

[@solochan2955]

Я как эту груду металолома увидел, сразу понял, что марка стали соблюдена 👍

[@user-ff7jh4gv7d]

😀😀😀

[@thomasslone1964]

says the man with no copper wire or fuel in his war tanks

[@user-nb2jl8mp5d]

@@thomasslone1964 оf course. we drank it.

[@IANAZIST]

​@@thomasslone1964 у него вообще танка нет😂😂😂 А вы на чем ездите?

[@Gavnodango]

Технология ЖСС (жидко-стекольная смесь). В состав формовочной смеси входит прокаленный песок без глины, затем его в специальной емкости 0:50 перемешивают с жидким стеклом и перемешанной массой заливают модель. Залитую форму накалывают 4:20 для последующего подвода углекислоты. Опоку накрывают колпаком и подают газ СО2. После чего залитый формовочный состав ЖСС приобретает твердость.

[@wirtdonners4212]

Литьё так себе. Льют из отходов и дерьма.

[@coyote4440]

Спасибо тебе, добрый человек! Только-только собирался гуглить что подают по шлангу

[@dvdv6913]

​@@wirtdonners4212для такой детали супер метал я думаю не нужен

[@ZIPGBHFVBLF]

точность видимо тоже.. там резец гнет что ппц..@@dvdv6913

[@vladbis]

@@wirtdonners4212 но стати достаточно чисто отлито. без каверн - на расточном видно

[@sngt85]

I liked the moment when a worker lost his cart wnen running and throwing scrap metal into the fire and barely got there himself. Incredible work safety.

[@thomastrain7311]

And kept his flip flops on all the while

[@mercedesvan-doors34]

I wonder what percentage of the metal they produce contains actual worker, with or without sandals of safety.

[@guillermozalles9303]

NASA spent millions making a pen that could work in zero gravity. The Russians just used a pencil.

[@rcasturi55]

Full respect to the repair crew. Hats off to them.

[@anoninunen]

*hardhats

[@garis1161]

Эти люди выживут после любого апокалипсиса.

[@usapower6208]

В отличие от уzzких

[@elpanchosancho2]

Bahahahahahhahahah ( that's laughing in American) very true comrade.

[@usapower6208]

@@elpanchosancho2 You're mexican. Don't allowed to laugh as American.

[@svinpauk179]

Да они на производстве этом каждый год разные, так как предыдущие заканчиваются. так что не факт

[@user-du6yr1qx5d]

Работа формовщиков впечатляет!И остальных тоже...👍🎉

[@allancopland1768]

These skilled guys are keeping stuff affordable.

[@A_Stereotypical_Guy]

And dangerous

[@gortnewton4765]

@@A_Stereotypical_Guy I was going to say the EXACT thing!!! And dangerous.

[@gavinjenkins899]

@@A_Stereotypical_Guy Okay when was the last time you donated extra beyond the cost of the stuff you order to buy PPE for the workers? What's that, never? Huh weird.

[@A_Stereotypical_Guy]

@@gavinjenkins899 there should be a margin in their profit for PPE. Besides, most PPE can be homemade.

[@RiDankulous]

There's probably a few very low cost procedures and equipment upgrade that can help with safety greatly.

[@ArneRagnarsson]

2023 and India still working as they living in the stone age.

[@chriskelvin248]

Technically, the iron age 🤭.

[@zbynekcech6942]

@@chriskelvin248 Yep Random iron age :D

[@RiDankulous]

That's a broad conclusion as there are huge numbers of manufacturers and large ones which produce high quality parts. Still I wonder how useful these particular parts really are as they apparently contain significant defects.

[@patty109109]

Always interesting seeing how people can make pretty advanced parts with limited materials. It’s obviously within sufficient spec for customers to buy it.

[@Coecoo]

It's possible these things either go to a third party or the customer themselves with sufficient extra material so final adjusting cuts can be made accordingly.

[@piotrlewandowski]

There's nothing advanced in that gear. Albeit large it's quite simple machine gear. Looking at how rudimentary and inaccurate the casting form preparation process is, poor quality of the metal junk they used to cast the gear is, there's barely any guarantee of any quality. In addition, manual labour and low quality of tools also affect the final result. I can't see how there's any "spec" being met considering how the whole process is botched.

[@wackbirdz]

@@piotrlewandowski Oh look, another web developer that clearly doesn't understand metallurgy in the slightest.

[@piotrlewandowski]

@@wackbirdz Oh look, another random anonymous dude who superficially judge another person in internet without knowing anything about them. I have a degree in mechanical engineering :) I wrote a thesis on this :) I actually worked sufficient enough years before I switched to software engineering (because regardless of how surprising that might be to you: people change careers). Now, I could tell how using scrap yard junk steel is a bad idea to produce machine parts like that and why it is challenging and risky. I could tell you why having consistent quality of steel, and the quality of control of the whole process is important. I could tell you that machine parts require specific types of steel containing elements like iron, carbon, molybdenum, chromium, nickel, and how and why these ingredients affect property of that alloy. I could do that, but looking how quick and shallow your judgement of me was, I doubt you'd understand half of what I would have to say about it.

[@vast634]

Hand made might be cute for decoration at home, not for industrial equipment.

[@FADNaR]

Впринципе как бывший формовщик в РЖД на литейке скажу, что у нас примерно тоже самое, только формы синие 😅 Ну ладно, ок... замес формовочной смеси автоматизирован в бункерах если только.

[@MrMaxwins]

а защитные сандали вам выдают?

[@FADNaR]

@@MrMaxwins хз что хуже... говно-синтетические боты с твердыми носами в которых ноги охренеют и синтетическая спецовка. пришкворчит - не отдерёшь. кто-то прям на тело носит, но у меня к вечеру соски стёрлись в таком варианте. футболку пододевал

[@user-rd3dz1vy7t]

@@MrMaxwins защитные сандали только для специалистов, мы в защитных бахилах ходим.

[@user-bu7qx3hd3w]

А сталь тоже из обрезков разных марок? :)

[@NikovK]

I'm going to throw this out there; if this were a series of photographic plates of a bunch of blokes with flat caps and overalls in a mill town somewhere outside Liverpool doing sand casting in 1860, we'd all be amazed what they were able to do with such simple equipment. And that gear would go into an ironclad battleship's guts and not leave until the scrapyard cut it out. I think we underestimate the value of 'good enough' in building the next, more perfect generation of machines.

[@jumpstar9000]

Not even that long ago. I used to work in an engineering company back in the 80s with no health and safety or guards on the machines over here in Yorkshire. It was great. A lot of people think everything comes out of a clean room made by robots and 3D printers.

[@LuciaArkwright]

Relaxing video to watch, thou would like to see the gear in function where-ever it is intended. Trusting it'll do a good enough job on par with the rest of the machinery.

[@mohammadalhasan4253]

when people like Joe Rogan say that "aliens made the pyramids" because "who the hell can do that kind of work without laser cutting and precision tools" and everyone who never seen a machine bein made agrees with him. These are the kind of guys could LOL!

[@Avaruusmurkku]

Standards exist for a reason. Those blokes in 1860 would have made a death trap mechanism that suddenly fails and kills 100 miners or whatnot. "Good enough" is absolutely horrendous. You have to follow engineering tolerances, so unless this gear is going into something very simple, It's a disaster waiting to happen.

[@NikovK]

@@Avaruusmurkku Why are you assuming it isn't going into something it is perfectly suitable for?

[@beanabong2896]

I wish all of these "experts" would gift these guys the modern tools and technology they are writing about in their critique. If not, they should keep their first world opinions to themselves. These guys do their best with what they have.

[@peoplez129]

The problem is, they're selling this stuff overseas, and it gets binned the same as if it was produced with higher quality....and if they have to, they'll secretly sell it through another country if someone is trying to avoid their product, until there's literally no place a company can go to buy stuff without getting something they're trying to avoid. These are literally fraud parts once you realize how the supply chain gets peppered with these parts. A well made part and a poorly made part can mean the difference between a long lasting part or not, or a part that requires more maintenance and fuel....to the point that they actually end up costing more in energy alone than simply making the part in higher quality in the first place. It might look like a big sturdy chunk of metal, but when we're talking about machines at the scale of requiring gears this large, we're talking a lot of force that can rapidly induce wear and tear. I mean just look how easily he was able to shave off material with what was a pretty worn edge...that's some relatively soft metal. Now imagine this put into a machine with other higher quality gears that are stronger....they'll grind it up over time, creating even more wear and tear. Now imagine just the logistics of getting a replacement and putting it in when these fail. What it all means is these parts simply are less efficient and not worth it, they're like using a dirty coal powered plant for energy instead of something more modern. Everything becomes more costly in the long run. It's like if I sold you a car with an engine made out of plastic....it might run for a little while, but eventually it will melt and you'll need a whole new car much sooner than you wanted.

[@beanabong2896]

@@peoplez129 point taken.

[@gavinjenkins899]

@@peoplez129 All industry is driven by the customer. Stop buying the cheapest thing available without asking questions, and that won't get made like that.

[@user-og1wv7bv7u]

Марка стали "хари кришну" и соостность на глаз - эпично!

[@kolchinw]

а с чего ты решил, что там нужна высокая точность? ты посмотри, какого уровня там производства, епт. поди не гипердрайв собирают

[@Willykurtz]

😂 Да, шестерня для мельницы. Хотя при нынешнем уровне глобалижадности такая может и к Маску попасть.

[@user-pi5cv1ge8m]

А ведь у Индии были перспективы стать вторым Советским Союзом.

[@user-ml9tw5bb2w]

​@@user-pi5cv1ge8mэто Пакистан, а не Индия.

[@user-pi5cv1ge8m]

@@user-ml9tw5bb2w Спасибо.

[@badseednut]

Great way to recycle all those road wrecked tricycles, and make decorative gears. Seriously, this defies any law of total quality, precision machining and manufacturing and any other law of engineering. Genius in their own way.

[@RLstavista]

And by "genius" you actually mean spastic mental retardation 😆

[@gavinjenkins899]

What's your alternative?

[@ElectricalCurrent-bz7ou]

This dude really is stuck in his own little first world bubble

[@ElectricalCurrent-bz7ou]

News flash not everyone lives in a good country they make do with what they have

[@gavinjenkins899]

@@eye-of-omega as opposed to what? Still waiting for your alternative

[@user-lf3wj7cp9j]

В сандалях, на босую ногу, там где литьё и механообработка, это вооще жесть.

[@kevinfromvirginia1796]

OSHA? Who in the hell is OSHA?

[@firstlost2636]

It looks more like playground than production factory 😂😂😂

[@raymonschepers994]

The material (steel) that is thrown into the huge furnace could easily take a life or create a illness that could end life as well…. The end result is a very discutabel cog of an unknown steel variant that can never be as strong or as hard as been given for such an end result. I’m stunned things like this still happen!!

[@Garnsta]

Even if ppl like to moan about the quality of the product, I always like when ppl are working hard to use what they have in hand. And I believe they know suitable applications for the products where it doesn't endanger anyone. Hopefully.

[@ajsindri2]

with the sped up voices, I feel like I'm watching star wars

[@ricklarouche4105]

Jawa’s !😂

[@satipsrl5207]

My great respect for these workers whos got up early morning and work hardly for a piece of bread and a dish of rice,to ensure a better future for his sons and daughters..😢😢

[@Santiago-qr8du]

I worked for this company years ago. We always made the joke of throwing molten steel down their backs with the rookies. It was very funny!.

[@unarmored9973]

It's really interesting to watch such a large cast made by hand, but it also gets to me when I think about how much danger these guys are expected to put themselves in for their bosses.

[@clown134]

yep. and all the bootlickers making excuses in the comments, as if were living in the 30s

[@nitromartini1422]

Similar risks are evident daily in industry right here in the US. OSHA is undermanned and generally incompetant. People get seriously injured and killed very frequently in American industry.

[@qwertyzxaszc6323]

I was scared for them the whole time watching this.

[@unarmored9973]

@@nitromartini1422 You are absolutely correct, and employers more often than not "imply" shortcuts by having unreasonable timeframes. Last place I worked (one of the largest employers in America), the policy demanded basic safety procedure like buddy lifting, ladders/carts to get high items, carrying only one item at a time... But doing it the way they DEMANDED, nobody could get their duties done in time, and that's just something that was absolutely unacceptable to regional and project managers, it would always result in write ups. I mean even if state shows up to investigate, the bosses would just blame the workers for not following the "instructed" procedure and just terminate them. It's just a sick and exploitative system, a lot of us sacrifice our health and longevity simply for a marginal increase in corporate profits (i.e. to buy a few CEOs a new yacht and vacation homes).

[@novens]

It is a little further on than the Industrial revolution, manual labor, child labor, dangerous labor and yet, here we are...

[@krunkle5136]

Love how its sped up making all the dirt poor workers sound like chipmunks. It really brings dignity to what's going on.

[@user-vf7nn8dv5p]

Why do you need so much metal processing when you can use “precision casting”. In general, of course, this is the Stone Age.

[@Brighton40k]

А ведь поначалу я беспокоился, что они могу попортить марку стали, если не вытащат деревяхи, мол углерода добавят, а потом посмотрел что они используют как материал. Чугунина, сталь, железо всё вперемешку. Как говорится, всё полезно что в горн полезло. Причем всё это вместе с грязью и краской. Прям отлично. Металл что надо. И это еще не припоминаю режим охлаждения. Какой он там в яме, вообще черт разберёт. Ладно еще всякие кустарные методы производства черновые сглаживаются постобработкой, но блин, для таких крупных деталей обязаны быть требования по прочности, составу стали и прочему. Я подозреваю такая деталь куда дешевле, чем произведённая как надо, но и к аварии приведёт, износится быстрее. Причем работяги трудятся в дико опасных условиях без средств защиты, лапая песок пропитанный смолой отвердевающей от СО2 голыми руками, горячая сталь рядом и тяжелые предметы, а на ногах из защиты только тапочки. Хотя, может это продукт для какой-то развивающейся экономики, которая пока не может сделать лучше, но это всё дикая дичь. Назвать эту штуквину деталью язык не поворачивается, это просто железяка в форме детали

[@user-tb9vs5zc1c]

Техника безопасности конечно на высоте,на литейке в тапках,ваще караул,ну а по работе,умеют конечно,чего тут сказать)

[@northwestrepair]

Now thats METAL GEAR SOLID except its not a snake

[@shaneroberts2492]

The bottle cap shims was my favourite part!!!

[@DavidSmith-bh7fd]

It looked like they were throwing random scrap into the blast furnace. I don't understand how they're controlling the quality of the steel. Mad respect in any case, they clearly have manufacturing skills. OSHA would have a heart attack if they came into that shop tho LOL!

[@wallpurgesnight8209]

OSHA would have a field day in most American business too are a joke. Tis why not much built in the u.s. too & we know fat cat Americans want it made cheap so they line their pockets at human cost NP

[@damianboj3809]

"I don't understand how they're controlling the quality of the steel." LOL. They don't, simple as that 🤣

[@saidultima]

😂😂😂😂😂😂😂😂 it's "Good enough" quality@@damianboj3809

[@lbgstzockt8493]

There is so much steel there, if you approximately know what kinds of scrap you put you can be relatively close to your desired composition.

[@kvach9403]

At the end, they throw a wheelbarrow with flip-flops

[@capt_bry]

23:18 good to see they are wearing the proper safety sandals while handing molten metal.

[@BLAXAMUXA]

They dont need any labor safety, instead they have 250 millions of people in Paki and 1.6 billions in India. Plenty of labor source.

[@nalmesa]

☠️

[@lbgstzockt8493]

Just as important as the safety squints when cutting with an oxy-acetylene torch

[@downey2294]

not to mention the safety children walking around

[@oberonist]

cheap labour power loves safety sandals

[@WormholeJim]

This make me believe in humanity. Human ingenuity at it's finest.

[@PbPomper]

This is just very old tech. We have learnt so much about the physical process since. There are loads of different compositions, which unique characteristics, heat treatments, surface treatments, etc... Create high performance metal parts is a like being a chef. You need to follow the recips, master the skills and understand the process. These guys are more like fast food or road kill chef. Just grab whaever you can find and make something that LOOKS like a giant sprocket.

[@WormholeJim]

@@PbPomper Yeah, I basically agree with that. I understand what you're saying, but -that is also how I can tell that you're not getting my point. I mean, you don't see chimpazees just grabbing whatever they can find and make something that looks like a giant sprocket. You don't even see chimpanzee appearing able to or even _interested_ in grasping even the concept of a sprocket, what makes that a thing. So yeah. Refining methods over and over, incorporating new techs and materials as they become available to refine some more. Those are what seprates the microchip from the sledgehammer. Literally.

[@GamesRealmTV]

Im impressed, but in same time i got left with so many questions! Nice video tho

[@darthgator639]

The Jawa's from Tatooine! Now I know where they come from! Nah just kidding, anyway, metallurgy was still not invented when this video was made. For a gear which needs a specific hardness and heat treatment it seems odd to just use the family cutlery to fabricate it.

[@ghksdhfb]

Адский труд и в тапках... Здоровья всем вам

[@2010travelz]

Так а кто им мешает какие-нибудь говнодавы надеть? В шлепках с раскаленным металом работать такое себе.

[@aheles125]

Я тоже заметил они все время в тапках, и все без перчаток. Наверно к 50-ти годам все помрут от разных болезней.

[@KidWanderer79]

At least they have their safety flip flops and sandals on.

[@SWturnikmen]

Здорово конечно что они всё это делают, но покажите как все эти детали работают, многое сырое и не точное, покажите сколько эти детали служат. Для контента конечно хорошо, вот для работы сомневаюсь.

[@SpeedFireARL]

мне кажется зубья имели форму лучше до того как их обработали

[@sovograf]

мне тоже, но возможно нам кажется

[@soolos]

Не путайте форму с шероховатотью поверхности. Скорее всего поверхность поправят потом, нам просто это не показали.

[@SpeedFireARL]

@@soolos если форма не соответствует эвольвенте.. имеет ли значение шероховатость? тем более ее можно было обеспечить шлифовкой направляющими, образно рельса с доской и насаженной наждачкой или ушм.. после такого строгания же, визуально, зуб стал хуже чем после отливки

[@victorkravchenko8779]

Ничо, на месте притрется

[@1992jamo]

Quite incredible. I really did not have high hopes for a useable product at the end.

[@Phaeton0025]

I still don't

[@dancanndungu3514]

Do assume that you never saw that guy who almost threw the wheelbarrow to furnace.

[@subjectt.change6599]

Am I supposed to be impressed by this example of 1000 year old technology?

[@johnpaparella7345]

Looks like their tolerances are in inches.

[@smzig]

I wonder how many cutting bits they go through on that lathe since they're not using any coolant.

[@I.AM.Issachar.]

They were using coolant you didn't see that fan next to the machine 😂😂😂

[@eyeeyeful]

didn't see one pair of safety glasses. That would make an awesome coffee table.

[@robmorris87]

This is like the "amazing"video of Indian mechanics "repairing" machienary cylinder heads on a rough concrete floor with a hammer and chisel.

[@ocwaldos]

Эти видео нужно показать в передаче удивительные люди😂😂😂 Вроде бы делают стараются только не понятно где такая продукция используется??? Качество, точность, ГОСТы и ТД и ТП, про это данные умельцы наверное никогда не слышали😂😂😂 Это делается ради видео и контента потому что собирать на таких деталях что либо просто опасно для жизни и бессмысленно, работать если и будет то не долго и очень плохо.

[@bope9301]

The metal hills are classified to obtain the correct metal structure at the end, it is then simply converted into wheelbarrow units

[@ravenna6543]

I 100% saw aluminum casings in the same wheelbarrow as a steel coil. lmao

[@operator8014]

@@ravenna6543 Aluminum, India's other steel.

[@IgorFrancish]

Если свойства полученного металла в изделии не важны, то можно и так... Зубья поотваливаются, новую сделают. Главное, что бы процесс шел!

[@snakebebop]

22:24 That guy's gonna be in some 4chan gore thread someday with the way he works

[@sietenotas]

Que laburo!! Saludos desde Argentina!

[@guhbnu]

me:what alloy do you use? foundry : YES

[@dewinmoonl]

i'm convinced sped up indian language is what the minions use

[@BrettonFerguson]

I've always wanted to make an oven out of blocks in my back yard to melt bronze. There is a coal power plant in my city and there is plenty of coal on the railroad tracks leading to it near my house. I once collected a 5 gallon bucket of coal in about 30 minutes. Then I would melt bronze and pour it into forms. I could make swords, daggers, axes, armor, and things. Like Ancient Greek Spartan armor and weapons. The most I have ever done is making crosses and other trinkets for necklaces out of melted aluminum cans. I used leftover tile grout to make the forms. I would shape the cross or whatever I wanted to make out of wax. I would often make three at a time. Pack the grout around them. Wait for the grout to dry. Heat it and drain the wax. Then I would melt aluminum cans and pour them into the mold. Once cold I would break the grout with a hammer and remove the aluminum crosses. Grind off any excess, sand, and polish them. Sometimes the hole at the top for the necklace would be full of metal, so I would need to drill it out. Then attack a thick black string through the hole for the necklace. Then give them to people. The crosses had a lot of detail. Not just a flat square shaped cross. They had decorative carvings on the cross beams and a Jesus hanging on the cross. I considered it practice making them I gave them to people for free. Someday I hope to have the time and proper equipment to make more difficult things like swords and armor.

[@mattyboolin]

Jesus Christ dude no one cares

[@chrissimpson9687]

Some people just don't know when to shut the f up.

[@sedumedimoeng5127]

Nope, that's quite impressive and indicates that you're very intelligent. I'm a physics major and making anything metal from scratch has a very steep learning curve. Most of humanity would never make it out the other side. This guy makes something that actually works and looks good.

[@BrettonFerguson]

@@mattyboolin I care about my family and what they think. Wife and kids. Not about Matty Boolin from the f**king KZbin comment section. 🥴

[@Wormweed]

Very nice steel toe sandals they are using. And a great mix of copper and all sorts of steel and iron mix.

[@grumpa5798]

When an OSHA employee watches this.... he immediately goes into an epileptic fit and is at risk of biting his tongue off.

[@jambriest]

The fact they all seem to have their toes shows they're masters at their work 👍

[@Digital_Griffin]

Suddenly I understand why "Made in Germany" lasts longer

[@Adil1amin]

What a dope. Why are you comparing poor people with billion dollar companies. Toyota outlast any European shite.

[@hastyone9048]

See how nice these guys play in the same sandbox.

[@glazyonka5899]

You should think about times when machines were broken because someone used cheap details were made this way.

[@bruceogletree7995]

As impressed as I was with the skills exhibited, I was equally distressed at the workplace conditions and practices. I suppose as long as there are people willing to work under those conditions, they will be exploited.

[@user-cf1oj8xx5t]

Это капитализм , он эксплуатирует людей и даже детей . Капитализм зло

[@kenton6098]

Welcome to the third world. These conditions are not seen as particularly alarming. They are standard.

[@kenton6098]

@@user-cf1oj8xx5tthis is manufacturing. It takes place in both capitalist and socialist countries.

[@tonyblanco3142]

these guys dont worry about OSHA and PERSONAL Protective Equipment PPE...they are possibly overpopulated so who would give a hec.k...

[@satipsrl5207]

European protective laws are for idiot junk workers,I'm sure about heavy automation and bureaucracy blah blah is more dangerous condition instead of personal skills and experience of these people workin g

[@TJlolbagger]

They somehow made the teeth profile significantly worse while finishing. That's impressive, in a way.

[@codeblocks4067]

lol

[@PGVGAMER]

this guys be like, glove protection? glasses protection? naah i trust god!

[@themadmailler]

any machinists care to chime in on how he managed to create the tooth profile on the shaper?

[@user-pg8go4bz7x]

Когда человеческая жизнь дешевле шестерни.

[@mad_t]

учитывая, что эта шестерня из мусора с допусками уровня "и так сойдет", этот факт еще печальней, чем кажется на первый взгляд.

[@key_mard2727]

В этом видео великолепно всё!...только не пойму почему кровь из глаз потекла...

[@user-cy9lf5yo1k]

Техника безопасности конечно,желать лучшего в шлепках по металической стружке

[@testplmnb]

how do they control the mix/hardness and other properties of the steel if they throw random metal trash into the furnace.

[@hbh3144]

application they are intended for is also random

[@seklerek]

they don't

[@peoplez129]

And now you see the glaring problem. In reality, no company would deliberately want such a part. What you are really witnessing is a counterfeit foundry that peppers supply chains with these parts. They get sent off somewhere, sanded to look like all the other better made parts from other places, and X out of 10 of those parts ends up being these. They go into some machine, break quickly, and the company is forced to replace it again....and again...and again....for a higher cost than buying a properly made part in the first place....but they can't avoid it because of how these are just snuck in with higher quality parts.