No. 1 - Cutting Keyways - 1941

A metal working industrial tutorial on how to create keyways. Keyways are important in locking gears to shafts, so they are not able to turn independently from each other, under load.
The feed and speed section is something a lot of people look for - because most of the charts are set up for skinny round milling cutters, not those big side-milling cutters.
This film covers how to cut a specified keyway using a side tooth milling cutter on a horizontal milling machine. It shows one way to hold a round shaft, how to calculate the proper cutter feed and speed using a 5" cutter, and how to align and make the cut.
This film is part of a series of Defense Department films for training machinists in preparation for World War 2. The technique and care that they demonstrate in the work is still important to appreciate today.

[@fededevi1985]

Those old U.S. documentaries are really well made.

[@mctavishmcardle6906]

some gorgeous photography in this - that horizontal mill is so clean & shiny! great lighting too

[@feslerae]

Maybe I'm nostalgic, but it seems instructional films were more professional back then. I see stuff now that tries too hard to be funny rather than explain or properly show things.

[@darthvader5300]

The best things about machine tools in the 1940s and 1930s is that every instruments such as monitors, sensors, indicators, effectors, feedback systems, etc ARE ALL 100% ANALOG-BASED SERVO-MECHANISMS that shows everything simultaneously regardless whether you want to see them or not. And in the late 1970s and early 1980s they started using an all analog fiber optical technology based instruments combined with an all analog fresnel lens optical vision enhancers with fiber optic cable directed incandescent light bulb(s) to provide clear lighting and to measure, monitor, sensor, to provide feedback with precision ranging from 10 millionth of an inch to 11 millionth inch. With such machine tools YOU CAN LEARN EVERYTHING AND NOT DEPENDENT ON FRAGILE SILICON IC CHIPS THAT CAN RENDER ALL OF YOUR MACHINES INTO USELESS SCRAP JUNK! Using precision engineered machining grinders with self-adjusting mechanicall automated adjusters to compensate automatically for wear and tear, jigs and fixtures, positioners and aligners, bolt lockers, angles and degrees mechanical finder-adjusters-bolt lockers, and all ancillary mechanical devices, gadgets, instruments, rulers, measuring tools used by 1900 to 1960s master machinists. One can master all. kzbin.info/www/bejne/rIrdgoGdftykndE BEGIN Japanology - Small Factories kzbin.info?search_query=japanese+small+scale+industries+&sp=mAEB Without mastery of the low tech, you can't have the high tech" Masayuki Okano

[@darthvader5300]

Nick Coote Nick Coote1 month ago Takes me back to my apprenticeship days! No end mills back then, just cutting discs. Surprised he didn't take a roughing cut with a thinner disc then finish cut. Plenty of oil as cutting fluid, no 'stinky' white cutting fluid.. Reply Travis Bickle Travis Bickle5 months ago Those machine tools won 2 World Wars for the United States, they helped create the "Arsenal of Democracy" as Franklin Delano Roosevelt called it... Shame kids all want to write code for "GTA 79" We still need tool room machinists and Die Sinkers today, and pay for an experienced man can far exceed $20.00/hr, w/full benefits and the pride that comes from creating complex tooling from very exacting blueprints... It's honest, descent, good work for a man, sometimes even a woman... Show less Reply 11 Phil Menzies Phil Menzies5 months ago Yeah. USA all the way! The input from all the other allies had absolutely no bearing on the outcome of those 2 wars. Neither of which, apparently, the USA wanted to be a part of until their hand was forced .............. Reply 6

[@garywills5682]

Nice mill, vbm , I did an apprenticeship in the 70s . The vbm I had to use was line shaft driven from the 1880 90s . Man she could still turn out great parts . I did work for a steel mill in Pennsylvania. Bearing blocks , roller shafts much more. Heavy work but I'm so happy to have done it.

[@JonTheBrush]

Gawd, Mertric makes life soooooo much easier! Still a great video!

[@Lmr6973]

Got to love the the way the dials were made back then.

[@loftsatsympaticodotc]

Wonderful to see clear, B & W, well defined photography, with the accompanying step by step instructions for each sequence of such jobs.

[@oddtools2812]

Thanks for putting these videos up. I have lots of books from this era and seeing the videos really brings the whole process to life.

[@sibalogh]

I just love these old workshop videos...

[@stashu5242]

Good videos. The old military training vids are excellent.

[@screwgate1]

Love these type of old movies

[@dennisobrien3618]

Love the old Gerstner toolbox. Wonder what it looks like more than 75 years later.

[@timthompson468]

0:54 Safety glasses! We don’t need no stinkin’ safety glasses. Great video. I work in electronics, but this is fascinating. I wish I had an opportunity to learn this stuff, but I don’t think I’d be very good at it. Thanks for posting these videos.

[@obfuscated3090]

Take a community college course. I did. You can learn it like you learned electronics, and the concepts you learn translate to MANY things.

[@TLervis]

That scraping work on the horizontal mill 😮❤️

[@MrJohnnaz]

What a beautiful machine, looks like it might be a Cincinnati.

[@obfuscated3090]

Keith Rucker and others still teach scraping courses. My bro attended one and loved it. His next project is rescraping a Bridgport we rescued after buying it cheap because it had a stuck gib.

[@dfpolitowski2]

Did you know its not uncommon for some shops today to be using the same machines as in this film. Repair/rebuilding shops are a good example. It just doesn't pay to buy a new machine to make a key-way in a shaft once in a while.

[@red66chevy]

thanks for posting

[@kisspeteristvan]

Fantastic

[@gazza116]

the invisible safety gear got me .

[@JP-kk5vw]

Nice!

[@michaelclark2840]

Nice mill.

[@evildrome]

This machine appears to be the umm.. "inspiration" for my Parkson 2N. The controls are different but the resemblance is uncanny.

[@evildrome]

@Travis Bickle That does sound very interesting. I got a tour round the Rolls Royce blades factory. The hot stage blades are forged and we saw them go from little chunks of bar to finish ground. Will you be able to leave the facility and go into assisted living in your own place (eventually)?

[@samhouston1673]

I want one. Now where to get and how much?

[@parrotraiser6541]

You'd definitely want to do a batch at once, with all that calculation and setup.

[@peterfitzpatrick7032]

"All that calculation" as u call it is second nature to a machinist... & one-offs are more likely produced this way ..production runs are usually done differently such that a less experienced worker can accomplish the same task accurately... google jigs & fixtures.... 🤗

[@joeys8317]

Not really much calculation or set up. An experienced machinist could have that set up done in maybe 20 minutes

[@ardvarkkkkk1]

Parrot Raiser This is a very simple job.

[@rolandocrisostomo2003]

I have a Burke horizontal milling machine, all I do is play it by sound, if the feed rate is to fast, it will sound loud.

[@webtoedman]

I have one of those! It's a little brute, really makes the chips fly.

[@benniemcdonald1365]

Run the same machine in the 90s.real American tough.

[@timthompson468]

Those machines amaze me. I’m curious did anything every go “wrong” with them? I expect these days in six months everything would start breaking down.

[@codprawn]

Old British machines were just as good - I have a lovely Elliott Sturdimill - good name it weighs over 3 tons or almost 7000lbs.

[@red66chevy]

how were the power gear changes accomplished? it was intriguing how just holding the lever up changed rpm and down changed feed. My K&T you have to wind to change gears

[@aykfc]

@@timthompson468 mostly just wear on the metal parts rubbing together that causes issues with it not being accurate or having to tighten something down extra hard. It's kind of a pain but if you're careful, the wear isn't too bad and you can usually compensate. The frustrating part comes in when you go and replace one part that's really worn and the gears and bushings are no longer meshing right after.

[@darthvader5300]

British machine tools were designed to be simple AND PRECISE and to last ad infinitum.

[@jacobjames1171]

Train horn at 9:35?

[@UseitLoseit]

Takes me back to my apprenticeship days! No end mills back then, just cutting discs. Surprised he didn't take a roughing cut with a thinner disc then finish cut. Plenty of oil as cutting fluid, no 'stinky' white cutting fluid..

[@luviskol]

And they say that the metric system is too complicated.......

[@karlhrdylicka]

luviskol, I doesn't matter which system is used they are just numbers if you ignore the fractions with the imperial.

[@loftsatsympaticodotc]

George Campbell...Best? yes; origin? NO! Inches etc. were a thumb width, or division by a dozen of a certain long ago king's foot, etc.(England). Years later Napoleon brought in the now universal metric system based on physical constants. btw, this comes out of my memory; where did you get your idea from?

[@MathewHammond1]

George Campbell no it’s not lol but it does add extra work

[@mansnilsson4382]

@@loftsatsympaticodotc Swedish measurement legend C E Johansson got so tired with US and British definitions of an inch being slightly different, that he told them both to shut up and accept his definition of exactly 25.4 mm as an inch. Sounds crazy but is actually true! Read here: www.mitutoyo.com/wp-content/uploads/2013/07/E12016-History-of-The-Gage-Block.pdf Further, one might notice that as soon as US inch-fans get into measuring for real, they all end up using thousands, which is as decimal as millimeters, just not the same. Fractions? No way.

[@niftykeentypedog]

@@geocam2 Imperial units are, nowadays, defined in terms of metric units, but they owe their origins to far more obscure and ancient measurement standards.

[@bobcox963]

Check out the Gerstner chest

[@127069]

Id love to chance to have a Cincinnati no2 in perfect condition

[@csonracsonra9962]

Im still using one in 2019 and outs one of the most rigid machines in the shop

[@flatsurfaces1913]

The Standard system (inches) is far more complex than the Metric system.

[@MuseumofOurIndustrialHeritage]

Yes. The Metric system was created as a result of understanding that an interrelated and base 10 system of measurement is preferred. This concept of measurement might not have been developed if earlier systems of measurement hadn't first been attempted. I hope these films are appreciated as being part of the historic record. We are not advocating that things get done exactly the same way today. Technology properly evolves through time.

[@trikebum5]

There may be some truth to that statement. BUT, when we started going metric back in the 80's and 90's EVERYTHING went to hell! Our machines, cars , tractors, trucks and and tools are garbage compared to the earlier versions, with a very few exceptions!!

[@highstreetkillers4377]

@Museum Metric is based on "the power of 10" makes understanding easy. Metric is also more accurate, increments are smaller. Metric also perfectly translates into volume and mass. If an objects density is less than 1g per cm3 it will float on water. Metric threads are also better. Programming is way easier in metric cause your using whole numbers, no fractions. ie 12mm tool has 6 mm radius. A 5/32" tool has what radius? You have a 1000 mm you can say that's 1 m. But if you have 150" inches you say 12 ft 6 in and sometimes a fraction. Inch fractions don't translate into ft. List goes on why metric is far superior

[@webtoedman]

@@highstreetkillers4377 A 5/32'' tool has a radius of 5/64''. The metric system is a boon for persons who are unable to multiply or divide by two.

[@josephdestaubin7426]

@@trikebum5 Interestingly, the reason the Reagan era push toward adoption of the metricsystem failed was that the machinist union, among others, believed that the move would facilitate the decline of American manufacturing by allowing foreign machine parts into the Country. Unfortunately, the unions failed to understand that by abandoning the metric system "change over" the unions were signing their own death warrant by crippling US expansion into forign markets. Basically the unions failed to understand that it was much less expensive for foreign interests to retool for the US market and it would be for the US to retool for the foreign market. And in the end we just ended up buying the whole product from overseas. This in turn helped create to some measurable degree the disposable world that we live in now. To be sure, this is not the only mistake but the unions made. But I think it was the largest mistake, with the most far reaching consiquences. My father grandfather and stepfather were all Machinist oh, I'm a history major. So it's easy for me to judge. But as I'm old enough to remember the transition, I feel comfortable saying no one other than the economist could have predicted the consequence.

[@COIcultist]

4.34 after doing the maths to find out it's 1.17125" to the centreline it then dimensions it as 1.1725". Yes I am a pedant.

[@daveyt4802]

Math! A bit different from a HAAS machining center. :)

[@triariicat8448]

Dis they have endmills back then?

[@mansnilsson4382]

An end mill would create a stress point because there is no natural chamfer when the keyway ends and thus cracks are bound to start there. The keyway cutter creates a gentle slope as it cuts and thus no crack-inducing stress points will form.

[@harryfischer6741]

Give us something about the builders of the machines, the machinist's are using...

[@obfuscated3090]

That history can be found in websites and forums, not video. vintagemachinery.org/

[@therussianmachinists2409]

Is it me, or is the key way not look centered at 11:22

[@Fischer977]

What did they smear on their hair back then? Is it grease? Or machine oil?

[@joeys8317]

Fischer977 pomade

[@kenp3L]

Wildroot Hair Tonic, perhaps. Brylcream, maybe.

[@MuseumofOurIndustrialHeritage]

No. I am 65, and at that time it was Brylcreem. Back then it must have been "greasy kid stuff"!

[@seraphim1833]

One thing that they barely mentioned was machining direction. You CANNOT climb mill on these old horizontal mills because of the way their lead screw was designed. If you did decide to climb mill, the slack in the lead screw would cause it to feed way too much into the material, likely causing your workpiece to get thrown across the shop. Climb milling isn’t a problem now since new machines have ball screws.

[@highstreetkillers4377]

Doesn't matter, old machines used ball screws. That only happens if you take too big of a cut per tooth. CNC machine does it too, you'll get a servo x axis alarm though. Or the spindle stalls.

[@dfpolitowski2]

Bro, I climb mill all the time with a conventional lead screw. Taking a reasonable size cut. Also you need to get the slack out screw first then cut. You just need to use your judgement.

[@FabFunty]

need more numbers but apart from that nice video 😉

[@1ginner1]

Must have been before radii were compulsory in keyways due to shaft failures.

[@ardvarkkkkk1]

1ginner1 It's still not.

[@dtom1145]

No need for safety glasses back then? Eyes were replaceable?

[@MuseumofOurIndustrialHeritage]

Take a look at the Millers Falls Tool Co. film. The guy sticks his hand into the wood cutting lathe while it cuts tool handles! I am sure accidents happened, but apprenticeships and hands-on training was common, in those days. Part of what you were taught was how to avoid killing yourself. That generation may have injured itself less frequently than the modern one would in the same circumstances.

[@MuseumofOurIndustrialHeritage]

Working people of that time may have been even more aware and cautious of the risks. I survived working with high voltage vacuum tube equipment. Try finding anything over 12 volts, these days.

[@scottvincent1596]

I’ve never met any “old one eyed” machinist. Have met several with missing fingers.

[@Mishn0]

Jump in your time machine and go yell at THEM. You're wasting your effort whining about it to us, here.

[@Kolajer]

Safety squints were all the rage back in the day, still are in fact.

[@RU-zm7wj]

Just think, if you used metric, all the numbers used would be zeros instead of 15 thousandths or, .001678 or .001456739 etc., plus all the multiplying and dividing of multi-numeral equations. For example: 20x6.283"=125.664"=10.472 ft. per min. for just one measurement. Whew!

[@ardvarkkkkk1]

R U 1 2 The only way that the numbers would end in zeros is if accuracy was not important. His answer, 1.171 inches comes out to 29.743 mm. Still a fraction.

[@nettyvoyager6336]

25.4 mm to an inch whats complicated

[@highstreetkillers4377]

Metric is more accurate and far superior. Even NASA works in metric

[@axisfiveraxisfiver5844]

I wonder why they cut conventional and not climb mill

[@ardvarkkkkk1]

axisfiver axisfiver Try climb milling on a conventional machine. You will find out what what the term crash means. Conventional machines use standard Acme threaded lead screws. These screws have backlash. If you were to climb mill, the force of the cut would take up the backlash violently.

[@spyem1]

I’m no machinists but my god the imperial system seems utterly ridiculous!

[@ardvarkkkkk1]

Scott Wooten Nobody uses common fractions for anything very accurate anymore, for a reason.

[@nettyvoyager6336]

its all CNC now

[@highstreetkillers4377]

Still the exact same thing. You just hire bunch of dummies to operate it while you program the movements so a guy isn't standing there cranking dials, making mistake

[@obfuscated3090]

Not in the real world. Repair and custom machining work often use the same vintage tools you see in the video. Repair machining is what keeps factories going. It's faster to cut metal for individual parts if their complexity doesn't require CNC than it is to program and set up CNC machining centers. My machine shop owner bro (I help sort out older CNC machines and his computers) is a multi-millionaire and most of his fleet is ancient. He even has a near-perfect Cincinnati shaper older than 1920. He has CNC too but manual machines are critical to making money. No CNC of similar capacity to his WWII American Pacemaker lathes would pay off in custom and repair machining.

[@user-hq4ws1wb3t]

It's sad but all the industrial heritage was blown up in the China direction

[@garyjonson1872]

"Made in China"? NO WAY!

[@elWieslaw]

But why do not they teach that it should be milled with safety glasses

[@MuseumofOurIndustrialHeritage]

This film is 75 years old. Procedures and rules were different then.

[@kenp3L]

6:53 125.664" is _not_ equal to 10.472 ft/min.

[@chrisaberhallo]

they muricans and inches...

[@karlhrdylicka]

chrisaberhallo, nothing wrong with yards ,feet, inches and thousands of an inch, ignore the fractions and both imperial and metric are just numbers.

[@peterfitzpatrick7032]

A good machinist can use both metric AND imperial systems with ease and convert on the fly too !!! 😎

[@chrisaberhallo]

​@@peterfitzpatrick7032 , a good machinist doesnt get in contact with the imperial system....

[@chrisaberhallo]

@@karlhrdylicka nearly everything is wrong with this system, btw the definition of the imperial system is based on the meter!

[@jimmyt636]

@@chrisaberhallo Ya totally agree......I had a customer come in with 500k worth of work for me but the prints were all in imperial.....No thanks....I'm above that imperial nonsense.

[@scottpecora371]

OMG I just cringe, eye protection !

[@parrotraiser6541]

Not to mention wearing a tie.... :-)

[@donaldcampbell7894]

Those machines still run to this day. Solid. But I am a CnC machinist. I would rather put that in my hurco. I could one shot that key way on size in about 15 seconds in cutter comp. yes those machines helped win the war. There is just no place in the modern machine shop. It would be impossible to turn a profit. Pun intended.

[@MuseumofOurIndustrialHeritage]

Do you still check the work? Much of the content of these films are about stressing that the job gets done right. Of course technology improves over time, but I still don't see how humans will no longer need to verify that things are being done properly.

[@donaldcampbell7894]

The CnC I run is accurate to 14 decimal places. It displays only 5. Of course work is checked. It is a totally different era in the machine shops of today. Gotta love it

[@staffordduecker665]

@@donaldcampbell7894 I'll bet it's not accurate to fourteen places. I'll bet it's barely good for .0002".

[@webtoedman]

@@donaldcampbell7894 14 d.p? Six d.p is one millionth, you can get that sort of variation by breathing too hard, in the next county. I call BS.

[@heavenlymachining5674]

@@MuseumofOurIndustrialHeritage We have a machine shop that resembles the one in the video. heavenlymachining.com for a peek. There used to be a CNC shop a block away. They went broke sold their machines and the owner got a job teaching welding to high school. "Those who can't do teach". We are still going as strong as ever. "Those who are putting on their swords shouldn't brag as if they were taking them off."