Retrofitting the Schaublin 125 CNC lathe - Episode 33

[@DolezalPetr]

jesus christ nooooo poor table :(((((((((((((((((((((((((

[@RotarySMP]

I really think the poor Maho deserves better :(

[@zoidbergVII]

You will have to cast a new table next!

[@RotarySMP]

@@zoidbergVII That would be cool, but way beyond my equipment.

[@DolezalPetr]

@@zoidbergVII or try welding it and re-milling

[@RotarySMP]

@@DolezalPetr Come on, you have seen my welding "skills", you dont have to put the boot into the poor Maho. I'll probably leave it to remind me not to forget things I learned, but if I do repair it, it will be a cast iron plug and epoxy.

[@Rustinox]

And as is tradition, those cutters don't ask questions. They just go for it. But at least, you have a very well made part. That's a win.

[@RotarySMP]

Yep, it is an uncaring machine.

[@moccaloto]

love the split screen double cam thing👍

[@RotarySMP]

Thanks. It is a bit of extra effort in the edit, but makes it all a bit more interesting.

[@remcoverhoef7015]

Thanks for including all the mishaps, it makes the channel extra educational.

[@RotarySMP]

Thanks. Sometimes I wish I would retain my one painful learnings better!

[@yak-machining]

Now you have to cast a milling table haha

[@RotarySMP]

I wish :)

[@MrZX1206]

A spaceship through the void, lucky guy, you got a good one.

[@RotarySMP]

I thought that was cool when I showed her.

[@WoLpH]

Ouch... I feel your pain when it hit the table 😢 Shit happens though, it's still perfectly functional

[@RotarySMP]

I was mostly annoyed that I had learned lessons and then forgotten them.

[@Ryan-dz3jo]

Ooooffff, that hurt to watch because I feel your pain. Turned out great in the end and you survived the landing.

[@RotarySMP]

Yeah, I was really disappointed at my performance. The Maho doesnt deserve that.

[@misterfixit1952]

I always find inspiration in your videos. We just received a new heat pump on a wooden pallet. I was going to throw away the pallet but after seeing this vid I realized I needed the scrap wood for new core boxes. Yep, you're always an inspiration.

[@RotarySMP]

Thanks for your kind feedback. Pallets are often much more interesting and exotic timber than we think. I picked up on that from Laura Kampf.

[@petergamache5368]

Ouch! That was a sad crash indeed. One thing you can do in LinuxCNC to provide a sanity check - set up your config to also unhome your axes when you e-stop or cycle abort. This (at least for me) serves as a reminder that the machine may NOT have all the coordinates "sane". Servo-based systems aren't as bad as steppers but they can still get out of sync sometimes. Setting up your CNC like that forces you to pause and think for at least as long as the homing cycle takes. If I were doing production work, that behavior would be annoying but as a hobbyist (when most parts are 1-offs) it's better to save the tooling/machine and waste a few seconds between cycles when I've cancelled for some non-emergency reason.

[@RotarySMP]

The Maho has linear encoder feedback. It cant get out of sync. That is one of the best things about such a set up. You dont need to home it except from a cold start. I had a decent work flow a year ago, but forgot it. I'll laminate up a little cheat sheet and hang it on the control, as the main points to prevent this are pretty simple when followed.

[@nickp4793]

Nice job. I liked the split screen view, and I bet it made your life easier so you can concentrate on the work instead of the filming.

[@RotarySMP]

Thanks, generally the camera set up and start comes first, and then I cane generally ignore them while the machine does it's cuts. I sometimes bump into the camera stand, and you'll notice the wobble.

[@dermozart80]

YEAAAAH! More casting!!! MOOORE!!!!!! MOOOOOOOOOORE!!!!!!!

[@RotarySMP]

Glad you got your fix :)

[@forgeperformanceand4x4]

Have you thought about a fixture plate top for the mill? I run zero points on ours so we can load on sacrifical plates that have saved my but more than a few times. Aluminium with a few drilled and tapped holes

[@RotarySMP]

I think that is a good idea.

[@forgeperformanceand4x4]

@@RotarySMP just some 20mm thick alloy with a locating strip in it the strip you mill in so it drops into your t slot few bolts and bam. No more whoopsies a d infinite clamping options

[@RotarySMP]

@@forgeperformanceand4x4 ... and it would hide the aweful divet in the table :/

[@Cyruscosmo]

Just got me a new mill... My grandpa told me to learn by the mistakes of others... Cause you won't live long enough to make um all yourself... ;-) Where did I put that hunk of 25mm aluminium plate?

[@akfarmboy49]

i'm a machinist for a lot of years, I don't have any friends that do there own castings, I'm impressed with your ability to keep focused on every step of your projects, I like you Maho mill.

[@RotarySMP]

Thanks for watching and commenting. As you can tell, I am neither a machinist nor foundryman :)

[@akfarmboy49]

@@RotarySMP your casting turned out good. Your choices of carbide insert cutters is good. You might want to get a couple other sizes between tiny and large. I have been buying lots of them lately on eBay. When possible try using taller risers blocks above table. I have older CNC mill that has has one Retro fit before to long it might need a second retro fit upgrade.

[@RotarySMP]

@@akfarmboy49 That is a good idea. I have been thinking of getting a 40 or 50mmindexable mill to span that gap. Also taller risers would have helped. Thanks.

[@allnicksweretaken]

Reminds me of my CNC training. No one told us that our cnc mill forgets it’s place in the program and it’s Z location if you pause the program. That end mill went into the aluminium work piece like a hot knife through butter at rapids feed, until it hit the vice and snapped.

[@RotarySMP]

Yeah, that is a horrible sinking feeling. Loosing position in the program on pause sounds like a pretty poor controller. LinuxCNC is fine with that, but loose tool offset on E-Stop.

[@allnicksweretaken]

@@RotarySMP yeah, it was both fascinating albeit horrifying to watch that demonstration of power in that brief timeframe. x) My buddy and I where both shocked and perplexed. Mmm, we didn’t have a state of the art machine to play with. It looked nice and all, but apparently it was as smart as a brick.

[@stewartfrye]

The casting doesn't look like it needs any filling, Great,,,,,,,,,,,,, But, your mill table does, ouch,,, But when your done filling your mill table let me borrow that filller my vise needs a few repairs,, LOL man that hurts to see..... LOved the video

[@RotarySMP]

Thanks for the support. Painful lesson again.

[@gregwmanning]

Casting videos are my favourite. What a brilliant result!

[@RotarySMP]

Glad you like them!

[@Elektronaut]

That mistake with the table sure is a bummer but the casting looked great, it machined well and the part sure looks great! Even the engraving is the right side up! 😉 congrats!

[@RotarySMP]

I would rather have the engraving on it's head than that table scar, but couldnt choose :(

[@josephlovell6951]

So sorry mate... it broke my heart to see it can only imagine how you feel

[@RotarySMP]

Yep, it really was not a good moment.

[@michaelmiller5566]

Nice job

[@RotarySMP]

Thanks for commenting.

[@jster1963]

That casting and part came out SOOO GREAT!! When I worked at Buick, I watched raw castings turn into a running engine at the end of the line. Your cast iron looks just as good as the engine cast iron I used to see. I'm so sorry for your table. And it's so true about proficiency. Flying a plane is not like riding a bike. It's like an Olympic event. If you're not doing it constantly, you won't win. Nice work!!

[@RotarySMP]

Thanks Jasper, really hurt my pride this one, as I had learned that lesson and then forgotten it.

[@jster1963]

@@RotarySMP I bet! And me2;-)

[@chili0230]

great choice of music!

[@RotarySMP]

Thanks for the feedback.

[@misterfixit1952]

I'm really sorry about the Oops on the table. Being the first one always hurts more. You are right about the plug and JB Weld repair scheme as being the only solution. Maybe putting your logo in the plug could be a "feature". If nothing else, It's a good incentive for making a fixture plate, something I plan on for my VMC, especially as I get used to the quirks of the system and the pitfalls of the learning curve. Sorry, you get to be my inspiration for disaster avoidance.

[@RotarySMP]

Thanks. It was not the first scar in the table. The machine came from a tech school on the German border, and had two or three scars already, but this is certainly the worst. Yep, make the fixture plate straight away.

[@16siemon]

That is a very nice casting! After the little table mark, i saw the chamfer tool go down and hit that threaded bar.. Not going to lie, that had me hold my breath

[@RotarySMP]

Yep, not my best perfromance.

[@williamwestonn]

When programming. Split the program so that you always have a comment at every tool change / G43. This will give you a reminder when block searching, to always restart from that position. And if you need to reposition or change something, just edit the following lines :)

[@RotarySMP]

Good point, I will add that to my PP.

[@bobweiram6321]

Even factory cast iron parts have some inclusions, hence the bondo fills. I wouldn't worry too much about the gouge on the table. I would TIG fill it, machine it and then recreate the grooves. If done carefully, it should be impossible to tell it was damaged.

[@RotarySMP]

I will leave it for now, in case I forget what I learned again. If I do fix it, it will probably be a cast iron plug and epoxy.

[@StanislavG.]

@@RotarySMP braze fill it, so it'll look like a gold tooth :))

[@RotarySMP]

@@StanislavG. That would be aweful :/

[@RJ99729]

@@RotarySMP I was goin to suggest that too, my drill press table has quite a few brass filled woops in it. Kinda grows on ya. Kintsugi style

[@RotarySMP]

@@RJ99729 Too bling for me :)

[@robertfontaine3650]

slowly but surely.

[@RotarySMP]

Yep. Bit of progress.

[@jamest.5001]

What i noticed working really well. Is making a large reservoir inside the mold. And being certain to melt extra metal. And have a runoff with a vent , leave room at the opposite end to leave room for any contamination to either go to the end past the part mold or float to the top of the fill port. "Sorry" My foundry lingo is lacking for shure! But i am getting really into this stuff. Can you cope with all the spruing around? Haha...

[@RotarySMP]

I am pretty limited in the capacity of iron I can melt and handle.

[@HM-Projects]

Machinist pebcak, luckily it wasn't worse and glad that Maho spindle survived. One reason I will never be comfortable being a CNC machinist, I have the attention span of a 2yr old and I'm not made of money. The cast iron part came out great, excellent work!

[@RotarySMP]

Yep, me too, and I dont use the Maho often enough in the last year due to the lathe conversion, to be good at it.

[@mumblbeebee6546]

I got nothing clever to write this week, so just congratulations on the solid casting!

[@RotarySMP]

Thank you very much!

[@bostedtap8399]

Ouch!!!, done that more than once, great job on the castings, machined surface looks great, very consistent material, swarf was uniform. Impressive work, in front, and behind the camera, Thanks for sharing. Regards John.

[@RotarySMP]

Thanks for your kind feedback.

[@joell439]

My heart absolutely sank as I was hitting the stop button on my screen and the tool head was still lowering. I sure hope the distraction of capturing video for us didn’t contribute to that happening. Robots just have no feelings. Part came out super nice. The mixture of old and new is not lost. Hand planing wood to CNC planing iron you cast yourself. Other than the tool height mishap, hope you had fun.

[@RotarySMP]

Yeah, looking at that video I also dont understand it. I have my hand on the feed override, but misinterpreted what was going on. Super annoyed with myself.

[@garul1669]

I am so so sorry for your milling machine, when it happened to me i was sick for a week

[@RotarySMP]

Yeah, especially as it happened due to a forgotten lesson learned.

[@petevance422]

Part turned out beautifully!

[@RotarySMP]

I am pretty happy with that result.

[@zoidbergVII]

Good to see we are all human!

[@RotarySMP]

No one would confuse my work with automation :)

[@hairyfro]

Consider the gouge in the table a badge of honor. After all, it occurred while you were machining a part you cast for a cnc conversion of a Schaublin lathe that you've undertaken. It's a tangible reminder of your perseverance.

[@RotarySMP]

Thanks, that is a very positive spin on it.

[@misterfixit1952]

I watched a vid from Floweringelbow showing a circular dross trap at the end of his side sprew run (?) which catches the dross in a centrifugal trap before pouring into the mold cavity. No dross filters needed.

[@RotarySMP]

Thanks, I have seen those ued before, but have so far been too lazy to try one :)

[@robertwatsonbath]

Nice job. Neat voiceover cameo by Mrs Rotary. I'm a few days late watching this, so I hope you've stopped beating yourself up about the mill hiccup by now. Stuff happens. Glad to see you found time to give the name plate a bit of a rub for luck :)

[@RotarySMP]

Thanks Robert, Shame one moment of inattention took the polish of an otherwise nice result.

[@jimsvideos7201]

Well on the one hand you customized your table a little bit, but on the other you got a great surface finish! 😂😯 But seriously thank you for taking us along, it is indeed doing the job twice to film and share it too. Aside: LPI developer is conveniently talc and acetone in a spray can, if your guy has any that has gone TX. Also aside: In the old old job an engineer made, for NDT techs, a definitive connection between currency and probability of detecting cracks, which was intriguing.

[@RotarySMP]

You are right! I think all professional jobs are like that.

[@wilcojuffer5940]

Verry nice lamp you have on the Maho, when you want a flater result for the 020 endmill take for the 2e pass a smaller step over (1/4 of the endmill) nice video I cry when you make the hole in the Maho 😢😢

[@RotarySMP]

Me too. Thanks for the tip on the step over. I am still getting a feeling for milling, as you can tell :/

[@sparkiekosten5902]

Beside the mishap you should be proud of that work! You made a professional part from start to finish! Thanks for taking us along for the ride. Keep up the good work!

[@RotarySMP]

Thanks for your positive feedback.

[@robertsteinwandel6658]

I just wanted to say a huge thank you for your epoxy granite advice a few months ago! At the time I hadn’t done a real casting yet, but you helped steer me away from zeeospheres and sent the Thomas Zietz (spelling?) calculator which worked perfectly for getting an initial formula. I ended up using 4 aggregate sizes and was able to quite easily do 11% epoxy by weight with very few voids. My lathe body casting was 250lbs and headstock is another ~80 so not huge but for me it was a big deal. Im flattening the inserts in my body casting to attach linear rails to for the main ways now. Its been a big process, 3 ft long and steel so it was hard to hand scrape. We talked months ago about using an angle grinder flap disk, and I was able to use that to rough in my ways to with about 2-3 thou. I am now (terrifyingly) using a cutting wheel to scrape the ways. If you’re interested I could definitely tryto make a quick video, but basically using the cutting blade making light backwards strokes it makes a very similar pattern to a hand scraper. Im using a surface plate and prussian blue and starting to get some very good contact area. Thanks again for all your help, have a great day!

[@RotarySMP]

I would definitely like to see a video on that project. Not just the grinder scraping, but also the castings and project design.

[@robertsteinwandel6658]

RotarySMP Heres the link, Ive never really made a video on youtube before,so this is basically me rambling for 7 minutes and might not make any sense lol. But it does hopefully show the basic plan Ive got? I didn’t have the thought to actually show all the parts I have ready for assembly unfortunately, but Ill try to make another video thats more complete and polished later. Anyways, if you get a chance to watch it let me know if you have any thoughts or critiques! Thanks, kzbin.info/www/bejne/kIDFZYWanqqDi8U

[@RotarySMP]

@@robertsteinwandel6658 Subbed!

[@cavemaneca]

Excellent improvements on the casting, especially with the larger part. The result of your study and practice really shows. On a side note, seeing how diligently you are on making progress combined with the warming weather makes me want to get out in my own shop more. I mean, I still have that big lathe I need to finish rebuilding...

[@RotarySMP]

I find that the YT weekly posting probably makes me acheive more progress, even if it slows me down, if that makes sense.

[@JoseSilveira-newhandleforYT]

Casting went great. I loved the sound of the face mill cutting through it 🙂 Nasty accident on the milling table, but it will become a permanent reminder and you'll never make that mistake again - we learn a lot from painful mistakes. In the end it's a beautiful part, completely made from scratch and a lot of work 🙂

[@RotarySMP]

Thanks Jose, It was a lot of work. I switched to conventional milling with the big cutter to reducing the hammering, so It sounded better.

[@JoseSilveira-newhandleforYT]

@@RotarySMP Yep 🙂

[@Raeilgunne]

the best casting sand is hooker sand from Australia. It has microscopic hooks that help hold the molded sand together. My factory bought it, a few truckloads a week, for aluminum casting.

[@Raeilgunne]

after I typed that up, apparently only "large multinational auto maker" calls it that. We used it for decades and only recently started using a black sand and waterglass mix

[@RotarySMP]

I have never used a naturally bonded sand, so I have no comparison, unfortunately. I have used petrobond once. That stuff feels like playdough :)

[@Raeilgunne]

@@RotarySMP we used it to make cores, rather than molds. Have a hundred or so core making machines making cores for cylinder heads.

[@jc3745]

I love how you have all the safety gear on, but still wear your sneakers. I hope you don't splash onto your shoes when casting.

[@RotarySMP]

Those are steel capped work shoes. Maybe I should look for foundry shoes.

[@simple_fred]

For that center feature, you could make a leave in plug with sand and water glass (sodium silicate) that hardened with carbon dioxide. Myfordboy has a couple great videos on those. Good luck.

[@RotarySMP]

I considered making a core (which is what it is called), but it is not critical that this hole is weel formed and this is simpler. When I make cores, I dent to make baked, sugar bound ones.

[@simple_fred]

@@RotarySMP Core, yes, thank you.

[@claeswikberg8958]

26:40 bendy bendy, done that on a manual mill once, funny what you can do when your focused on the cutter

[@RotarySMP]

Yeah, that was also dumb. Should have used a shorter one.

[@wheelitzr2]

I'm so sorry... 😭😭😭 I totally feel that pain my friend... If that was this rough watching through my screen I can only imagine how that was for you...

[@RotarySMP]

Yeah, that was not one of my better performances. Poor Maho.

[@arnljotseem8794]

Oh, that wound in the table hurt. Physical pain in the stomach. Nice castings thou, and good job on making the part from scratch.

[@RotarySMP]

Thanks. I was pretty bummed about that divet. Especially as it is not the first time I learned that lesson.

[@spaghetticallahan9292]

I spit my coffee out when that tool hit the table. Following that I had uncontrollable anxiety about that hold down clamp stud on the right side of the part sticking up so high. I have definitely made similar tool height offset errors before. Cost me a Kurt moveable jaw. That casting came out pretty amazing. I've taken to using the anodized aluminum Saunders Machine Works fixture plates, one more layer between the tool and table and the quality is spot-on. Great video.

[@RotarySMP]

The fixture plate is a good idea.

[@69hytek]

Man I felt for you when that crash happened. As an Aussie I think that deserves a memorial day, and another public holiday of course :P On a serious note tho, consider a fixture plate. It'll cover up the evidence and give you a bit of sacrificial meat should this happen again.

[@RotarySMP]

Yep, good suggestion. Something I really need to get around to.

[@TrPrecisionMachining]

Very good video RotarySMP

[@RotarySMP]

Thanks for commenting as always.

[@Pauly5150]

Once again, a great watch warts n all. All far above mt skill level, but I learn and enjoy as I watch. Thanks for sharing your hard work.

[@RotarySMP]

Thanks for the encouraging feedback. Not one of my best performances that. Bummer.

[@crozwayne]

Youre not the only one to do that, I have seen people just about destroy machines, spindles, fixtures and tables etc for the very same reason as what happened to you. Mistakes catch us all out eventually. Great video as usual

[@RotarySMP]

Especially disappointing as I programmed the post processor with a safe approach, and then forgot and deleted those lines. Lame!

[@gubr]

You can get some cheap metal ash filter barrel thing that goes before the shop vac, I got a cheap one and it came with metal lined hose, and metal attachments so vacuuming hot chips is no problem.

[@RotarySMP]

Good idea.

[@vincei4252]

Oh my god. I just got to the part where the mill crashed. That's awful and things were going so well! Hugs from across the ocean!

[@RotarySMP]

Thanks Vince. I think the Maho is going to stop playing with me at this rate. It was a dumb mistake.

[@wizrom3046]

Wow sorry about your table! 😬😥 I definitely second the idea of making a big fixture plate. CNC is much better that way. 👍

[@RotarySMP]

I need to look into getting a plate.

[@wizrom3046]

@@RotarySMP ... it is a fun CNC task if you get the machine to CNC all the holes and threads on a grid. Would be a pain on a manual machine but hey now its a CNC. 😁

[@RotarySMP]

@@wizrom3046 Would be a good use of the Tapmatic.

[@wizrom3046]

@@RotarySMP tapmatic are great hey. 😁 But dont rule out threadmilling. If you have a 60 degree thread milling bit the CNC can just spiral cut the thread. You'll probably never tap another thread again.. (well at least on a CNC) 😎

[@Reman1975]

The casting process was looking so well thought out and exicuted that I was sure the castings were going to turn out unusable (they do that just to spite you for thinking you've got all bases covered). Glad to see you outsmarted the little blighters. :D The table crash is, as "Elektronaut" mentions so eloquently somewhere else in the comments, "A bummer". That bed looked in perfect condition before, so it's a shame.......... But there's always a plus side. The NEXT time you gouge the table it won't be as emotionally devastating, because it will have happened to an already scared surface (See, even an atomic mushroom cloud can have a silver lining. :D). It's similar to having a new car. The first time you find a stone chip on the bonnet (Hood) it's devastating, but 10 years later, when the car's covered in little scratches, scrapes, dents, and rust spots, you'll happily use your bumpers to punt shopping trollies (Carts) out of a parking space rather than getting out of the car to move them if it's raining. Owning "Pre disastered" things really takes the pressure off you trying not to damage them. :D

[@RotarySMP]

In this case it came out of a school, and already had two scars from then, but I still feel bad adding more. I know what you mean though, that is why I buy used guitars, so I am not the first to scratch them.

[@Reman1975]

@@RotarySMP Yes, and you don't feel quite so bad about smashing them over an amp at the end of a set in a Jack Daniel's and ketamine induced heavy metal rage. LOL ! It's odd how the mind works. One thought leads to another, then another, until you hit a very strong memory..... so I'm just going to detour on a bit of a tangent here. :D When my siblings and myself were kids my parents used to take us on caravan holidays. In the early days the caravans we could afford were horrendous old things that would have been held together with duct tape if the stuff had been readily available in the UK back then, and the holidays were about as enjoyable as a week living in damp infested squalor could be. Then dad got a promotion and a fairly weighty pay rise, so him and mum decided that it was time to buy a BRAND NEW caravan ! The next holiday we had was somehow even worse than usual. We needed to try and keep the dog off the seats (We didn't even try to do that at home !), shoes had to be removed before entering the AWNING, and dad would have flipped if we even thought about going into the caravan wearing them, and clothing had to be dusted off to prevent stray grains of sand getting into the carpets! Everything also had to be kept spotless, clean, and mark free. It was like being in the army, but without access to punch bags, or any other way to deal with the stress. The following year all us kids banded together and said we'd rather go stay with one of our aunts a few miles down the road than go on another caravan holiday like the last one. We all explained that it wasn't a holiday for any of us if we're too worried about damaging the caravan to have fun. We dug in our heals and no one went on holiday that year. A few months later the new caravan was sold, and when summer was over, another tatty old caravan turned up (When prices had dropped) ! Us kids helped mum make new seat cushions for it from some truly horrendous heavy gauge patterned fabric that she'd got cheap, and my elder brother helped dad recondition the brakes, and "Derust"/underseal the chassis. We had some of the best holidays ever in that one. It was already such a battered mess that dad wasn't afraid to near as damn it take it off roading to find interesting places to park up for the night. They had that caravan for around the next 10 years until us kids had grown up to the point where we were all working, so organising family holidays wasn't really a viable thing anymore, and when it was no longer needed it was sold to a young couple with a baby for a little more than it had originally cost.

[@RotarySMP]

@@Reman1975 That is a really cool story! We once drove around the NZ south island in some ancient Leyland van which my dad basically bolted a park bench into the back of (car safety was not a big thing in the 70's), with some heavy old canvas army tent. Sounds awful to me now, but we had a great time.

[@garymucher4082]

Sorry you messed up the table section. I know that had to be heart-aching. I know because I drilled into my floor model drill press table and I was ill for a while. So maybe you can repair it with machining some type insert to fix that area. IDK. However the casting and machining for the actual part was amazing to see. Thumbs Up!

[@RotarySMP]

Thanks Gary. Yeah, I was was really PO that I did that. I haven't repaired it yet. Maybe I will machine a plug for it at some point.

[@sbell2496]

Great job all around! Mistakes are the lessons we recall the best. Great video work!

[@RotarySMP]

The painful think about that lesson is that I learned it last year, and forgot it again. Dumb.

[@werneramort2703]

I love the possibilities and openness of LinuxCnc. But this detail had the 432 better solved. It was so that even if you start a program from block x, the control reads the program from the beginning and takes over all zero offsets and tool offsets...

[@RotarySMP]

I rerendered the program in the CAM software to add the 3mm Z increment cuts, so it was not the same file. The dumb part was deleting all the stuff already machined, including the header for that tool change, where the G43 was. My logic was that the tool was already in, but I forgot that LinuxCNC erases G43 at a program stop.

[@bazzaf246]

Sorry to remind you of it, but that really made my heart sink, as I've just read, will be a good reminder of what not to do, for all of us! Still binge watching the lathe playlists, I'm really enjoying the shaublin, have gotten here in a day or two from episode 1, your progress in video editing and cameramanning since the mini lathe is astounding! 👌 cheers, can't wait for some chips 😊

[@RotarySMP]

Glad you are enjoying the series. I keep trying to learn and improve on the editing and camera craft. More to come in the new year

[@na57y]

really appreciate that you show this painfull failure to us. I enjoy casting of cast iron, not much people can do this. Casting aluminum or brass is quite often but cast iron is rare. Great work Mark. #3 fans

[@RotarySMP]

Thanks for your supportive feedback. I was really disappointed in myself for doing this. It is one think to make such a mistake, but to unlearn it and do it again is frustrating.

[@johannesmajamaki2626]

@@RotarySMP At least now there's a permanent reminder, right on your mill table what you'll benefit from it!

[@RotarySMP]

@@johannesmajamaki2626 Yeah lucky :/

[@EdgePrecision]

I didn't read all the comments so this may have been mentioned in another. When running a tool in to a part after changing the program or setting the offset. Always push feed hold when it approaches the work piece (The machine could also be in single block as well to the first clearance move). Then look at the distance to go display on the control. If there is enough room for the tool to go there and not a long distance in the Z minus than continue with cycle start. This is a very simple way to avoid this kind of crash in the very beginning of a tools cycle. Don't just push cycle start and hope you can stop it with the emergency stop in time.

[@RotarySMP]

The really worst part about this crash, was that you taught me this last year. I had practiced what you taught me and had it pretty well down (I thought). It really sucks to find out I forgot what you took the time to teach. Sorry about that. I set up the PP with a G43 on tool change, an M1 conditional stop 50mm above the work to test with a 25-50-75 block and had practice with the feedrate turned right down approaching, and looking for DTG. However, in the year of working on the Schaublin and barely using the Maho, I had forgotten that LinuxCNC cancels G43 when you exit a program, and also gotten out of the practice of checking the DTG, or looking at the tool offset value. When I modified the CAM to add the Z levels and regenerated the g code program, I manually deleted everything I'd already done, and since the tool was already in the spindle, deleted the tool change block. I remember when deleting, having that nagging voice saying maybe I should leave that in... That is how I lost tool offset, and also lost my safe approach conditional stop. Since I will never be doing this on a daily basis, I think I'll laminate a checklist to remind me of the work flow before starting. Just seeing DTG in the comments, reminded me of how I practiced that last year. If you stop a program half way through, edit and repost it, what is your procedure for removing what is already done?

[@EdgePrecision]

@@RotarySMP Aren't you a aircraft guy. A check list sounds good. I usually just put a GOTO(N sequence number (If your control will do this). Just the number no N no space.) statement in the code right after my G43 H and D to Z clearance move. But you need a N sequence number in the code (It will give a alarm without it). also make sure there is a XY position (If not the same) on that line. I would suggest you experiment with this before doing it in a real setup. But if you delete the bulk of the code (I do that as well). Do not leave out the G43 line. All controls (Except the mazatrol. You don't even need a G43 on it) reset this value. If you reset the control. It doesn't hurt to reread the statement in any case.

[@RambozoClown]

@@RotarySMP If I stop a program, tweak it and rerun it, I always make my starts at the tool changes. This is mostly because I learned on old goofy controls where the tool offsets were in the program not the control. Sure that would often mean cutting air for a while, but that's better than cutting the machine. My ah ha moment wasn't the tool going into the table, but having a 1/2 endmill rapid into clamp and being snapped off and winged across the shop, because I tried to save time by skipping a chunk of code that had been run.

[@RotarySMP]

@@RambozoClown Thanks. That makes sense.

[@RotarySMP]

@@EdgePrecision Thanks. I did check to make sure I had good X and Y values in the start of the code I left. I checked but LinuxCNC does not support GoTo, which doesn't really surprise me. Goto is generally hated in the coding community.

[@helmutzollner5496]

a lot of work indeed. well done. great progress.

[@RotarySMP]

Thanks. It was good to make a mechanical part again.

[@RB-yq7qv]

Nice job with the castings. One has always be on the alert with CNC operations, there good till they stuff up.

[@RotarySMP]

Yes they are. Very uncaring devices.

[@RaptorMachineToolCo]

sorry you messed up your table.. i always use a fixture plate just in case ! nice job Joe

[@RotarySMP]

Sounds like a fixture plate is a good idea.

[@platin2148]

One of the good things with just iron cast is that it doesn’t make the horrible black dust like a graphite cast. Had todo a stone for the hot air of our ofen and that basically ruined the mill as the stuff is now everywhere.

[@RotarySMP]

It is pretty messy, but I like machining it.

[@MrPhatNOB]

When that tool crashed I grimaced so hard that my face contorted into a fist. You have my sympathy! Excellent finished product though mate. Very professional fit and finish. Love the effort you go into in your videos, and also the fact that you show mistakes in all of their glory so we can learn as a group :D.

[@RotarySMP]

Thanks for the feedback. I really would have preferred less error sharing there :/

[@antonwhittle415]

That was a great vid.

[@RotarySMP]

Thanks Anton, I wish the Maho didn't have to suffer so much for my art :/

[@bradthayer6782]

Really nice videography; love the split screens. It’s really deeply satisfying taking scrap iron and turning it into a beautiful machined part. Very sorry about the boo-boo in your table. Could you tig weld to partially fix it?

[@RotarySMP]

You dont want to put heat into a mill table and warp it. Also, you have seen my welding :/ If I repair it, it will be a cast iron plug and epoxy.

[@R9000]

Beautiful part! Been watching a lot of your vids of late, you make some really cool stuff! The casting element is certainly a nice bonus that you don't see on many other machining channels.

[@RotarySMP]

Thanks for your support.

[@johnmccanntruth]

Really nice job. That was a big week.

[@RotarySMP]

Yeah, That casting session took me about 5H, as I normally start the furnace before moulding, but left it off for quiet. The machining also tool me a lot of hours. I am very slow at this stuff.

[@MRCNC1967]

So, so, so sorry about the ding to the machine table. Hate to say it in hindsight but this is why we NEVER work on any machine surface directly. We have plenty of sacrificial plates with evidence of dumb programming mistakes. The plates came out fantastic, great job on the castings, they will be your constant reminder of a job well done.

[@RotarySMP]

A fixture plate would be a good idea. Shame I didn't get one when I first got the mill.

[@MRCNC1967]

@@RotarySMP Well, you can always add a sub-plate to the work table, and with the added advantage of hiding past sins.

[@RotarySMP]

@@MRCNC1967 Might well do that.

[@misterbreakit2006]

Skilled metal haemorrhoidism with the stick welder :)

[@RotarySMP]

Considering this weld got jammed into the fires of hades, the uglieness was its smallest problem.

[@squelchstuff]

That crash was so hard to watch. My heart sank for you mate. I can only guess that you forgot to make that checklist I suggested last week? Work holding - Secure. Work holding Clearances - Verified. Rapids - Disabled. Tool Offset - Set. Safety squints -On. Mother on speed dial.

[@RotarySMP]

The lame thing is that I have that in the post programmer, to add the lines with the conditional stop to make a safe approach, but those were the lines I deleted.

[@squelchstuff]

@@RotarySMP Oh man. I can imagine just how that occurred, and it is so easily done. Filming it all for our benefit can't help much either. Task saturation is an insipid thing. The finished article did turn out to be great, and I hope your composure quickly returns. I did suddenly remember some Schweitzer Deutsch cuss words from some 30 years ago on your behalf.

[@RotarySMP]

@@squelchstuff I think the thing that hurts worst is that I implemented all Edge Precisions advice in the PP, and practiced it... and then forgot it all.

[@stevensmart8868]

Great video once again. Interesting stuff throughout. Cheers rotary

[@RotarySMP]

Thanks for watching and the feedback.

[@michaelsilva7085]

It must be so satisfying to make a part from scratch! Great job!

[@RotarySMP]

Yeah, I am happy at how the part turned out.

[@groebster]

😱...an apparently undamaged machine table has received its first hit. Bullseye. My feelings are with you, Mark! But that's how it happens, the machine is worked with, it's not a museum. Apart from that: great work, the parts look excellent!!!

[@RotarySMP]

It came from a school in southern germany, and had a couple of marks in it when I got it, and I added more. This is by far the worst though.

[@richardbradley961]

WONDERFULL JOB, WELL DONE. PUT A PLASTER ON THE MILL TABLE IT MIGHT HEAL UP . REGARDS RICHARD.

[@RotarySMP]

Thanks for the positive feedback. Bruised ego on this one that is for sure.

[@matthewsimmons6831]

A gasp, a yelp, a wince, my hand over my mouth and legs crossed when I saw that crash. Ooof. But hey, end result looks great and you're still in one piece. Thanks for being able to show us! Really enjoyed seeing the casting retry and the process.

[@RotarySMP]

Thanks for your feedback. It was not a pleasant moment.

[@luckygen1001]

Have you still got the slag at 15:55? if it feels very heavy it has lots of cast iron mixed in it. Using that kind of scrap will make lots of slag. Black iron oxide has a melting point 100C above cast iron but rust has a lot higher melting point so when the two mix in together and minerals dissolved in the water come out it makes the slag behave like mud. When that happens it traps a lot cast iron in that slag so it is hard to separate. Thin scrap like what you were melting is grey and when remelted it will give at most times a soft iron. I never melt that kind of scrap (rusty/dirty) to avoid the problems you had. Here is another type of scrap to avoid, any cast iron that has been heated and cooled many times ( firegrates) as it will make far more slag than rusty/dirty cast iron.

[@RotarySMP]

Thanks for the feedback on that. You nailed that diagnosis. More and heavier slag then I get from brake rotors. Bummer, as I still have a couple of buckets of this scrap. Probably worth my while to spend an hour sand blasting the scrap before I use anymore. Living in a big city likeVienna, it is not that easy to get cast iron scrap, except brake rotors. Scrap yards here no longer allow browsing.

[@michaelbrocato7535]

Man I hate seeing that ...but its part of this type of work human error.....these motor mounting plates have become really expensive really quickly. Also love the casting process!!!!! Great job ...on that part

[@RotarySMP]

Thanks. The plate was a lot of (unnecessary)Ä work, but I like the result.

[@Dellpodder]

Great video! (Except for the table bit 🙁.) I always look forward to watching these while enjoying my Sunday morning coffee here in the US. It's awesome to see someone doing cast iron parts in the home shop. Hopefully I will get there some day. I especially like how you showed the side-by-side of machining and tool path during engraving.

[@RotarySMP]

Thanks for the feedback. I kind of like doing the Multicam stuff as well. Bit of a PITA to edit, but makes the boring bits more interesting.

[@KingBjord]

without a vent hole for the molten metal and using CO2 or pre-heat to stabilize and / or evaporate water from the mold, might be why you get the worm tracks/voids in the casting, small steam explosions, not a professional just a guess, hope it helps :)

[@RotarySMP]

I am pretty sure they were slag inclusions. Once sand blasted the slag is gone, so you only see the void, but before blasting there was slag in there. Also I saw slag go down the hole, it had to go somewhere. :) My green sand has pretty high porosity. Vapour problems are normally more a surface feature than buried. I have had it on aluminium castings, with the sand too wet.

[@KingBjord]

@@RotarySMP Good to know! Thanks for the reply, what then could be done to reduce slag? one channel I watch doing copper/brass/aluminium "scrapes" the slag off the top periodically during melting phases before pouring, is this the case with iron or is higher temps needed to burn it off?

[@RotarySMP]

@@KingBjord Slag is the mix of oxides (rust) and contaminents like sand, which float on the surface. (Iron Oxides are dense than Iron). You cant burn it off, as it is already oxidised. I scope it off at regular points in the melt, but that scrap I was using is thin walled and has a lot of rust, so it makes more slag than normal. You have to experience an iron melt, the radiant energy is intense, so just scooping off the slag your gloves, legs etc exposed to it heat up really fast. Slag is also very sticky, especially when molten, but not hot enough to pour, so it buids up on the the scoop.

[@KingBjord]

@@RotarySMP ty for the info, looking forward to more videos

[@RotarySMP]

@@KingBjord Thanks for your feedback.

[@BinaryMachinist]

One more tip about casting that I don't see mentioned. Add some vents. They don't have to be large, take some solid core ~16 gage copper wire and poke holes for air to release. If you make them correctly, they won't allow metal to come up through them and the most you get is a tiny nub on the part.

[@BinaryMachinist]

I see you do have a couple vents though they are large. The smaller ones work nicely and adding a bunch all over the part makes it easier for air to escape

[@RotarySMP]

Yeah, when I did the second one and added vents, I considered reopening the first mold to add them, but decided to leave it. I dont see any defects related to gas not escaping.

[@ptonpc]

I felt for the table. Ouch!

[@RotarySMP]

Me too.

[@Si-Al-Ti]

Great episode!

[@RotarySMP]

Thanks for watching.

[@azenginerd9498]

Pilot checklists usually evolve from "oops" occurances. Maybe a modification to your post processor that pops up a checklist reminder after program interruption... "Hey Bozo! Don't forget..."

[@RotarySMP]

The problem here was me deleting stuff I programmed my PP to put in there. Dumb as!

[@spikeypineapple552]

Well done mate. Making parts is hard. I do this for a living, and I still crash(recently just indexed the turret of my 14inch lathe into the chuck). I can tell how worn out from it you are in the outro, but keep going! For sure something on your control isn’t right though, you should be able to stop this stuff in time. In my experience, 99% of crashes are on linking moves, so entry should (in my experience), be 1percent rapid, 10% feed override. Don’t worry about single block. Then just swap between 0% and 10% feed to inch into the cut.

[@RotarySMP]

I learned this lesson last year with a crash, and Edge Precision did a video to teach me how to avoid it. Based on his advice, I edited my PP to do an M1 conditional stop 50mm above the part, dial back the feed rate, watch the DTG etc. Problem here was that I added the Z increment cuts in CAM and outputted a new file, which I manually edited to delete all the stuff already machined. As the tool was already right, I deleted the tool change block which would have added the G43, and also deleted the safe approach block. I was on the feedrate overide, and had it dialed right back, but had lost the practive of checking DTG, in the year I barely used the Maho. Idiotic.

[@spikeypineapple552]

@@RotarySMP for what it's worth, I really love watching these, thankyou for making them. They're a really nice mix of technical and machining

[@lennywintfeld924]

Came out beautiful, but maybe it would be easier to start out with a bit of road plate (or similar) from the scrap yard.

[@RotarySMP]

Scrap yards here stop letting the public in for shopping about a 20 years ago. More of a PITA for them, and safety liablity than it was worth. It might be different in the countryside, but in the city, no chance. Plus, I like casting :)

[@shedtime_au]

Entertaining as usual. This inspires me to get the little toy 3020 table mill working. :-)

[@RotarySMP]

Go for it!

[@chowtownpiper]

That crash hurt my soul!

[@RotarySMP]

Mine as well. Thanks for your comment, it helps train the algorythm.

[@m3chanist]

O god that hurt, every nerve in my body clenched then farted ! The horror! I can't unsee it..... edit: had to go get a drink, a stiff one. Your table...now the grieving starts. Thanks for showing it, hard.

[@RotarySMP]

The problem with the seven stages of grief is that denial is ineffective when I was the only person involved.

[@m3chanist]

@@RotarySMP Aye...you can run but you cannot hide, from yourself. If it's any consolation, I dropped my rotary table last week, slipped from my grasp only the concrete slab, missing my feet however so there is that...I'm still grieving.

[@RotarySMP]

@@m3chanist Glad you missed your feet.

[@sourabhkumawat4863]

I use boring strategy from fusion 360 whenever i have to mill a circular hole like this....i have made tons of similar holes with same pair of inserts with that strategy in mild steel. It continuously plunges into the material rather than lead in/out and saves time.

[@RotarySMP]

Since my YT channel is commercial, I cant use the free or hobby version of CAD/CAM, and teh pro licenses are more than the channel earns. I used a 20 year old version of FeatureCAM, and have to live with it's strategies.

[@simonvongunten9288]

Awesome work! 👍 very impressed how the quality of that motor mount casting turned out. I hurts to watch that endmill digging into the table though!

[@RotarySMP]

It sure did hurt, especially my pride. Some consolation that the result was good.

[@milloons2847]

Sorry for your damaged table. Seeing it happen hurts, guess I share part of your pain ;-). Knowing many others do as well does it bring some relief? Thanks for sharing your experiences

[@RotarySMP]

Thanks for your support. The Maho thanks you as well :)

[@tablekwan]

r.i.p. dear table

[@RotarySMP]

It is still there, glaring at me.

[@trollforge]

Thanks for the added info... man, I am sorry about the table...

[@RotarySMP]

You and me both!

[@KennyEaton603]

You took that apprentice mark pretty well. I ran an entire tool path .030” deep into my table at one point. But my table is aluminum, so I just decked it off. Still wasn’t happy about it, scrapped the part and had to countersink 140 holes after I resurfaced the entire table (table is an aluminum fixture plate, self-built machine)

[@RotarySMP]

The aluminium fixture plate idea sounds appealing. It would hide that scar :/

[@KennyEaton603]

@@RotarySMP if you cut into your fixture plate, you can tell people it was fixturing for an old project 🤣

[@RotarySMP]

@@KennyEaton603 Sounds like an excellent idea.