SECRET Process Of MACHINING FLAWLESS Parts

[@Kardos55]

I spent many years in an EDM shop (wire and sink) and always thought that watching a wire EDM in action is equivalent to watching grass grow or paint dry. You (and your video team) made it exciting and very interesting.

[@trevorgoforth8963]

Thanks Karlo, It's definitely not easy to make one of the slowest machining processes exciting 😆 Thanks for watching!

[@marcus_w0]

@@trevorgoforth8963 but damn, those cuts are precise. There's a DIY Qire-EDM solution, I was thinking about building one for my hobby shop - but the needed arc generator from BAXEDM is over $3000. That's a solid investment for a hobby project. I've seem some people trying to build them themself out of an old stickwelder - but the precision comes with the timing - and an estimate won't really do.

[@stanislavtimanov]

Hello, colleges. More than 15 years experience fanuc wire EDM in Russia. Extrusion tools .

[@Jessie_Smith]

I mean super accurate tolerance and a disappearing act is cool and all but whoever ground that block to perfection is the real hero here 🤣🤣

[@trevorgoforth8963]

Hahaha you ain't wrong! I'm just glad we didn't have Mr. Nogo do it. 🤣

[@mohammedalbattal77]

For sure Mr nogo will use bearing ball trick to achieve the perfection 😂 I miss that perfect character Mr jessie 😂😂😂😂

[@jdsharp1366]

And the key to it all is the guy that drilled the hole lol.

[@Jessie_Smith]

@@mohammedalbattal77 Maybe we can talk Beau into coming and giving Trevor some training lol

[@Jessie_Smith]

@@jdsharp1366 lol Exactly!

[@wickedcabinboy]

I am neither a machinist nor an engineer. I've watched many EDM videos and wondered how it could be done without leaving a kerf. Yours is the first video that explained the process and clearly detailing how it is done. I suppose others merely assumed that their viewers already knew that it required *TWO* different blanks.

[@saslightadjustments]

hello bud, its correct. whenever you cut something into two, a gap is created to at least the width of the blade, no matter how small the blade may be! Apparently also including a blade 1/4 the sized of human hair! Crazy!

[@AlexKarasev]

Growing up in the USSR, as an aerospace college student I had a summer job in 1990 at a plant in St. Petersburg (then Leningrad) making parts for various missiles. They had a row of basic versions of this same machine (among other cool stuff).

[@NMCKE]

I'm not a machinist, just took some high school classes a while back. Zero tolerance is insane, especially with metal heating and cooling - great job!

[@pplpilot]

no such thing as Zero tolerance. Absolutely everything has to have a tolerance.

[@h.a.6790]

Zero tolerance has little to no application in real life as far as moving parts are involved. You need tolerance to offset shrinkage and expanding of materials. That's the very basics of material science.

[@KekusMagnus]

It's not zero tolerance, just very very precise. Tolerances on wire EDM are as low as 2 micron but that's not zero. Things like gauge blocks have even tighter tolerances and you can clearly tell because they "stick" together due to Van Der Walls forces as if there was glue holding them together, yet there is nothing, just blocks of steel.

[@flipadavis]

They are using an iron alloy know as an Invar. "Invar, alloy of iron that expands very little when heated; it contains 64 percent iron and 36 percent nickel." "Lohaus says it had been long suspected that this behavior was somehow related to magnetism because only certain alloys that are ferromagnetic (capable of being magnetized) behave as invars." "As the temperature of an Invar rises, the spin state of some of those electrons increasingly flips. As a result, the electrons become more comfortable cozying up to their neighboring electrons. Typically, this would cause the Invar to contract as it warmed up. But here, the Invar's atoms also vibrating more, taking up more room. The contraction due to changing spin states and the atomic vibration expansion counteract each other, and the Invar stays the same size."

[@Mirage5892]

Done EXACTLY the way i was expecting

[@kevinwinwood2204]

This is a brilliant fit, very impressive, kudos to you. I was a prototype machinist in 1984 and learned to use a Charmilles wire EDM. We made some basic parts, but there was no skim cutting available. I made a “punch & dye” of my first name, but they did not fit together, close but no cigar. We then got a 4 axis Mitsubishi with skim cutting. Made a couple of name plates for senior managers. The die from steel and punch from brass, the fit was not as good as Titan, but it impressed the bosses. Can’t imagine what it cost, all the programming was manual, but then again, we were an expense department!

[@QurttoRco]

Metric units would be nice as a pop up. Love Trevors presentation

[@pizzaparty-r1c]

I remember when I was in machinist class and the instructor demonstrated zero tolerance. He had two pieces of perfectly machined surfaces of steel blocks. When you slide them across each other, they would stick together. Air tight contact.

[@niloy.b]

Barry is going to make pixiedust out of trevor when he watches this! 😆😆

[@trevorgoforth8963]

😆 He interrupted our video so I had to talk some smack 😜

[@barrysetzer]

For my next video im gonna full slot that block

[@dakudsi1304]

Do you sell the punch and die itself? It so satisfying to have on my desk 😬

[@christophervillalpando1815]

Awesome Video Trevor! Thats a cool looking part! 😎

[@trevorgoforth8963]

Thanks Brother

[@robertdufour2456]

Unbelievable! Congratulations! Thank you for the education and inspiration

[@afelias]

ok ngl first 15 secs BLEW MY MIND. I thought it was CGI, like a Blender model, until I saw the hand. I heard that super precision machined parts had invisible seams but holy shit man

[@Galactis1]

This gives me like, feel good vibes. Like my anxiety makes me feel so good when this goes back to smoothness, and complete. Beautiful imho.

[@vonpredator]

If you try this at home…. Make certain that your steels are both annealed or the amount of warping after cut will make your fit impossible. Nice video Trevor!

[@greeneyesfromohio4103]

What’s annealed mean?

[@trevorgoforth8963]

Thank you sir!

[@apostolrobert5810]

@GreenEYESfromOHIO annealing is taking the stress out of the material by cooking it, even plastic can be annealed

[@angrydragonslayer]

@@apostolrobert5810 i wish i could be annealed

[@greeneyesfromohio4103]

@@angrydragonslayer - 😂😂

[@Sara-TOC]

Awesome video Trevor! I always had an appreciation for EDM. It was a nice break from CNC machining.

[@sferg9582]

The first piece I ever made like that was back in 1985 with our first SODICK 1WH Wire machine. First attempt was spot on with some attention paid to the details in the program while taking into account the wire diameter and the ensuing "overburn" as a result of the spark gap. The part was presented to the company President and he was amazed. That sold him on the technology and we over the years had purchased over 10 more wire EDM machines.

[@truegret7778]

I love you guys and anything Titans of CNC! Great audio/sound fx while sliding the punch into the die.

[@LostButMakingGoodTime]

A great many people appreciate the tactile and precision art qualities of things like this. You could produce a “punch and die” set like this as an executive desk toy and sell a million of them. I would definitely love to have one.

[@vintagemotorsalways1676]

Beautiful slip fit

[@UnevenMedia]

whoaaah I thought the opening noise it made was a start to a song and just fit the shot really well haha

[@zeddysven]

Customer : How efficient is the cooling system on the ONA? ONA: Yes

[@cembellsteve]

That was amazing !!!! How in the hell did they cut stone with that much precision when building the pyramids? No CNC back then . Whats so cool about yall's channel, I can finally show my wife what I do at work. I mean with out the clean floors and grinding dust everywhere. It's exactly the same.

[@MrGreen876]

We already know your goal is more subscribers. I don't need reminded before and after the actual content...

[@PhillipTorrickeBarton]

Can you please use imperial and show the metric conversion for your measurements? The old world is hard to compute in the modern era :P

[@a.meireles.boxing]

Mesmerising ❤

[@ibtesambhatti1650]

So mesmerizing

[@ProjectShopFl]

You guys have the best toys.

[@donniehinske]

Awesome video Trevor! Super interesting!!!

[@davidabilash2962]

iam so glad , you people making wire edm video I too wire edm operator

[@lucasomalley]

Timing on the outro of the show was as precise as the cut of the block.

[@DavelyDriven]

I did and am present. Not a machinist either. Driver, but hey, take what ya can get lol

[@siccmade_3604]

So you could literally make the sickest puzzle box from Hellraiser.

[@Max-rw4fr]

I like this guy and his explanation 👌

[@borderm3]

If it was zero tolerance, it would never come back apart. It would “optical contact bond”. Whoever’s interested in this would be into it! Very similar to ringing gauge blocks.

[@shahfaisal3923]

I'm your subscriber from Afghanistan.

[@TheMoody876]

I would gladly pay to have something like that on my desk at work

[@173roberto]

I loved this video!

[@philiprowney]

When my 3rd cousins husband [ biiiiiig Irish family ;-) ] worked for Ilmor [ Mercedes F1 racing :-D ] he called the machine a 'hot wire eroder', it was 10 years ago ;-) PS I also felt the rush when you slid the part to the edge to let it drop as you let the air in. Put that in an average press and your corners would be burger though, lol, great work.

[@justinahmann9482]

I love it. We had an agie cut classic and the manager at the time wanted me too run it but it hadnt been ran since the early 2000s. I read and read the book checked the de ionized water, Checked my pulse, flush, had the wire auto feed working. Everything. Only had floppy copy programs and we didn't have the right software or something. The world and me will never know.

[@jrautomopeddrone2221]

How did you fixate your punch to finish cut it all around? EDM from 2 sides? Glue it? Grind the holding tabs?

[@rpm4999]

Ido a fair bit of W edm If i make a punch i may leave 2 or 3 tags and finish the part before de tagging but then surface grind the start point for the tags Thinking of trying hot glue when i get a chance

[@trevorgoforth8963]

In this case I clamped it to the table and wire cut the tab side for the second op. I purposely cut in a little on each side of that face so I had a place to find my edge and tilt my axis. That way you're not relying on indicator accuracy and trying to get it perfectly straight but instead your using the machines accuracy, touching each side with the wire and tilting the axis.

[@rpm4999]

Hey be good if you could show this i have always struggled making spot on punches

[@Stasiek_Zabojca]

Yeah, I wish it was mentioned in this video.

[@jrautomopeddrone2221]

@@trevorgoforth8963 you did tilt x and y or U and V for clamping errors?

[@crashman5555]

how much temperature change is allowed to still function?

[@tomatomoussin9134]

Top professionnel and fascinating ❤👍🏽

[@alan.macrae]

Absolutely amazing machining. Thank you for sharing this.

[@Ворчун-д8у]

Давным-давно , ещё в юности видел как слесарь "дядя Вася" на спор, врукопашную изготовил два кубика . Причем при сложении их ЛЮБЫМИ двумя гранями и опускании в керосин , эти грани оставались СУХИМИ !!! А так то да , технология впечатляет.

[@thedopplereffect00]

At what temperature difference between the parts will they no longer fit together until they equalize?

[@dointh4198]

That fit gave me goosebumps. Considering your shop is well temperated at 20°C/68°F for precise measurement, I wonder how the fit works at 0°C or +40°C? Might be fun to watch.

[@Patrick94GSR]

plot twist: they put the die in the oven and the punch in the freezer before filming the video. lol

[@travisirving2009]

That Hellraiser cube!!

[@ergunuregil-om7wk]

Muhteşem bir makina 😮😮😮

[@wcfields7354]

That's some bad ass shit. I wish I had the time to make something like that.

[@Xenicon2006]

This is literally the first time I'm seeing a video from this channel and I'm being yelled at for not subscribing? 🙁

[@spinnito]

Sooo satisfying!

[@ericluba6287]

That's so flipping cool

[@Robert-cu9bm]

I'm confused to as how you get the wire in for the die? As with the punch it was cut from the edge, if it's a wire in assuming it's like a really precise bandsaw.

[@itswilliee]

Think of it more like a scroll saw, the blade/wire has a top and bottom so you drill the hole feed it through and reconnect it

[@Robert-cu9bm]

@@itswilliee Thanks. That makes a lot of sense.

[@onionhead5780]

Wow! That is amazing.

[@benevolencia4203]

5000 years from now someone will find these really cool and awesomely crafted parts and suggest the technology was given to humans by space aliens. You know what they say: history repeats itself.

[@ErikS-]

4:48 - Watch out! Before you know it, you open up the "Hellraiser Universe" with that 'box'.

[@galaxiedance3135]

I'm a Tool & Die Maker and ran everything in the shop.... An EDM can cut things out as fast as a person could on a bandsaw with a course blade if you really want it to.. The accuracy will be less but perhaps for clearance on a stripper it wont matter. As long as you get your offsets correct and settings for speed... perhaps a second pass where there is just a touch more sparking... It's actually not that difficult to make. Looks cool but is not difficult.

[@fearlessjoebanzai]

It's kinda incredible that even with how precise that block is and the punch, air was still able pass, allowing the punch to rest into place at 6:00! Or did you have an air hole cut into the stand, underneath where you got that shot?

[@spinnito]

1:27 ALSO GUY: "Whatta!! By doing this we discard a complete block to the recycle bin" 😆

[@igorpuschner786]

I don't need tools, but damn, I'd love to buy one of those blocks from you!

[@zajawamotocykle9256]

1:30 hihi Barry!!!!

[@barrysetzer]

Haha whats up man!

[@corujario2752]

Imagine doors/compartments of vehicles using such precision.

[@elshansalimiyan5066]

Ammmmmazing 🤩🤩🤩

In Turkey we have this phrase: "Kılı kırk yararak". Which means "By splitting hairs into forty".

[@september1683]

Very impressive. Even though; here in Germany, pre-school children do it with a hand file. :-)

[@David-yy7lb]

Thats awesome man... just for fun put that piece under a high power microscope so we can see how much gap there is between the 2 pieces because there's always going to be a gap but we just can't see it with the naked eye

[@24Swords]

Nice we used to do that a lot during my apprenticeship u should cut two different profiles on either sides of the job

[@TheMadScientistOfLuton]

With tolerances like that, try making that collapsible hexagonal floor panel thing in that UFO that Bob Lazar worked on

[@Zihark_]

Who knew precision machining would lead to a lesson on the birds and the bees

[@mattheweburns]

Imagine technology so precise it could be made out of one block! Do you think we will ever be there?

[@josephpk4878]

Had no idea. Always thought it was a single piece cut with some form of insanely powerful laser.

[@littlehills739]

cool ill wait at my mail box for delivery

[@Maninawig]

Here is a suggestion for an update: Make a 8x10x2 die with a 3x4x2 hole so that the edge of the 3 comes to the center of the 8. Then make 3 1x9x2 punches hollowed into cups and place it next to a figurine where they measure 5.8 high. Call it the wall of the future.

[@davidescobar5366]

You guys should make/cut out a puzzle of at least eight similar looking pieces and try and solve it. With so much precision only the exact piece of course should fit.

[@ChefofWar33]

If only wire EDM was actually fast. We would use it for everything!

[@djlinux64]

Build a machine with many heads

[@MasterCraftFishing51]

Getting them to to mate together after you cut them. That's the real impressive part for sure one tiny little ding and its all over but the crying. Then its to the surface grinder we gooo !!!! Then off for a fresh go at it lol . Trust me I have never experienced that in my life . But I could see it happening you know what I mean. From a bystanders point of view of course

[@kuldeepsankpal6443]

4:48 5:55 Satisfaction 😌😌

[@jollygoodfellow3957]

Imagine using this process to make perfectly layered steels. For example, a "San Mai" blade where one type of steel is sandwiched between another. Machine blocks of metal to this perfect fit, then heat to forging temperature, and use a hydraulic press to forge-weld the steels together in one press across the whole length of steel. Then quench, grind to shape, temper, etc.

[@kidfunkyfri3308]

Inconel machinegun barrel with the rifling done in an EDM

[@PaddyBoyBKLYN]

That would make for an awesome hidden door latch

[@shanemeyer9224]

Man I would love a small fidget toy made with Wire EDM that would be neat

[@anthgov5966]

Where can I get one, this would be an awesome conversation piece in my office for a non machinist.....

[@MiniPeugot]

Did my part. I want 10% of your revenue now.

[@ElKostya]

Покажите макро или микро сьёмку поверхности, какая у неё шероховатость, пожалуйста

[@spekky9012]

Is there wire deflection within the center of cut? Depending how long the cut is, and how many spring pass cuts there are?

[@tonyrichmond9428]

Nuts!

[@hannesaltenfelder4302]

What kind of crazy material is that wire made of?

[@hollywoodstarfish]

Ok 😅 subscribed 😬

[@Repuuaaaaaa]

How did you make finish on a punch after cut off?

[@ReaperOperator]

In a vacuum would these cold weld in place?

[@timlawrencekruk1338]

That's craaaaaaazzzzzzyyyyy

[@rang5210]

When I look at these things I can't help but wonder that maybe this is how the transformers robots also works. I mean whenever they transform into their vehicle mode, you can almost see no flaws or marks in anything. You can't even tell if this car is a transformer hehe

[@ragcage]

What kid of tools or machines require this type of precision?

[@nicklucero24]

Where can I buy one at? Not the machine. I'm just looking to buy the metal toy itself

[@andrewgedge4015]

Where can one buy something like this, not this size or style exactly, but some piece of flawless CNC art?

[@stefanblumhoff2744]

What is the sensor that senses and controls the distance between the work piece and the tool?

[@mediaboxentertainment]

that sprice. how they do that 🤔😱👍🏻

[@ericsandberg3167]

What RMS surface finish do you get on the walls of the punch and die parts.....just curious......

[@trevorgoforth8963]

That depends on many things, in this case we only used one rough and two trims which left us with about a 25 RMS. If we used 5 trim cuts you can get down to a 10 easy. In carbide you can get as low as 4 micro inches.

[@berniepragle948]

@@trevorgoforth8963 I don't believe it's exactly correct to spec an EDM finish in terms of RMS. RMS is more of an indication of a consistent finish in a specified direction. Think about the very, very fine "thread" type finish you get on a lathe in one direction. Even less applicable in carbide because if you magnify an EDM'd finish in carbide enough, you actually see something that looks like concrete with divots and pockmarks, no "grain" structure. Very picky comment though, this was a very, very cool video. Thanks for the great work.