Setting Up the MOST Complicated Tool in CNC MACHINING

The World's Smallest Boring Bar! The Tornos Swiss Nano uses the Horn Boring Bar.
0:00 The Worlds Smallest Tool!
0:53 Locating the centerline of the Spindle
1:35 Using the Perfect Zero system
3:17 Straightening the tool
#Machining #Machinist #Engineering

[@Joe___R]

Going super small is always 100x harder than going super big. I couldn't imagine having to use such small and delicate tooling.

[@donniehinske]

Gotta give props to Horn for making a boring bar this small! This video was a pretty big challenge to make so I really hope y’all enjoy!

[@Nunak91]

Great content. You have so much passion, curiosity and love for machining.

[@donniehinske]

@@Nunak91 thanks! I honestly find machining very interesting. Which means I got lucky because it’s the only thing I know how to do 😂

[@iansandusky417]

These boring bars are absolutely nuts! Amazing job as always brother!

[@Nunak91]

@@donniehinske I can tell you it's everything but luck! You've earned it.

[@Nathan-vq9ch]

Really appreciate the HD quality on editing team to capture the roving inspecta & Donnie not bad himself, wonder how ant's make their tooling?

[@owariyf3097]

whenever i go to work and grab a .375 flat grooving insert, check it with my calipers and it hits perfect like it does every day; it makes me feel like a deep respect for the people that make the precise tools we use to make precise parts

[@ProDMiner]

dude for real! micro parts, and like watch smiths blow my mind.

[@yoavallon]

They managed to make a boring bar interesting.

[@mattsmith1318]

Underrated comment!😂

[@CATANOVA]

You can make anything interesting with the right amount of enthusiasm.😑

[@mattsmith1318]

@@CATANOVA it's a play on words.. The tool is called a "boring bar".. Because it bores.

[@CATANOVA]

@@mattsmith1318 So what of the Musk Boring Company then, do you think he was having a play on words with that one LOL. PS I was holding a straight face. 😊

[@jamesbizs]

@@CATANOVAI can’t tell who made the dumber comment. You or the guy you’re responding to. Do you not understand it’s a play on words? And no, musks isn’t a play on words. It’s a troll.

[@Will-No-Co]

Ok. That’s great, but who’s the mad scientist that made the boring bar? That’s insane.👍

[@crazycooterMN]

Probably horn.

[@crazycooterMN]

Probably horn.

[@printgymnast368]

​@@crazycooterMNdefinitely horn

[@kevinspacey5325]

I could! Also that boring bar is too long for that job! I could do better.

[@CATANOVA]

Carbide shrinks a lot when you cook it.

[@RTM459]

It’s amazing, but watching true watch makers make screws by hand is on another level.

[@donniehinske]

What’s crazy is they were making mechanical watches in the 1800’s without any of our technology

[@deanavitale3072]

As in all your videos . . . . gotta stay to the end! Nice job Donnie and the videography never ceases to amaze me.

[@donniehinske]

Thanks ma!

[@halfhappy117]

We ordered our perfect zero kit with our next swiss machine, should be here next month! It will be a game changer for our micro stuff!

[@donniehinske]

They work super good!

[@mgk1397]

​@@donniehinskeThey do, I've used one several times. That trick moving off center to be more accurate when finding the center of the spindle is new to me though. I never thought of that but it makes sense, thanks! (When centering live Tooling I like to spin them to avoid any runout on that side causing inaccuracy)

[@stevieg2755]

What amazes me is watching a channel like wristwatch revival and being astounded in the level of precision of these Swiss movements like Rolex and Omega that were made in the 1950s before CNC was ever dreamt about,that to me shows the talent those people had

[@donniehinske]

It’s insane actually. They were doing this in the early 1800’s

[@CATANOVA]

4 micron letter pitch kzbin.info/www/bejne/pKfciml-esusd8U

[@alexanderrybicki6270]

We should hire ants to be machinists.

[@nuclearmedicineman6270]

That's just crazy talk. They already have armies, do you really want to give them the tools to build tiny firearms? We'll be doomed if they learn machining!!!

[@alexanderrybicki6270]

@@nuclearmedicineman6270 What is this, a votech for ants?

[@BC-wj8fx]

What is this... a comment for ants?

[@paulkraus4799]

After seeing this part in person , I can really appreciate how small this part really is . Also love Bro ‘s shirt

[@JesseGonzalezFishing]

Saw this running at the BOOMBASTIC Open House. Pretty crazy

[@crazycooterMN]

I have a customer gearing up to drill some .0007 holes. They're trying to drill through .015 thick material, gonna be the craziest thing you can't see! $24,000 nsk spindle going to 80,000 rpms and NS tool made the drills @ $400/pc. Trying to get 80-100 holes per drill. They look like bee stingers!

[@LoneWolfPrecisionLLC]

That's nuts. 21 times dia

[@wolfiemuse]

@@LoneWolfPrecisionLLCwith speeds and feeds and a quality tool it can be done! Wasn’t it Titan who recently did 40x D?

[@drafty0183]

Yes it was, but an 0.0007" drill is on another planet compared to that, specially at $400/pc. You couldn't tell if you've broken one. And how would you get it out of the hole it it breaks off in the hole. My mind boggles at the thought. GOOD LUCK with that project!.

[@aperson7624]

Serious question..why not just use a laser to drill that hole? It's gotta be easier than using those tiny tools.

[@mehmettemel8725]

I thought wire EDM would be the way to go since it's only .015 thick.Then again they must know something I don't.

[@TylerBrigham]

This made me glad that other people make small stuff. I make a little .08” cone every once in a while and I want nothing to do with a .008” boring bar. That camera alignment system is cool. I’m going to check it out

[@Zsycho1010]

I once had to drill a part with a 0,7mm x 30mm drill. I was shaking just unpacking the damn things and the drill operation took forever.

[@nasonguy]

Me sitting at home watching this: "Hmm, yes... Incredible! Makes perfect sense!" My home shop: a broken angle grinder and a harbor freight drill press.

[@holdilocks]

Most machine shops in Florida expect those results without instruments, you would have to find a way to center it on your own with indicators and a loupe.

[@kevinspacey5325]

Cheap lowlifes. I hate owners that won't invest in equipment to make their employees setups faster, more accurate, and cheaper. It boggles the mind!!!!!!!!!!!!

[@nikolaishriver7922]

Unless you have your own shop, you're at Lockheed or Northrop and have 20 years formal experience, the machining industry here(Florida) SUCKS. Been informally machining on my own and writing G-code for fifteen years, I can mill/turn/fabricate anything anybody needs. I live and breath machining and creating in my spare time. After wasting my time going to tech school to get a piece of paper formally saying I "learned" how to do this, and trying to get into formal manufacturing, I went back from my machining passion, to doing electrical. If there is one thing I have learned in life regarding your career: ALWAYS go money over passion. I'll start my own shop one day. Best of luck to any and all machinerer's asked to be doing a master machinists work, on a machine operators salary in these insane stingy shops here in the swamp.

[@chauvinemmons]

What is it about NASA it seems to blow people's brains up all for 10 bucks an hour. Yeah I'll have to give that one to you Florida is in fact a shit hole of manufacturing

[@kevinspacey5325]

@@nikolaishriver7922 I agree 100%

[@markdavis304]

Great video Donnie! Crazy tools Horn makes!

[@ChuckMcFarlin]

PH Horn was my go to for small tools that always worked great. I never had to go that small though,

[@dominic6634]

Always preferred making small stuff. Even though the larger stuff is in someways trickier

[@donniehinske]

That’s crazy. That’s the opposite opinion I have 😂😂😂

[@CATANOVA]

Less chips and you don't get a bad back.

[@Nunak91]

That doggo was unexpected!

[@donniehinske]

He runs the machines and checks my parts

[@maninthemiddleground2316]

Lol … the thumbnail had a “world’s smallest boring bar” was thinking “a small bar full of bored people” 😅

[@coreyfro]

How can you call it a boring bar, it's so exciting!

[@opendstudio7141]

That EDM machine can make insanely micro sized carbide tools.

[@JimmyLuffjr]

When you check the RA of the bore I will really be impressed.

[@tech-utuber2219]

What is the process to grind this tiny boring bar? Did they grind it approximately to size, and then incase it in resin in order to minimize vibrations to finish it and then dissolve the resin away afterwards? Any video links on this would be appreciated.

[@drafty0183]

THAT would be a process to see.

[@marcosflores-march7278]

So cool. How about showing us how you make that teeny-weeny boring bar. I want to see the machine that has that task.

[@pirminkogleck4056]

i use Horn in my hobby Shop and since then i am able to hit Bore Diameters to a few microns and better ! love my horns

[@dr.emilschaffhausen4683]

It's not often we get to use the word sauntering. Great video.

[@tubbytimmy8287]

So the tool must be precisely located and straight... But I still don't understand how the tool is strong enough to cut metal when it's too brittle to handle? I imagine the cut deflection is pretty high too?

[@kevinspacey5325]

Roughing drill and yes, it deflects. Notice he's using 2 passes. He bought that boring bar, but I would make one in my Anca cnc grinder that was much shorter to help with rigidity. Also solid carbide.

[@eddiegarcia7959]

WOW!!! ABSOLUTELY AMAZING!!!

[@importanttingwei7747]

Grinding videos more of them please

[@kgranno]

Absolute genius! 😮

[@stephenallen4374]

I knew you guys could do it you guys make machining fun and challenging

[@shaniegust1225]

Nice video Donnie! 👍

[@sportswolf1]

If I didn't see it with my own eyes I wouldn't believe it!

[@steve0stang]

Amazing information!! This is golden!! Thanks for sharing 💪🏻BOOM!

[@Scott-weeks]

You guys are the best. I want to know how to manufacture that part pictured 😊

[@travisjarrett2355]

I'll now be submitting my resignation. Thanks bro.

[@donniehinske]

😮

[@ksmechanicalengineering92]

Amazing

[@Skook91]

Contrary to popular opinion I have found precious little from PH horn to be properly designed. Their carbide end of things seems top notch but interface from carbide to holder and holder to machine is beyond lousy. They make impossible looking tools and sometimes they turn out to be impossible to use too. Good video but I if you want micro tools, go right to Mikron for drilling. I've drilled thousands of .008 diameter holes in stainless with .0005 runout without any problems. That'd be like running a .500 drill with .031 runout, that would be insane... Mikron drills are so forgiving.

[@Roberty98]

Insane! 😆

[@cncdan1364]

All about the direction of the work and force. I started running on a horizontal mill and couldn't believ how might bites would hold 1 inch plants with a finger nail. But since imall the work was being forced into the mighty bits

[@m-tech1816]

Thanks, I'll keep all that in the back of my mind, when I ... weld my barbecue back together, or whatever is up next

[@GarageWorx]

Pretty cool 😎

[@batmantherooster]

Incredible ❤️❤️❤️❤️❤️❤️❤️❤️

[@jaizenfisher7195]

You guys should make a video about what it takes to work for Titans! I'm a student at a vocational school right now, and this is my absolute dream job!

[@aperson7624]

So, something I learned at Boombastic: They don't actually make any parts for production. They are basically a CNC marketing firm with education on the side. That Trumpf laser 3d printer they had? Trumpf sold so many that they took it out of Titan's shop because they literally can't build them fast enough. And all the guys I talked to agreed, they make 1-100 parts for a video, but they don't do production anything. They have 12 camera operators on staff. If you really want to work for Titan, be a video editor or camera operator. If you want to actually run a machine, you need to understand what every screw and circuit in that machine does and why. Your job will then be to teach.

[@nikhook1114]

I noticed a few things that I would address. Firstly, when you put the part that you are boring in the chuck/collet, you didn't check to see if it's running true. Secondly any tiny tool such as this should not be put in a holder that has a screw. I understand the you find the center of the hole with the camera but if you held that boring tool in a shrink fit holder it would be running almost perfectly true and concentric to the holder already. Just my 2 cents. Good job regardless.

[@kylelaw7210]

How do you make that small of a boring bar?

[@Silver_Nomad]

In the next episode: We are setting up the smallest mill in the world to machine 3 nm process on a piece of silicon.

[@palpytine]

Tenths are only the "smallest possible scale" if you measure in bananas. Metric machinists can measure in microns.

[@modalize]

there is somethin to talk about.. how they manufactured that boring bar

[@CATANOVA]

What if the temperature changes, what would this do to the offset and chipload? Does that machine have thermal management on the screws?

[@donniehinske]

Yes the machine has thermal compensation but also benefits from being so small. It doesn’t require much force to move. It’s such a small machine it actually helps with the accuracy

[@CATANOVA]

@@donniehinske Holding a ruler on screen I estimate the width of the cutting face of that tool to be around 210 microns (0.0083") lol. What made me think of machine thermals was pondering what kind of pitch must be on the ball screw driving the axis with respect to smallest repeatable move and also what kind of chipload in terms of the usual feed per revolution one would be running. The feed per rev must be incredibly small, so much so that any fluctuation in machine temperature would have some kind of effect. I am a 10 year Solidcam user. The machine simulator option is a lot of work to get set up.😁 Thanks for taking the time to reply.

[@verakoo6187]

Horn can make boreing bars this small, yet god forbid they make a .1-.15 bar that can go an inch deep. Lol

[@sandibabic9597]

I see the smaller your parts get, the raw material seems more oversized. Off course you can't really work with 3 m long needles, but may I ask, what would be the smallest diameter rod, you would work with on a swiss machine? I went with a 3.2 mm in diameter rod on a Citizen L32 machine, and I kinda regretted that decision, yeah it might work, but problems occur way too often to be considered acceptable.

[@donniehinske]

It depends on the machine and the barloader. Tornos has done .5mm stock I think. I just keep the same 3.2mm bars for simplicity sake

[@fluxpistol3608]

I went to a boring bar once, it was also small.

[@nyanlauncher7350]

What about speeds and feeds?

[@phillhuddleston9445]

I've used a .018" drill on 304 stainless on a radius and that was a PITA but I can't imagine using a .008 boring bar on any material. I only had to do one hole on about 6 or 8 parts and broke several of the drills and scrapped a few parts that were difficult to make, it was all done on a Bridgeport. The second time I did the job the boss order cobalt HSS drills vs standard HSS drills and I only broke two or three drills instead of a dozen or so. I used a small keyless drill chuck that had a free spinning, knurled ring that spun on a bearing that you use your thumb and one finger to feed the drill into the part with, the chuck had a spring loaded shaft that it slid up and down on, the spring pulling it upward with little pressure. There is no way you could ever use the quill to feed a drill that small that would not give you enough feel and you can not regulate the force good enough. His boring bar is smaller diameter than a lot of chips are thick, I would not want that job fancy alignment tools or not.

[@CATANOVA]

Isn't the play (in every direction) on a Bp 0.018"

[@aperson7624]

Honest question...why not use a laser? It should be *way* easier to get a laser concentric and focused to that size vs using a drill. Plus, with some optics, you can adjust the beam diameter! Or is that the niche I need to get into, precision micro drilling...via laser!

[@chauvinemmons]

​@@CATANOVAon a really wore out one on a good machine it should be . 006 or better you know what you're doing you should be able to hold .002 all day long I used to do better than that I used to hold better than . 001 true position on very complex variable geometry nozzles.

[@CATANOVA]

@@chauvinemmons I was referring to the slop in general with them, having owned one and struggled with it. Normally one would lock up the axis not in use and wind the knee up as far as possible. Some of old timers would tell you that you need to torque up in the cut, whatever that means lol. Generally though you can't really use carbide with them because of the slop resulting in tool breakage. I gave away a draw full of HSS/cobalt when I sold mine and purchased a proper CNC where the difference is night and day. I Would still have a Bp today but just use it as a super flexible drilling machine because there are some jobs a CNC mill simply can't do where the touch and feel of a manual machine like the Bp comes in to its own.

[@alfonso355]

Are you guys doing Rolex in Texas?

[@eugenebutrik3398]

I wonder if jumping up and down while talking is really necessary for a good video? :)

[@Pan_Czosnek]

how much rpm do you need to use that's small tool

[@brandons9138]

All of them.

[@donniehinske]

@@brandons9138😂 @Pan_Czosnek 16,000rpm

[@drafty0183]

He said 80,000rpm in a NSK spindle ($24,000). Blows my mind.

[@kevinspacey5325]

Why not show the making of that boring bar in your guys cnc grinder? Easy money on a Walter!

[@nathandevine552]

After all that would have been great to see him drop the part and utter a string of cuss words.... LoL

[@89sirmonk]

That is really cool. Also, no thanks. Personally i dont ever want thay kind of work.

[@kevinspacey5325]

You can do it! Don't shy away from $$$. Also this is why they make these videos, to bring back manufacturing to the USA. . . . and money. . . .

[@cncdan1364]

I make bushings for trains andngo i hate hold that .00025-.0005 tolerance down the bore

[@danielbraniff8517]

Geez

[@st.michaelthearchangel7774]

The dog.

[@lucianofontana8121]

Why not edm ?

[@kevinspacey5325]

I'll tell you why. . . $$$$ Finish the bore in process on the swiss in seconds vs. having to automate an Edm drill to cut 1000s of parts (slow cycle time) . . . . All the machining of the feeder bowls, railings, robot loader jaws etc etc etc. You have to consider the cost at all times. It's much cheaper to buy that camera (works on MULTIPLE applications) vs. all the work for an Edm. Hope this helps, A Senior Toolmaker.

[@lynnrunningdeer7364]

Couple of million dollars and you can have and make whatever you want.

[@faaf42]

In don't think you explained how can you use the boring bar without it breaking like you said you would in the beginning.

[@verakoo6187]

All the RPM is how lol

[@stevieg2755]

.008 is double a hair size,just saying

[@ernest6980]

.004 is average hair diameter i call BS

[@MrJdebest]

Maybe public hair !

[@kgranno]

BS, how?

[@kevinspacey5325]

I've mic'd mine. . . . it's about right. A woman's leg hair however. . . . My wife looked at me funny 🤣

[@burville100]

@@kevinspacey5325 🤣

[@donbotting5700]

That’ll be a no for me Dawg!

[@ankithmistry]

I'm not gonna impressed until you do some titanium stainless or inconel with this :)

[@petrolak]

at this scale it's probably better to use some sort of spark or laser machining

[@wolfiemuse]

Well, if you can get a CNC to do the job, why buy a new machine?

[@kevinspacey5325]

@@wolfiemuse bingo. Edm or laser is a whole another setup on a part this small. Finishing the feature on the swiss in seconds saves huge $$$$$$$$

[@joshuawentworth7426]

Why such a long tool for such a shallow bore? Pointlessly weakening the tool.

[@Shamefulbird]

Perfection do not exist

[@CATANOVA]

If I were to send you a million dollars right now would that not be PERFECT!

[@Shamefulbird]

Would be perfect if it was more than a million XD

[@CATANOVA]

@@Shamefulbird 😉

[@Muttley3000]

Boring 🎖

[@shivnillal3601]

thats so boring

[@kevinspacey5325]

Turned in a YZ 125 cylinder head to be re-sleeved and bored to size back about 15 years ago. The shop had a banner hanging from the wall that read - "I love my job even though it's boring"

[@shivnillal3601]

@@kevinspacey5325 sounds pretty borning tbh

[@kevinspacey5325]

@@shivnillal3601 "borning" lol

[@robertf6523]

Indubitably boring xD

[@leyvarecio3699]

This video has a lot of boring content

[@graphixkillzzz]

what a small, boring video 🙄 🤪😂🤣👉

[@Blazin2133]

Fascinating!

[@ProDMiner]

WTF this is awesome!