SNS 310: Machining a Cast Iron Prism Straight Edge

[@dcallan812]

You really need to send a really small straight edge back to Lance, and explain you had to take more off than you thought. (Then send the real one a day later.)🤣🤣👍

[@glenncpw]

I am glad you showed a portion of the cleaning - unless you have a mill, and use it, you can have no idea of the mess after a milling operation, and especially cast or ductile iron. Good Vid. Thanks

[@CapnCrusty]

Buy some coupling nuts and several lengths of bolts to fit them cause they make dandy little jacks. You can TIG SAE thick washers to the bottom for broader bases and add jam nuts for locking if you like.

[@ronnydowdy7432]

Love watching the show. Bringing back a lot of memories for an old school tool &die maker. Plus my years in the Air Force machine shops.

[@frfrpr]

Talk about good video work. Gosh. The slo mo, sound and actually seeing the work. Top notch video. A+

[@Kenjiro5775]

I love the look of freshly machined cast iron. It has a color that really appeals to me. Love the channel too. Your dad and granddad would be proud to know you are carrying on so well in the 21st century.

[@bulldozer7656]

Great job Adam. Always love the process. Thanks for bringing us along

[@Platyfurmany]

When you first talked about doing this project, I thought to myself, "Yes. We're gonna get some more shaper action." I have to admit I was disappointed that you didn't use the shaper. That shaper is just so damned fascinating to watch! Btw, you've got at least one, maybe two cutters on your cutting head that are cutting deeper than the rest. I could tell by listening, especially when you slowed down the frame rate.

[@fricky11111]

You have the only 40 minute videos on youtube that I will sit here and watch from start to finish...normally I'm a ten minute video guy. Good stuff

[@rhocass]

That carver vise is something else. Being able to fine-tune jaw lift sounds like a lovely feature to have

[@JNeff99]

Great video. I always know your videos are filled with little pearls of techniques that make projects go smoothly. Thanks for them.

[@SkypowerwithKarl]

Many don’t know it, but don’t use tapping fluid/cutting oil when manually tapping a hole in cast. Use air down the flutes to extract the crumbs (I won’t call it chips). Once you have established a good start, blow out every few turns to avoid too much build up of cuttings. Once to depth blow out and start to back out cautiously. If you encounter resistance stop, go in again and blow then try again. If the powder gets behind the cutting edge relief, it works like a wedge to wreck the threads, tap or break it off. Using cutting fluids makes a mud that’s even worse to get out. The best tap for manual tapping is a spiral point. Don’t use spiral flute as it can stretch the lead(pitch) as it pulls too quickly into the hole. Never use a roll form tap in cast materials or non ductile materials (strong but snaps or crumbles when bent) for example: cast aluminum, iron or 7075 aluminum.

[@roydavies2442]

If you use cutting paste/fluid when tapping cast iron it will give you tight holes.

[@thytrin2103]

Man, I can feel the satisfaction and back sighing with relief when you used that skyhook! Well done as always Adam, great video.

[@machinemoverman4614]

I would have thought you would’ve used the shaper, but you know more about it than I do. Good job Adam!

[@forrestaddy9644]

Here's a niy-picky refinement: One problem with a table vise is it turns your machine table into a structural part of the grip. Tighten the jaw and the clamping force against the work a few inches above the table surface tries to bow the span of table upwards a small amount. Therefore, heavy clamping forces are to be avoided on smaller mills like a turret mill. Adam's K&T mill table is maybe 3" wider and nearly an inch thicker thus abler to restrain heavier clamping forces without undue deflection. Whopper HBM tables are robust enough to restrain most anything. I have a lighter version table vise I used infrequently on my turret mill. It didn't take much grip on a 20" long part to bow the table up 0.001" in the center (I checked it once with an improvised bridge gage.) I wish I had better numbers but my check was years ago. The lesson is: if you use a table vise regularly, expect end bearing wear on the table ways on the saddle depending on table rigidity, length of the clamping span, and the vigor of the grip. As ever, YMMV and everything is made of rubber - even robustly designed milling machine tables.

[@snaprollinpitts]

I liked the slow mo on the end mill, pretty cool. thanks Adam

[@markfergerson2145]

I for sure ain't no kind of machinist but I've watched enough of your vids, TOT's, Quinn's, Tubalcain''s, even AvE's that I wondered why you didn't support that thing in the middle *before* you started that first full-length cut. You guys are great teachers!

[@ellieprice3396]

Nice job. Thanks for another good one. I'd like to add that when long parts are machined on Bridgeport machines a slightly convex surface often results due to table drop. It's a common problem to be aware of, especially on worn machines with loose gibs.

[@Da5idc]

Great video, the close-up and slow motion shots are awesome

[@KentuckyReef]

Love the new camera work; and then he dropped the ABOM, with the slow-mo😁👍

[@sickboymech92]

For short machinist Jacks I use a coupler nut with matching bolt. Get rid of any the forged markings on the top of the bolt head and round it slightly. Love the setup, beautiful clamping system.

[@TheObersalzburg]

Great tip. Thank you.

[@danielson9579]

Loved the slow motion when milling the ends of the prism 🙂👍

[@MAL-92]

Is it just me or does anybody else think vacuuming a mill after your done is so satisfying. I used the brush attachment and always thought it was so satisfying.😂😂

[@BeachsideHank]

I hate working in swarf, I clean while in process not wanting to wait at the end- it may be less productive, but psychologically I feel I do a better job.

[@sleeper98]

Thanks for another great video. I really liked the closeup shots.

[@khattaklifetv4382]

kzbin.info/www/bejne/h3XWmmuIrLyqidE

[@peterparsons3297]

that cutter has left a lovely surface finish

[@tkskagen]

That "even though not perfect" is a BEAUTIFUL PEICE!

[@J800613]

Adam, something to consider is the stresses in that casting. if you do one on the mill again try roughing it all over then taking a light finish pass. You will still be dealing with deflection because of the higher tool pressure compared to the shaper but it should get you closer to true.Old time machine builders would rough machine their castings then let them "season" for a year or more outside to relieve the stresses after the skin was machined off, then finish machine them.

[@eugencsl]

Heard those stories too, about “seasoning”. Some old guys told me that when they had to do precision tools ( like parallels or angle blocks ) they chose the oldest material they can get from the depot, the older the better, especially steel that has seen some cold winters and hot summers...

[@paulwomack5866]

In the modern era, if you want to stress-relieve a casting, you cycle it in a heat treat oven. The required cycles have been well studied.

[@Xezma]

Yeah a lot of metals come stress out. Probably from their ole lady LOL, but no seriously. Pre heating to stress relieve works great. Cast does better than most considering the material your using. All I know is stainless is an acrobat after machining.

[@jeremymatthies726]

Another great video Adam. thanks for sharing your passion with us. from someone who isn't a machinist or metalworker, i still always enjoy watching your videos.

[@olddawgdreaming5715]

Good job Adam, thanks for sharing with us, Fred.

[@hubbsllc]

Great video, Adam - thanks for the closeups and the slo-mo. Love the finish on cast iron.

[@argee55]

Loved the slow motion of the end mill.

[@CarlHargreavesRustyRelicsUK]

Enjoyable viewing, I have the same caver clamps for my big mill. Great bit of kit. 👍🏻

[@neilrecords29]

👌👌 great knowledgable video once again, been a machinist for 25 yrs but always something else to learn on the way 👌👍

[@Kelly-ip8nn]

What a fantastic way to start my morning down under! Thanks Adam

[@a.bakker64]

hi I get this in the evening in the Netherlands 😉

[@CleaveMountaineering]

In my internship, I was fly cutting an aluminum plate, it was hanging off the end of the vise several inches each side. Probably 4" width x 1/2" thick. The unsupported ends vibrated and thus the tool cut ripple marks in the part. I had to cut more off, only running the cutter over the vise, then shifting the part to cut the other side. The machinist jacks you used would have been the perfect solution.

[@waikanaebeach]

Another great piece of work. I like the way you describe your thinking on machining, helps others understand processes.

[@khattaklifetv4382]

kzbin.info/www/bejne/h3XWmmuIrLyqidE

[@mikemcclune1440]

The surface finish turned out great on that cast Adam

[@DavidArnold2God-Glory]

Ah, what memories! Thank you for reminding me of both the "fun" of milling and why I retired. :-)

[@TomTalley]

Nice work using that rotary shaper. Thanks again for what you are doing. Sure is fun watching the machinist art being practiced by someone who cares.

[@chaineffect6437]

YES! I for one second the "Shop project" you mentioned! Some stubby Abom machinists jacks! Configure your design, sling some chips, heat treat, maybe some cold blue! Sounds like a fun sunday project and a cool video! Also, was awesome to see the 2-piece Carvers from the old videos at Motion! I remember those exact broach plugs from a certain video! lol Great set-up, and result, as always!

[@chaineffect6437]

@jacktheripped Clever thinkin man!

[@GQNissanPatrol_TD42]

Beautifully machined Abom! Great job! Thank you so much for sharing the video!

[@t3cker]

It's so satisfying watchin ur chilled work. I work in an milling company producing stuff for the automotive industry. It's ridiculous how crazy stressed our machines are set up trying to reach accuracies under 5 micrometers just because of cost-effectiveness watchin you producing the parts givin them their accuracy xD

[@markdavies9912]

Brace yourselves but I find the K&T vids much more entertaining than the shaper vids. The variety of cutters, set ups and work it’s capable of just appeals to me more. Let the wrath of the shaper fans begin! 😁

[@xenonram]

You can find tens of thousands of milling videos on KZbin. You know what you can't find very many videos about?

[@AlessioSangalli]

It's not about the mill vs shaper. I own a mill and not a shaper but in this case, even at the end of the video, Abom79 says a shaper would have done a better job.

[@markdavies9912]

I’ve run both a shaper and a mill in my time and I’m not disrespecting the shaper, it has its place. It’s just that what was initially calming and zen about watching it work has quickly turned to monotony. I don’t feel that the lathe, mill, welding and particularly the restoration vids. Abom79 is a genuine master if all of them and a pure pleasure to watch.

[@loydsa]

Love to see your work as always Adam.

[@krosskaien8618]

I'm always anxious when I see work sticking out such a small amount above the vise jaws. I couldn't help imagining the tool crashing, it was quite nerve wracking.I really the admire the confidence you have in your setups.

[@erikjoven2388]

Nice to see the mill get some love there :) i thought for SURE this would be a shaper project! That seems to be a really great piece of cast iron. Also nice to see the Sky Hook getting some use!

[@Ddabig40mac]

Love that Carver clamp set. What an awesome viewer gift. I'm gonna look them up. Finish on those faces is so fine, your fingerprints show up!

[@snifitall]

Beautiful work as allways.

[@carloscordero4204]

That's a good job Adam thanks looks really smooth on too the next job the stoker engine box !!

[@blackpete]

Oh, I love face mills and flycutters and stuff. They somehow have something elegant. Cast pieces are so nice to cut. No oil, no coolant. And no broken tools, if the casting is good and has no hard spots. Broke one or another in my apprenticeship.... Oh and nice plug on sky hook 😁👌 Nice video, as always.

[@garthbutton699]

As a substitute for a machinists Jack try using a 5/8" capscrew of the appropriate lenght and a high nut, helps if the capscrew face is faced off,snug up and your good to go.Beautiful results I might add🤗🤗🤗🤗

[@itswift]

Yep, I'm sure Adam has tons of fasteners laying around that could be used like this. Saved my butt a couple of times.

[@TitusKrakenDesigns]

nice video again! I love the slow-mo shots and the sounds, very ZEN! it is very nice to see how the tool eats the metal!

[@DarkFire515]

Love the slow motion end mill action!

[@greggoff4990]

You only get one back. Once you mess it up it’s never the same. Great idea showing the crane and cart.

[@minigpracing3068]

Thanks for the big gauge again, really is easier to see!

[@toolbox-gua]

Watching you work is always a joy. At 35:00 you were cleaning (vacum), I wonder if you could make a video of shop work, the cleaning around a real job lime this, taking care of chips and all that. How you collect it and then dispose it. Thank you and take care.

[@kimber1958]

The shell mill is mesmerizing but it does not compete with the shaper. Love you thanks for the great videos

[@kylemcalpin9324]

Not going to lie... I wasn't going to watch this one. But I'm glad I did. Very satisfying to watch.

[@Steve_Just_Steve]

I thought for sure you'd have that thing on the shaper : )

[@PeteHowlett]

That was always going to 'spring' clamped like that and as a 'gauge' it could be seen as not acceptable but it is not a finished product is it? And I for one am always in awe of your skill which is executed with such humility. Another great video Adam.

[@mohammedazaroual5925]

With such beautiful machines,the job will be always perfectly done,congratulations,you are the best.thanks.

[@dennissheridan8836]

At 21:31 you vindicated my thought that you should have a jack under the center of the beam, nice to know that I've actually learned something by watching your videos.

[@bennyogden4524]

Watching your work is very very helpful man just keep up the good work I've learned a bunch

[@erneststorch9844]

Your end mill was cutting perfectly. I am tool grinder and an operator was having a problem with cutting a ledge in cast iron . The holder was homemade and l suspected that it did run true. He was going to give me end mill alone I said no I want both the holder and the tool. After I ground the tool in his holder the end mill cut perfectly. What he was getting before the end mill was spitting chips . There supposed to come off like rain just as yours was doing. A old tool grinder told to hold any tool the same way they are using it on the machine and if possible use their holder. Nice job by the way.

[@jtb52]

Super video. So interesting your commentary. Enjoy the camping trip

[@GazinGeezer]

Slo-mo effect was interesting....Skyhook seems to work great for you. Hope you enjoyed Dunedin and St. Augustine. Pretty neat places,,,,

[@alexpav3167]

You know you're good when you machine tools for machining machine tools

[@mostlymotorcycles.]

So cool watching those chips come off in slow-mo.

[@coryhalvorson8874]

The slow mo of the side milling was so cool, seeing each blade of the endmill take a shaving, really makes me appreciate the efficiency a milling machine

[@yepperbgolley8215]

Fascinating! Thanks for all the great videos.

[@davehall7178]

It was flashing in your hand. Lol great job 👍

[@williamna5800]

Those straight chips off the end mill just make me happy, no idea why.

[@joeadams1225]

Thank you ABOM ! I can smell the hot machine oil and the craftsmanship,,, you are more influential than you know .

[@lancebaltzley]

Thanks Buddy, as always your work is beyond exceptional...

[@jamesmanoni]

I had a mild steel prism milled recently and boy the guys had a lot of trouble getting it close to flat but after a few goes it was only 0.03mm bow in the middle, a lot easier than scraping 0.3mm!

[@louisturner8842]

been a few months since I last watched you Adam. Your camera skills are getting top notch and your knowledge with cast and materials is becoming top notch. thank you bud. hang loose: peace n love

[@kellerrobert80]

Noticed that you're doing more machining. Thanks, Adam! And with some spiffy slo-mo bonus footage.

[@walterjwalnut9964]

Adam, on the slow mo passes, the audio suggests that one or mayby two of the inserts on the cutter are marginally lower than the rest. It definitely sounds as though an insert cuts across the surface, followed by a group that are merely scraping along behind it. On the narrowest face, there would be a couple of inserts in contact at anytime, while for the broader surfaces there would be four or five, and with the progressive feed each should be meeting new metal and cutting, but it really sounds like an interrupted cut as you would get with a degree of randomness in the insert position on the cutter. Your thoughts?

[@trevorlawrence8113]

Most used facemills are either worn or crashed to the point where the inserts are no longer all at the same level, say within .0005" or so. I've seen some at my shop that are .005" off or more. Unless the inserts are particularly worn they are still cutting fresh material, it will mostly just affect surface finish as your peaks and valleys will now be further apart. And most all milling is interrupted cutting, sometimes it's just worse than others. I have noticed abom and a lot of others like to center their facemills over the part instead of offsetting it to one side, the exit of the cut is where a lot of wear will happen on inserts, just due to the nature of carbide, so offsetting it so chip thickness is as thin as possible at the exit will help insert life a decent amount and allow faster feeding due to radial chip thinning, though I know this probably isn't a huge deal to manual machinists and the centered cut can produce a more symmetrical finish than offsetting. Sandvik's website has a ton of information on facemilling that I've found very helpful

[@Miner49er1]

Nice job on that straight edge! That machinist vice project sounds like a lot of fun, hope you can get around to it!

[@eumoria]

When will you hit 500k!!? Can't wait for it... another great video :)

[@stotheh]

That wee crane at 07:30 is just utterly adorable!

[@honeycuttracing]

That was one hell of a gift Adam!! They go for over $1,000.00 on eBay!!! Very cool video!!!

[@railgap]

Watching that big shell chew through that heavy cut, I'm thinking, "I love my Bridgeport, but it won't do that." Those K&Ts are beasts, for their size.

[@johnlee8231]

NIce job but you didn't hear me say set it in a couple of matching v blocks! lol

[@jerrysmith8086]

Hey Adam did a great job on that bar.

[@Debonair.Aristocrat]

That opening theme always makes me think of "Helplessly Hoping" by Crosby, Stills and Nash.

[@NavyShooter3]

Just so you know - I bought a pair of Noga Indicator holders because of you this week! They work some good! Thanks!

[@shawnstrode3825]

I really like your videos. Simple to the point and get it done. Some guys want to tell you about the machine, the tools, the set up, the math, the history about the part. And then repeat through out the video. Commonly they will run out of time so they will do a second video with a repeat of the same information.

[@redordead3868]

I love these videos. The mill is mesmerizing.

[@ndoghouse6853]

Damn! Thats beautiful. Id love to see it in action!

[@vijayantgovender2045]

Thank you Adam I always enjoy watching your videos I am from South Africa

[@steveshoemaker6347]

Thanks Super good...An the best part is it....Not a two part job video....Slow motion is really good....Thanks again...!

[@thompsonjerry3412]

Seems that the greatest challenge is holding on to the part.

[@martineastburn3679]

Looking at the physics of the bar, two laws play in. 1. Mechanical - center support cuts the bending of the bar. 2. harmonics in the bar - the bar has a fundamental length and rings (sorta) when stimulated. That is flex going back to (1). You did two fixes - change the frequency (rpm) and cut the sympathetic oscillation in about half. One might get good results like you did by putting the support at 1/3 -2/3 location(s) mixing any resonant to be much higher and maybe beyond that of the bar. Complex maching sometimes. Think of the lathes that turned 30' cannon barrels for battleships. What a lathe an milling.

[@ferfery2079]

You are one of the best ,thank you for videos

[@TomokosEnterprize]

Love to watch you work my friend !

[@skoronesa1]

I wanted to see more shaper, if for no other reason than to laugh at the people in the comments losing their minds over another shaper video. The shaper is -powerful, makes deep cuts -Leaves an interesting surface finish -Unique, not many channels on youtube have shaper videos -It's less boring than the mill which is just another spinning cutting edge Lastly, the shaper makes Adam happy, and that makes me happy :)

[@khattaklifetv4382]

kzbin.info/www/bejne/h3XWmmuIrLyqidE

[@65BAJA]

My Saturday morning is now complete.

[@khattaklifetv4382]

kzbin.info/www/bejne/h3XWmmuIrLyqidE

[@WreckDiver99]

Am I the only one that says "Clarence" every time Adam says "Clearance"? LOL...One of the greatest movies of all time.

[@AerialPhotogGuy]

Good thing the milling machine was available for this project. The milling machine has a table long enough to setup a 2 piece machine vise like the Carver set used here. Most shaper tables are too short for a setup like this. Side note: I couldn't afford to buy the Carver Machine Vise Set, those things are high dollar! (Nearly $1000 for the set I would like to have) I had to settle for a Grizzly set until I have enough time to make a set comparable to the Carver set. Every item I check off my list of "Tools to make", I wind up adding 2 more items to that list but it's worth the effort IMHO. Nice video!! :-)