Special Shaping Tool For The Mazak

A Special Shaping-Broaching Tool for the titanium parts on the Mazak.

[@markmuranyi9289]

As a toolmaker and a CNC machinist I am totally blown away by your expertise.

[@EdgePrecision]

The only way you can tap in turning mode is on centerline. In that case I turn the thread. On the Mazak I have never tapped in turning mode. If I ever did a part where I could not reach the thread with a threading bar on centerline. I think I would tap with the milling spindle anyway. Because I have never tapped in the turning mode. I’m not completely sure it does it with rigid tapping. Where the tap doesn’t need a floating tap driver. If that were the case I would never do it that way.

[@ClockwerkIndustries]

This channel is a national treasure for machinists and toolmakers, my great grandfather was a tool and die maker in the 1920s-1950s. I have an old vise he made from scratch I plan to refinish this winter or spring it should be a fun project. You make some amazingly complex and difficult to machine parts its awesome to watch!

[@ttjarrett]

That fillet is either a mission critical feature designed by an extremely experienced engineer or a useless cosmetic feature designed by an intern.

[@Rough_cut613]

"Hey Tim, did you remember to remove all those bullshit cosmetic edge breaks before we sent out that part model?....No? Oh well....fuck em'"

[@dennyskerb4992]

Luv it. “doesn’t matter, I just don’t want to look at it”

[@travl3217]

Pete, I hope that one day you will be able to show us the machining of the actual part again! That is a very intense part you are machining and I sure we would all love to watch you machine that.

[@missmymountain]

It's amazing watching you develop your own tooling. So much planning is involved for the products you machine.

[@zamkarapuza]

Are you an employee or owner of this company

[@spikeypineapple552]

These videos are like machining crack. I just can't get enough.

[@extradimension7356]

2nd time I've watched this a year apart ~ very compelling.

[@CorndogBrownie]

Fantastic work, love whenever you post something new. That finish almost looks like when they burnish watch components, very neat. Thank you for the time you put into this content. Greatly appreciated

[@jamo747]

I was starting to miss your videos. Glad you put one up.

[@dav1dsm1th]

Mind boggling to think that the tooling costs of a job like this exceed what most people would imagine the cost of the entire job should be. You must have developed a great relationship with your customers, where they know that for the quality they are asking for - they expect to pay for the same level of attention on the tooling as on the finished part. Great content - as always.

[@ClockwerkIndustries]

yeah I would assume, parts of this complexity, with little bosses inside the bore with fillets on them, they know they have to take these parts to a wizard, and they know the wizard will be charging big $$ but it will be done to spec without worry.

[@CalvinoBear]

The parts just get crazier and crazier! So cool to see.

[@Musicalbullet]

Another awesome video! Thank you for taking the time to share your talent. It’s very inspiring 👍🏻👍🏻

[@kisspeteristvan]

With every new 'episode' this part gets more and more impossible . Peter i've said it many times already , but you really are a master of the trade . I would be honored to learn from you . If on youtube i see this kind of amazing techniques , can't imagine what it would be in person . Looking forward to the completion of the part , possibly some tolerance details too (no drawing of course)

[@Xlaxsauce]

I do like that pattern on the tool. I'm glad you kept it.

[@Ryan-dz3jo]

Thanks Peter, your content and skill is fascinating.

[@gordonjones1516]

The versatility of that machine is phenomenal. So is your ability to utilize it.

[@leonelromero8349]

Very well thought out and excellent tool quality. Thank you!!

[@amishmilitant4618]

Your videos are always interesting. A lot of the time for me, especially when talking about the programming, you are way above my skill level. Self taught with machining and I have manual machines only. Wish I understood cnc programming, because it would be nice for curves and multiple milling. You sir are a master craftsman.

[@Eriond1]

A video about cnc and how to use it that was worth seeing. Great skill! After 22 years as operator and programmer of cnc machines, I'm not really impressed by most videos showing off machines and set-ups. This video was impressing, and I look forward to see this tool in action 😊

[@joshuawhite106]

Great Video as always Peter! Thanks for sharing.

[@jakedimmick1452]

you do really nice work. And I gotta say it again I love your Mazak mill/turn .

[@texastad1989]

Very nice Peter, thanks for sharing. I will keep this in mind, I had turned away some work that a tool like this could have done!

[@michaeljefferson2386]

Thank you for making these videos. They are truly awesome. I wonder if the genius engineer who designed this part has ever been in a machine shop. Someone should tell him that you cannot 3D print a part like this. Perhaps tie him down a la A Clockwork Orange and make him watch your videos... Your skills are legendary. I am glad you are sharing them with the world.

[@danl.4743]

lol. I remember that scene. You're nuts. (but in a good way)

[@4GSR]

I am a design engineer with lots of machining experience, not all "hands on" but very knowledgeable of tooling like Edge Precision uses. These parts are just a few of the many I've seen in my past and kind of know whom they maybe for. These engineers developing these parts have PhD's, and are developing this stuff, and they do work with shops like E.P.. One thing I would have done if this was my design, I would have put an internal key way in the part shown, and put the key as an external feature on the mating part. Got to remember, most of these parts are only made in small quantities for usually one job and never made again. Price is generally an option on this stuff! The oilfield needs it now! Bill us later!!! Ken.

[@toolbox-gua]

OMG! “It looks kinda neat that way”. Just perfect.

[@mehmettemel8725]

Peter your workmanship is amazing and admiring.One thing puzzles me is quite often you make your own tooling for the job which adds more to cost of part then again when they want something complicated as most of your work I suppose you can squeeze every dollar out of them where as my tight customers squeeze every cent out of me on basic few dollar jobs.😁

[@thomasgiovine2211]

Very cool tool Peater cant waight to see it work i have never seen Shaping done on a Mazak looking forward to watching

[@a.k.2023]

Nice job Peter! I will see it working! 👍👍👍

[@mannycalavera121]

I love these custom tool videos. Would love to make my own indexable cutters.

[@nicke5786]

You do some interesting stuff dude. I’d love to be able to pick your brain on some things that I do. Keep up the good work

[@gearloose703]

Angle grinder used carefully leaves a surprisingly good (looking) finish! I was just drafting a shaping tool for milling machine as well. For the sake of simplicity I think it will be a rod with a hole drilled across and an old carbide end mill.

[@danarrington2224]

I am so worried that this type of expertise will not be passed on to the next generation. They will know how to operate the machine and the software but this type of creativity is only learned through exposure to others who are willing to pass on their knowledge. Well done sir!!

[@63256325N]

Nicely done! Thanks for the video.

[@raybrown5890]

looks so great!!

[@cruch9]

Awesome! Love your vids! Learn so much from you!

[@levitated-pit]

ive never even thought of a mazak being used as a shaper before! excellent video ...thinking outside of the box

[@levitated-pit]

quote "the only thing you cant make with a shaper is a profit" looks like that myth is debunked

[@artmckay6704]

Thank you, as always, for sharing!

[@HP_rep_mek]

Cool tooling, great video!

[@tomsemo8186]

super interesting. How you think this stuff to do a part is truly ingenious.

[@aspeaerospaceprecisionenging]

that is awesome I cant stop watching your videos

[@bhavarkumavat3202]

Hehehe, that opening cut blew my mind , like that's next level of Machining method 📣🌸

[@rowycoracing]

Thanks for showing that. I learn something every video.

[@bcbloc02]

I always enjoy shaping with the mill videos.

[@roggill6599]

Nice job. Something to be proud of.

[@paulmace7910]

I wonder if the designer had this method in mind when designing the part? It seems like it’s about the only way to get that corner radius at the bottom. Creative solution to a darn near impossible situation. Good job.

[@markmuranyi9289]

I also wonder about this. Do the engineers know how difficult it is to make these?

[@CorndogBrownie]

mark muranyi speaking from experience as a machinist for nearly 10 years, and now going back to school for mechanical engineering, they most likely don’t. The guys in my classes are near brain dead when it comes to actual creation of there designs. They don’t understand the basic concepts of rotating tools. Can’t make a perfect square hole with conventional rotating tools. We have some very basic DFMA but most of these guys don’t get it. Straight outta high school or just been in post secondary for a while they have never been to a machine shop and have watched some videos here on KZbin but don’t understand the mechanics of how parts are usually made. This is why engineering firms shit a brick when they get a quote back on some specialty parts, just cause THIS kind level of fab and setup is required for what they think is simple cause the computer said it works

[@jonwatte4293]

@@markmuranyi9289 Some do, and some don't. Just like in any other profession, engineers come in "standard," "good," and "master" grades, but you can only know which is which when you hire them if you have good back door references, or have an interview process with actual practical work challenges involved. (You'd think there would be "bad" engineers, too, but if you don't cut it on the job, you won't be working as an engineer for too long, so those generally churn out.)

[@jonwatte4293]

@@CorndogBrownie A good machines shop building repeat business will send back a print with trouble areas ringed in red, and description of how to save money there. You can add value there m, and thus even earn higher rates, if you find the right fit for you. Just gotta be respectful about it -- "I can make it for X but if you changed these features, it'd cost Y," kind of deal. Unfortunately, you probably can't spend that kind of effort on every odd job you bid on, if you're mainly a "lowest bidder" job shop...

[@LogicIndustries]

And now we start the video, wherein our Master Machinist spends a whole day making a thousand dollar custom tool to cut a part feature that could have been functionally replaced with a dog-point setscrew.

[@garybouchard827]

Great video Peter

[@jesusisalive3227]

Very interested to see this work. I'm just getting into manual machining. I have a decent lathe and a 2hp bridgeport, today I made my first custom tool. I made a small fly cutter. I was pretty proud of my accomplishment until I watched this lol.

[@mihailfelixdumitresc]

Don't get too hard on yourself; this guy is 8 dan black belt in machining.

[@pamdemonia]

Congratulations!

[@m4rkw1]

Excellent work!!

[@TrPrecisionMachining]

Que grande eres..y que poder resolutivo..da gusto ver la capacidad que tiene tu mente..gracias de verdad por hacernos un poco menos ignorantes..un saludo

[@marvlinke7453]

The complexity of these parts is mind boggling. Impossible for this uneducated amateur lathe hack to contemplate what it does. Or just how expensive the part nor the rest of the machinery it is attached too Is. Amazing, thanks for sharing.

[@stevendoesburg6555]

Great video, thanks!

[@slavepetrich]

Amazing video again!

[@nf794]

On first look the thumbail looked like a huge thread cutter to me due to the ordinary finish. Great Job Again Sir

[@ROBRENZ]

Good stuff as always Peter! ATB, Robin

[@EdgePrecision]

Thanks again Robin!

[@Steve_Just_Steve]

You tha Man Peter!

[@ramustechnologies8634]

Creative solution to a feature that could probably have been designed a little better or at least with manufacturing in mind as someone else pointed out earlier. But then again we wouldnt have been treated to this video, on how to be solution oriented and find ways to overcome. Thank you!

[@natevanbynen6595]

That mazaak is very versatile!

[@leoblazer74]

I always think to myself I am going to skim through his videos and I end up watching every minute and they seem as if they were 5 minutes long.

[@curtisvonepp4335]

Petter Broching that Lug with your Broching Barr and tool incerts 180 ° index took some deep thinking we'll done .😁

[@1ginner1]

WOW, A thing of beauty.

[@CeErCeEr]

I am looking forward to watch this tool in action. Thanks a lot for this video dear God of chips and tolerances (:

[@micahhunter2706]

Wow, that's really clever how you didn't have to taper the whole pocket.

[@RambozoClown]

Yet another crazy part. Makes me wonder if Peter is giving kickbacks to the engineer so he will design parts that only Peter can make? ;) I used to like solving tricky problems, but I think if I had to make all these parts I would just lose it.

[@ironfistvail]

I LIKE THE FINISH ON THE TOOL

[@jasonruch3529]

You need to borrow "this old tonys" rotary weld table to show off your awesome homemade tooling! Haha!

[@EdgePrecision]

That would be cool!

[@budzab]

@Edge Precision It would be a good idea to make a flat on that Capto adapter to level the C axis with spindle orientation for similar tooling projects

[@EdgePrecision]

budzab all I have to do is take a Capto turning tool holder that’s designed to hold a square shank. Mount it in the adapter in the C axis. Than indicate on it. This will give me the orientation.

[@amitanshupattanayak837]

Great job

[@dean1841]

Yip! you're a Legend!!

[@katawatenshu]

great vid, what a crazy part! very minor critique about that bandsaw info at the start: text that scrolls by is focus-distracting since you have to wait to see what it says while you build the sentence up in your head, it can be better to have text show up all at once and then go away all at once. This lets people pause to read something if they read slow or read something fast and not miss anything. I think you struck the right balance with how much machining footage you showed at how much speedup.

[@peterfitzpatrick7032]

Agree... 😏

[@gusbisbal9803]

Can you do a video on the accuracy of your touching off method vs a height gauge. Your work is so precise and I feel that touching off can be so subjective to pressure and feel. Love your work. Its a master class every time.

[@EdgePrecision]

I can tell the difference between one click on the hand wheel. That would be .0001". Because the dowell pin is hard there is no give and it's round shape lets you approach the setting gradually. With a shim/feeler gauge you can not get the same feel. Also you have to know the location of the surface you are using as a reference accurately. A height gauge can be equally as accurate depending on its use.

[@Swehollow]

You are amazing

[@danl.4743]

Peter is the machinists' machinist. :)

[@miles32323]

You make some amazing tools peter!

[@jonwatte4293]

Thanks for showing the broken flute! Makes me feel normal :-) If you can finish the pass with a single flute, could you feed 3x faster with three flutes than what you do here? (Not that it matters much for a one off!)

[@jessereynolds8578]

You said 2 or 3 ten thousandths ..... not " millionths " or " a couple tenths " ..... thank you for that made my day sir

[@davidmendoza5186]

Pretty Slick there Peter. Necessity is the mother of invention. Make those engineers pay for what they draw on a screen. Not actually knowing the difficulties of machining such features.

[@Jay9999]

Dad..... Your the best

[@danieltong9592]

Very interesting Peter. Really cool how you go about these jobs you do. Does a part like that take long to quote?

[@CiaoMiao2013]

i want to see this tool in action!

[@leweckejoerg3335]

Very nice.....Top.....

[@465maltbie]

I wonder how many times do you end up putting this same part in the machine to do all these different steps? Doing that really adds to the chances of a scraped part. Thanks for sharing your custom solution. Charles

[@EdgePrecision]

All the ID work that runs concentric to the OD on this end will be done in one operation. Even the holes and ports you saw in the model. Including this key and the one farther in the bore. These parts have many operations it’s unavoidable. I just have to be careful about misalignments.

[@Runkpapper]

I don't know if you already knew this, but i noticed 10:26 - 10:27 that you didn't have your capto markings aligned between the holder and the blank

[@billcorrigan8456]

Dude are you serious?? Lol expert level

[@derick3482]

I make broaching tools all the time it's not that hard ph horn REV from italy inserts are already too expensive I don't have $300 sometimes $500 for a holder so I'll hack something myself

[@markowen7164]

Your mashine is pritty amsing. I have a small lathe. From China. 5 inch Chuck. And I'm not sure? 2 foot bed? But I enjoy and am happy with it. M

[@ehamster]

MUM, you told me never to hold a milling cutter in a 3 jaw, Peter is doing it so it must be ok!

[@mattstillman4494]

If you change the safety clearance in your cam output the machine won’t move away for so long. You can set a safe distance from diameter for x y z.

[@MaxMakerChannel]

Most of the time I see you make medium sized parts on this CNC. Parts that would fit on a much smaller CNC. How come yours is so big? Would it not be cheaper to run a small CNC and get the wear there? Does the size of the machine affect the cost of operation? I am just curious about why you have such a big machine whereas others have one that is half the size.

[@TuanNguyen-md8cc]

wow, you must be the old school machinist make it to modern machine shop. not too many modern machine shop want to make tool, they make tool to win bid quick, then ...... it. Thank for showing us these trick

[@greeceuranusputin]

Ribbed for Pleasure, plumbed for authenticity. I can't imagine the cost for the final part.

[@dougstrong3272]

PETER SOMEDAY YOU MIGHT WANT TO EXPLAIN HOW YOU DESIGN TOOLING. OF COURSE ITS EASY FOR ME TO SAY THAT. YOU PROBABLY WILL NEVER HAVE THE TIME. THANKS FOR ALL YOUR VIDEOS.

[@EdgePrecision]

Thanks Doug, there really isn’t a process per say. I always try to use standard tooling when possible. I look at the part and what I have available to me. If that won’t do the job I design something. And this is important. To do it with what I can afford or what I can build. There are many ways to do things. These are the way I come up with. I don’t contend they are the best or even the right way. It just my way. I present them for everyone’s interest and critic.

[@paulvonauth7254]

Not bad, nice video unlike many, I perform this routinely, almost daily....it's having "finesse", which many do not!

[@michaelskoblin2315]

Do you ever offset the threaded hole for the insert screw to help the insert "pull" into the seat by just a few thousandths?

[@EdgePrecision]

Yes about .005 toward the back walls.

[@derekgreen7319]

You should do a video on the shrink fit tool holders. Do you have one of those machines that do the heating and cooling process ?

[@EdgePrecision]

I did do a video. Capto 8 to .250 Shrink. 6 videos after this one. No I heat them with a propane torch.

[@derekgreen7319]

Edge Precision okay cool. At work we have talked about these shrink fit tools. Currently we have a couple of hydraulic holders but they have limitations. Primarily being incredibly expensive lol. Making shrink fit tools seems like it could be a cheaper alternative.

[@donmathias1705]

Great solution. One question. Why did you not just turn most of the shank to base dia and leave the pocket portion for milling. Like a "hammer head shark" Did it really need the extra material to aid rigidity. I notice you were content to leave front square and flat. Were you not worried about swarm falling down and being crushed between shoulder on job and tool?

[@EdgePrecision]

I guess I could have done it that way. It would have reduced the machining and also the strength of the tool. The tool isn’t really round it’s more oval shaped. I will be running high pressure coolant thru the tool and it will be stoping a good .187” from the back shoulder. I don’t think there will be any shaving problem.

[@wrangler5729]

Interested to see how well the insert holds up when it reaches the bottom of the bore. I’ve had similar issues while “blind broaching”. Also will you program this by hand or CAM? Could we see the code please? Great as always 👍🏻

[@jmaks]

The feature has a undercut, its not going to build up.

[@wrangler5729]

Yea I rewatched and realized that there is space in between the rectangle island and the back face. 👍🏻

[@literoadie3502]

Great work! I’ve always wondered, do you keep all the specialty tooling that you make for different jobs, in case you get that job again? If yes, you must have quite he collection of oddball tooling around that can’t be used for anything but the job you made then for!

[@EdgePrecision]

Thanks Lite Roadie! Yes I keep all the special tools.

[@literoadie3502]

Edge Precision Thanks for showing us, I know it takes a lot of time to make videos.

[@viorel22cr]

Do you think is possible to make a similar tool for a normal milling machine? Like your horizontal. But something that would not hurt the spindle bearings. The programming is possible in Esprit.

[@EdgePrecision]

Yes I have done this on my horizontal mill as well. The load on a shaping tool will not hurt the spindle bearings. As long as you don’t take to large a cut. On a normal machine you will need something to hold the spindle fixed/ orientated. Esprit doesn’t have a cycle for this kind of machining. It has to be done manually.

[@hankbauer9121]

What was the total time in machining this part. Very nice work

[@EdgePrecision]

If I wasn’t making the video less that two hours. Making the video all day.

[@billwassard2505]

Hi Peter, Would it be possible to machine out the outside rectangle key, then press in the key and tigweld up the outside.

[@EdgePrecision]

There are hole that wound be intersected. Also the heat from welding would distort things. Better to stay away from welding if possible. Especially on titanium.

[@micahhunter2706]

So right now I'm in the middle of learning about wrapped tool paths. I see that you didn't use one when you were roughing out the clearance areas of the tool. Was a wrapped tool path the option you passed up on? Specifically I mean a tool path that has your endmill 90° from your z axis and the path would mostly use the Y, Z, and C axis? Is that the path that you said it harder to program?

[@EdgePrecision]

I modeled the part with flats on the OD. If I had modeled it with cylindrical surfaces a wrapped tool path would have been the way to go.

[@kamilsuchowierski9574]

Why not use tail stock to support whole part when machining profile outside? Wouldnt that reduce vibration and extend endmill life?

[@EdgePrecision]

Yes but on this big machine the tail center can't get this close to the chuck. The part has to be at least a 20" projection from the chucks face.