Spindle - Cast Steel

[@stevemarschman3202]

45 years ago I toured ESCO steels Portland, Oregon cast house. They made huge stainless steel castings for the commercial nuclear industry. Every casting was x-rayed in 3 dimensions to locate porosity and defects. Then, they would have a crew that would grind their way down to a defect, grind it out, then weld their way back out to the surface. ESCOs cast house was pretty meticulous, yet every casting needed repair. So, what you encountered isn't unusual, but, it would appear the company that did these did not properly degas the molten metal, and too little attention was paid to detail when producing the pattern and the casting molds were made. Shame on that cast house.

[@lancer2204]

Yep, that foundry dropped the ball at several stages.

[@simovepsa6462]

no problem with stringy chips when the porous material breaks the chip 😆

[@flouserve]

There are many castings that come with very little material. I still remember a batch of impellers for Chile that, after being finished, looked like garbage. The end customer in Chile never wanted to accept the pumps for the mine because of how bad these impellers looked on the suction side.

[@markfiges999]

You have my sympathy Chris, in a past life I've BTDT, .......far too many times, and always with the same answers, ''there's no rime to get new castings'' and ''we mustn't upset the foundry'' Take care and stay safe

[@scania357]

I think they were trying to get a silk purse from a sows ear. Thanks for sharing.

[@ED_T]

Seco TH1000 is an amazing grade of insert, I've used it to get out of a couple difficult situations. Haven't found a metal yet that it won't cut

[@cyclingbutterbean]

Tell it like it is in the title Chris! I love it! Never met a casting that I liked.

[@FredBloggs-s8w]

When you get casting las bad as that, you send the whole batch back to where it came from. When I was helping to build industrial knitting machines, if the bars on which the knitting heads ran back and forth. had to be draw filed and and deburred, and if we found a bar which had loose flakes rolled into the surface, the whole batch was sent back to the manufacturer. to be replaced. We couldn't allow the knitting heads to lift a flake and sieze the whole machine up and would have totally destoyed the whole machine. Our main tollerance was two thousands of an inch.

[@johnlawler1626]

It would test my patience alright....one of them jobs you just got to take yor time and get thru and move on to better things. Great video thanks for sharing 👍

[@DeadlinePhil]

i feel you, once i had to deal with casting´s that were dipped in some black coating for rust prevention our something, there was still sand from the mold beneath the coating and a bunch of air pocket in the casting.

[@CraigLYoung]

Thanks for sharing 👍 and Merry Christmas to you and your family 😊

[@LongueCarabine]

Holy occlusions, Batman!

[@Supervisor000]

Даже у пакистанцев качество литья лучше!

[@ChrisMaj]

🤣👍

[@dazaspc]

When I saw the first drawing my immediate impression was that someone should break the creators fingers. Woeful would be a compliment. Those castings however the fault was with the pattern maker. Apart from the sag and undersize of the casting the filter broke apart during the pour and I would guess that is the sandy stuff you found in the metal. Sand does break away during a pour but it usally just floats out or mixes a bit more evenly.

[@NormanGnome11]

Why is the quality of these castings the fault of the patternmaker ? - Surely the fault lies with the moulding/casting shop and the quality of the steel used in the creation of the castings ??

[@dazaspc]

@@NormanGnome11 If the casting is to small not enough material it hasnt been made to the correct size or made for the wrong material. The molders are also at fault as sag, inclusions is very much related to how the mould was built. Coatings, proper sands, risers, shrinkage, and filtration of molten metal all their responsibility. Open the box to early even the way it was cast can affect the shape. The steel doesnt get lighter as it gets hot yet it is a lot softer. It needs support whilst molten and soft. You could blame the caster for the filter problem by putting the metal in to fast but if the mould is built correctly it shouldnt be a problem.

[@andylarkins5128]

Those look like hammered shit!

[@Mike44460]

Quality Control will forever be known as the Outa Control Department.

[@thelamb288]

W O W. Holy mother of God, I've had some really shitty "chilled cast iron" components with inclusions, and one that exploded on me, but those pieces of crap must have come from China! Now we all understand why there are no more European pattern makers left 😵😵‍💫. Well done to you for getting as far as you did. Me, I would have refused to machine any more of them! Cheers.

[@ChrisMaj]

@@thelamb288 And that's why I only work here. I couldn't deal with this shit if that was my business.

[@csours]

Interrupted cut says what?

[@vikingboodah6889]

Shitty castings...i really felt that in my soul. i personally love when i hit big voids and pockets of sand when im turning big unstable castings, keeps things fun and interesting.

[@alankeith7866]

They were really trying to get a silk purse from a sow's ear, weren't they?? If the customer doesn't like the outcome, tell them to call the foundry and have them recast the order, on their dime.

[@paulmace7910]

Customer supplied or did your company supply? If customer supplied then they get what they get. If they are yours then the big boss man has some ‘splainin to do.

[@ctrhenry]

Thats a part that should be hot forged instead of cast. Beancounters suck

[@theessexhunter1305]

Chris, jot down the hours put your time sheet in go home and have a beer.

[@juliusmilo5959]

Nice job...Thank You...

[@Rustinox]

Or else "how to destroy inserts as quick as possible" :)

[@josh3504]

Do you ever get clients who bring in components with imperfections like these, who end up trying to blame you for the imperfections when machining is completed?

[@jimsvideos7201]

7:16 That pore right at the bottom of the radius is just the thing to start a crack. Good luck to whoever accepts these for service.

[@ED_T]

Do the castings warp that much or is it just a bad mould? Also it looks almost like they welded the defects with hardface lmao

[@johncmitchell4941]

I'd be ok doing this on the clock like old times for a boss who decided to take on such ugly stuff, but wouldn't bid on or touch this in my home shop. Mat'l being SOS is not the problem of the machinist when the the print is one's backup/'protection'. btw, Inserts kicking butt on those interrupted cuts. Good watchin'! 10/10 as usual. 🙂

[@kevinsellsit5584]

You call them spindles, but to me they look like CV slip yokes...either way, someone is building something ENORMOUS and those castings are a fail as a spindle or CV slip yoke. Your ability to produce such a stunning finish while destroying hundreds of dollars in carbide is commendable. It is hard to choose an insert when each revolution includes 3 different materials.

[@EinhanderSn0m4n]

See what you do here is add a surcharge as close to exactly equal to the savings the client attempted to earn by Not Doing It The Right Way. Those money chips were cringe!

[@woobykal68]

Looks like it was cast in an indian foundry using sand from the beach.

[@DolezalPetr]

worst lumps of metal I have ever seen

[@shug831]

Extra charge just for the number of tool tips used!

[@briangarland9883]

Wabbler couplings!

[@JavierMacchello]

Murder of inserts

[@paulcurtis2779]

Time to refuse them and send them back. . not worth keeping. The likelihood that there are errors/faults inside that cannot be seen (short of imaging) then they're just a danger, prone to failure. . Send them back.

[@xsarchitect]

So my company orders extras of a certain casting because they know it will have some that won't make it through because porosity, somebody is either stupid or getting kickbacks........

[@프부리]

seco is god

[@ApukEldar]

👍👍

[@russellflemister393]

nice C's and Sixes seen a lot worse casting you did a awesome job with that casting

[@MWL4466]

Those castings were made on a friday afternoon i bet. Junk.

[@ChrisMaj]

@@MWL4466 Yeah, or Monday with a hangover 😅

[@stephenquandt6508]

I've seen better boat anchors made in the backyard 😂😂😂

[@jimsvideos7201]

Biggest Phillips screw I ever saw. 😅

[@johncmitchell4941]

No taper to the slots. Posi-drive?

[@patrickradcliffe3837]

Cast was made by a five years old.

[@465maltbie]

Wow, all that work and they look pretty unusable. Charles

[@lancer2204]

Hrm... core off centre, porosity, rough and uneven surface, parting line wandering all over the place, crappy dressing/fettling... not much attention getting paid in that foundry. Bloody hell... just saw the rest of the abominations... I'd be sacked if I let that trash leave our foundry!

[@timmontano8792]

Are you also the one who did the casting or did you men that you've worked on shitty castings before this one came along?

[@StreuB1]

Chyna, India, or Pakistan; where did the castings come from? Likely would have been faster and better if they would have spec'd it to be machined from a billet! Garbage castings making for a horrible time machining. Sorry Chris but well done anyways!

[@ChrisMaj]

Shit, probably they would have made better castings than that 😅

[@rairai3517]

Why don't the casting guys oversize by 5 to 10 percent that way your cuts are more symmetrical and you don't have as bad interrupted cuts or are they just lazy .......just saying.......

[@BruceBoschek]

Seems a waste of your time and talent, Chris. The pattern maker needs to go back to school, I believe. Thanks for sharing, nonetheless.

[@jimsvideos7201]

The pattern work looks ok, it’s the guys at the foundry who need a little talking to.

[@BruceBoschek]

@@jimsvideos7201 I'm certainly not an expert, but it looked like a poorly made pattern. The castings are certainly a mess in any case. The part would probably be best forged in any case.

[@charliemyres5450]

Bad pattern-making and worse moulding by the look of it. If it was my foundry, those castings would have been put back in the furnace.

[@KirbyHeath-l4x]

Easy money