How To Machine A Complex Part 600% Faster Using Trick Techniques

CNC Machining complex 5-axis part using DN Solution's DVF 8000T using the tabbing method. This part supplies power to Millions of people and we made one. Making a part from start to finish, genius fixturing techniques to save on machine time, money, and material all at the same time.
00:00 Intro to Machining a part using tab method
00:22 5-axis machine fixturing technique
00:49 Machining a part hang out of vise
1:56 Roughing Operation on material
3:17 Programming in Mastercam
3:52 Finishing on 5-axis machine
5:56 Tabbing Method in machining
6:40 Machining a custom fixture
8:22 Final operation on Complex part
9:43 Final part reveal
10:56 CNCExpert.com
Join this channel to get access to perks:
/ @titansofcnc
Join our community Discord! / discord
Help us fund FREE Education by purchasing tools seen in our videos here:
TITANSofCNCTooling.com
Create your free CNCEXPERT profile here:
rebrand.ly/TiCNCEx
FREE CNC Machining Academy:
rebrand.ly/TiAcademy
FREE Aerospace Academy:
rebrand.ly/TiAero
FREE Grinding Academy:
rebrand.ly/TiGRIND
Subscribe for daily content and expert knowledge: rebrand.ly/SUBTITANS
___
___
Follow us on Instagram:
rebrand.ly/TiINSTA
Like us on Facebook:
rebrand.ly/TiFACEBOOK
Join the conversation on our Facebook Group:
rebrand.ly/TiFBGroup
Connect with us on LinkedIn:
rebrand.ly/TiLINKEDIN
___
___
THANK YOU to our Partners who make this content possible:
Kennametal - rebrand.ly/TiKennametal
Heller: us.heller.biz/titansofcnc/
DN Solutions - www.titansfordn.com/machines
United Grinding - hubs.ly/Q013zHpC0
Mastercam - rebrand.ly/MastercamEDUTiYT
Tornos - bit.ly/3MDcqLh
Blaser Swisslube - rebrand.ly/TiBlaser
Solidworks - rebrand.ly/TiSLDWRKS20
Trumpf - rebrand.ly/TiTRUMPF2022
Markforged - bit.ly/Titans_Markforged
Tyrolit - rebrand.ly/TiTYROLIT
Mitutoyo - rebrand.ly/TiMitutoyo
Haimer - rebrand.ly/TiHAIMER
Schunk - rebrand.ly/TiSchunk
Kaeser Compressors - us.kaeser.com/titan
#Machining #Machinist #Engineering

[@adammiller4879]

Actually getting to see a real part, machined in a practical way, is the best type of video you guys can make. Love this

[@seraphim1833]

Top level machinists working together. That's good to see.

[@dominic6634]

Yeah usually its knives out

[@Joe___R]

Being able to make snap tabs is definitely a great advantage in 5 axis mills. As for the way you mounted it for op 2, I would definitely have added two locating pins. Even if the pin clamps worked well enough to maintain tolerance. Having that much more control over the parts' exact location is cheap insurance, especially for the last fixturing.

[@niclasnordblad5962]

Actually planning to run a part in this fashion in a couple of weeks once all the tooling has arrived. So the fact this video appears while im still mulling over the strategy to get a good result with tabs is a godsent. Keep up the good work titans!

[@Mazrim_Taim]

Stick with it - might take you a few goes to get it right but once you dial it in its a game changer. 90% of what we make in our shop now uses this method 👍

[@willianbr3101]

​@@Mazrim_TaimCan you explain to me briefly what this tabbing method is? Ps: I don't understand much of what he says, I'm still learning the English language

[@Mazrim_Taim]

@willianbr3101 it means you use the stock to your advantage as break off points or tabs so you have minimal work 2nd op work to do. This video explains it much better than I can!

[@tdg911]

Jessie is the Mr Miyagi of 5 axis machining. Wax on wax off. 💥❤🙏. Much love and gratitude

[@motoxing199]

Some slick toolpaths in this one, I’ve been wanting to learn how to program the tabbing method for a while now

[@bami2]

9:05 These 5D machines never cease to amaze me.

[@StauterAdventureCo.]

This is such perfect timing!! I’m explaining to the owner why we need a 5 axis!!

[@jan-ericlindstrom119]

Nothing new but it is a good method . I have used it for 25 years. Before YT .Keep up the good work titans!👍👍

[@IchibanEngineering]

Awesome part. Really liked that fixture.

[@danielrogers6090]

I use the method all the time. Love your work, and keep it up. 👌

[@owievisie]

Beautifull part and process. Also cool to see the deburing in OP2 that was milled in OP1. Show you also trust your own process. Great job and cool looking part

[@donniehinske]

Amazing video Jessie! You really are incredible at what you do!

[@lvxleather]

Very cool dude. I like those Mitee-Bite expansion pins, especially large odd size plates with random holes locations, makes it much easier to fixture.

[@TheGuy-xk9sf]

beautiful machining

[@Thepriest39]

I have used tabbing for a few years. I do love it when my part barely hangs off of my 4th axis and I can rip it off.

[@rexcarroll7288]

Been finishing parts 100% (no second position) with tabs since 1996. Tabs only need to be .015-.010 thick, width of tabs in the center .250 to .375. Best to use small End Mill e.g. 1/2 end mill when finishing tabs and the tab side of the part, reducing the torque on the backside of the part. Break tabs and blend with Dotco or Die Grinder. You can use a Serrated Vise and avoid prep operation for the Dovetail. Machine the part 100% complete in one position. Also, I have used Slot Cutter (Side Cutting Mill) to establish the Radial/Arc tabs in just 3 passes while finishing the backside of the part. Cut first Side, then 2nd Side leaving a small continuous .015 thick ARC serpentine tab, then come back and mill away the majority the tab's center of the ARC serpentine tab. The deeper you push the depth of the cut the shorter your tabs will be. At this point the remaining tabs will be short little "ARC" tabs that are more rigid than typical linear tabs. Though style works great.

[@savioer]

That's a very beautiful part and a job well done.

[@canaldeingenieria3575]

Definitely amazing what you can do on this type of machine. This is outstanding! 👋👋

[@fgee3719]

Great machining. I put my hat off ❤

[@CaptBeanerzzz]

I've found that on harder materials (stainless and Ti) it works well to come in and tab with a 3/16" to about 0.125" thick and then follow up with a 1/8" down to about 0.03" thick depending on that part weight. It tends to prevent the part from bouncing into the endmill and chipping it.

[@keithhasafastcar]

These are the kind of videos we want more of

[@maelsamael6349]

Absolutely amazing work! 👍 5D Perfect synchronizacion Never ceases to amaze me 🤯 Greetings to all CNC operators from Poland🇵🇱

[@Kardos55]

Nicely done.

[@aiartcrowd]

I love❤ how you film and edit videos in this channel 😊

[@Fraley2012]

Amazing work

[@R.W.89]

I saw something when you did the second operation. Instead of making steps with the roughing tool, how about ramping with it instead? Saves alot of air travel which is an efficiency killer. if you approach on the lower end and use the side to ramp up that should be the most efficient way. I have thought about it quite a bit since one of our shops' programmers regularly makes programs with 60-100% clearing distance(which isnt what i'm talking about here but still something that adds time) and on aluminum with fast feeds it doesnt matter too much but with 60 mm air travel both into and out from the part several times on a steel part with a big mill then it adds time. So if take long cuts instead of alot of air travel then good efficiency. Makes the mill work more like a lathe :D

[@anthonymartinez9415]

Tabs saved my butt so many times I love this method

[@noeygarza6522]

Beautiful work

[@bdude92]

Pure genius!

[@johnnyc244]

Very nice!

[@mostaphabiq4478]

i like how you machine this parts, thanks thats an educational video

[@artcnc8089]

Very good 👍

[@RIANRBRCHANNEL]

Hi friend amazing nice vidio and great machining complex great vidio and good luck

[@EZ_shop]

That was an awesome demo Jessie. Do you know what the part is for? Ciao, Marco.

[@joseguzman9448]

Realy nice job❤,well done

[@stevieg2755]

Impressive for sure

[@Exypno]

Genuinely impressive

[@ultrabeek]

Thanksgiving Day and I’m not watching the parade…I’m watching this awesomeness.

[@jbjosh3]

You should make an academy video for programing this one! Thanks for the content this helped me a lot with my project.

[@mohammedalbattal77]

Every time the passion goes out you go back to igniting it guys Mr. Barry have to be careful now because Mr .Jessie hits hard today BOOM 💥♥

[@PointingLasersAtAircraft]

I love expanding mandrels for fixturing.

[@danhyde7501]

Do you have a general rule on how thick you’ll make tabs on each different material?

[@jarekr5784]

The goofball at the end with the hands ✋️ 🙌 😳 😂😢😅 Great watching every single episode 👌 👏 👍 😀

[@aintdatsnipes177]

Nice finish

[@maxmoore7785]

Tabs are the absolute WAY TO GO. I love your second OP fixture with the collet. I need to start doing that. Great milling method. I just wonder why you wouldn't use HYPERMILL instead of MCAM. Your life would change.

[@TravisAnderson-zw1pd]

Ive heard my machine tool teacher talk about these break away tabs so neat to see it applied tool lofe equals extra $$

[@PorGaymer]

6:16 OH YES THAT SOUND. When are you making a video about all the pleasing and scifi sound metal can make :D

[@solomaster9315]

Great video

[@ianmurray3820]

Engineering?Fabrication?Machining? “Witchcraft” - that’s what this is.!! Even more impressive is how you manufacture a machine with so many moving parts with the play required to allow those parts to move but then end up with something so precise this stuff makes my head hurt.😁❤️💪🏻

[@drafty0183]

Watching the spindle and table move in unison - like dance partners in perfect time. We don't have a 5 Axis CNC machine, but watching that would never grow old either. I was wondering what the issues were that you had using a larger endmill at the start of the video.

[@ianmurray3820]

Vibration/ chatter..!?

[@rprice7670]

Tha ks for sharing guys

[@grebesj]

Good job!

[@pascalk.5409]

Just Perfect ;)

[@Yourmommaluvsme]

This video gets my biscuits burning!

[@SolidCAMisCOOL-uf1pg]

Very, very, very cool!

[@pyro1596]

Honestly, I'm more excited about the expanding bolts. Those would be great for a lot of fixturing

[@mitsosskar3862]

great work! do you zero-prob the machine for the second op?

[@Hanal503]

We just made and machined like this 40 years ago...!

[@hoangvuanhnguyen8161]

This kind of part is my favorite part I would like to do.

[@TexasBulldog74]

Beautiful piece.

[@gianlucamarinello]

Questa è arte! Spettacolare

[@policebox1092]

Awesome

[@NeoQJ]

Incredible 🎉

[@tj9382]

That is a thing of beauty

[@MrJugsstein]

Very cool

[@rugger302]

Where can I learn more about the tabbing and picture frame methods?

[@tomwhitbread223]

Personally do alot of 1 op vice ops. I prefer to use snap offs on an edge rather than tabs. I create a snap off of 0.275mm that leaves almost no burr on aluminium aerospace parts

[@raphaelholm]

Very cool simultaneous machining but I do feel it was over kill as you can get tools to break edge the part on op 2 with a double angle cutter. Way quicker. But it was a good process

[@pentamill_CN]

Nice, milling

[@platin2148]

Hmm with which cutter are these dovetails made?

[@armandmatossian2081]

haha 11:40 when he's complaining that it's not going to be in spec then feels up the part

[@KnoxGTX]

That’s bad ass!

[@sabriomar5823]

OMG you are perfect

[@Ernie-zk3gb]

MasterCAM You guys still use MasterCAM yes? With C having some RPM on the 8000T does MC require you to have both a Mill & a Lathe seat ?

[@DART2WADER]

Класс! Мне бы кое что для вела замутить из В95.

[@leviarias5281]

Where do you purchase the expansion pins?

[@hamzanawaz7945]

Everybody is just talking but Jessie is working

[@jeremymatthies726]

Jessie, on the second op how exactly was the part being held down on that fixture? The tab thing was cool.

[@dakotareid1566]

The pins expand in the holes holding the part

[@jeremymatthies726]

@Dakota Reid ahh, okay that makes sense then. Thanks

[@FreeKnowledge1111]

If this was in stainless steel, would making those same tabs be possible, or cause too much vibration?

[@CaptBeanerzzz]

I do it on stainless and titanium all the time, but I usually will add more tabs that are a little smaller and thinner.

[@JudahTroxel-xs9fw]

I have zero desire to learn how to run a CNC mill but dammit if I am not addicted like crack to watching these videos and learning all about it pretty strange Dynamic I guess but it's where I'm at LOL

[@jonlightfoot6739]

Cool video. Only thing I can’t for the life of me understand why he clocked the part in on the second op. Then used to probe to set the zero point anyway. Why not just set the rotation with the probe ?

[@christopherweaver2281]

What will this part be used for?

[@spearshaker7974]

I didn’t realize these things move the table while cutting at the same time and with precision.

[@pascalk.5409]

Do you use the rest of the Part for other Parts? or you have to throw it away?

[@dillansherwood2930]

Odd shape so they probably send it out to get recycled/scrapped

[@noppornkamnutchanart9991]

WOW! 🥰

[@balkanac1133]

Min 7, why didnt you turn the table 90 and use the probe to center the part on milled surface ?

[@shawnfee9107]

I use tabbing to get two 19ft. long spar caps out of one billet. I leave a .100" tab about every foot or so. Might be able to go a little more thin, but with material that big I don't need shit flying around lol.

[@precisionc3656]

How do you prevent surface marring from the end mill chattering against the part when you do the final pass in that last operation and you leave just 50 thou ? I stopped doing this as the last op because of that issue and started using cutting saws to leave a very amount of material that I could tap off

[@SiempreConTrasto]

Simply use a smaller endmill and stay away from your finished surface. You'll finish it in the next operation, so don't worry about some more allowance there. Process safety above all.

[@ronb5105]

Thanks for taking work away from small companies like ours. I thought you guys transitioned into teaching and not taking contract programming away from companies like ours. Well thank you for raising the bar and 5th Axis CG Inc. will keep plugging along getting our work word of mouth like we always have.

[@mikep3813]

Every time anyone does a job they're taking it away from someone else.

[@ronb5105]

@@mikep3813 Yes that is the nature doing any business.

[@Pudentame]

Cool. What is it?

[@scott98390]

This might be a dumb question, but what do you do with all of the shavings?

[@TITANSofCNC]

Recycle

[@Iranzotv]

How did you make the tabbing method? Is there an option in mastercam or did you draw an oval and machined?

[@sereezyyy7068]

There is an option

[@Iranzotv]

@@sereezyyy7068 In siemens NX too?

[@LoneWolfPrecisionLLC]

​@@Iranzotvin nx we just drive the tool with planar mills

[@Iranzotv]

@@LoneWolfPrecisionLLC i would like to know how to do it because im programming on NX at the moment and i dont know how to do it

[@CharlesShopsin]

How much would it cost to have a part like this manufactured?

[@Jatsekusama]

You are the man Jessie! But I don't get one thing - if you have a lot of these to make why won't you make a casting and then just perform finishing operations and make holes? It doesn't feel right to have this much leftover material, i get that it can be made into something alse but still you have to store it. Greetings as always, a pleasure to watch!

[@karl6313]

Material spec may not allow for casted material. Also casting has longer wait times, where I am the lead time on casting is 3 months from the date ordered to delivery, I can however order solid stock and it be delivery 1-4 days later typically.

[@Jatsekusama]

@@karl6313 thank you for the response. You are most likely right but what do you think about an aluminium forging then? The due time should be shorter at least

[@karl6313]

It would again have a lot to do with the customer and what they require. A forging or casting would be very reasonable solutions, assuming the customer/engineer think so. The one customer we work for requires the part to be made from a 304 stainless casting, does not matter to them we can produce the same part out of bar stock faster and cheaper than having it cast, not to mention the lead time just to get the casting is 3 months, but the process would be more efficient to use bar stock simply because it can be bar fees into the machine, so my door would never need to open except to check on tools. The engineer said casting, so it must be casting and no matter how many times we have pleaded to have the drawing changed, it must be casting according to the engineer. We make other pieces almost identical to the casted ones, but those engineers said casting or bar is ok. Sooo sometimes your hands are tied as a machinist, you must follow the print regardless of better methods sometimes.

[@luisalfredo50]

Es aluminio?

[@didiz01]

couldnt this part have been run in one operation if you flipped the tabs on the other side? with some minor hand grinding

[@woodlewoodles]

How much could one charge for a part like this?

[@Badge124]

Seems like you could have left the left-over dovetail piece in the vice and used it for the secondary fixture instead of setting up a new piece of aluminum and indicating etc.

[@john.hunter]

Is that a common thing to chamfer with ballmill? I'm used to 90 degrees chamfer mill

[@ronb5105]

Yes have done it for 30+ years