Precision Machining Techniques Used To Manufacture A Pump Housing

[@steve0stang]

30 MINS? Now that's HELLER impressive!!!

[@FiglioBastardo]

Good one!

[@oleclausing5768]

30 mins??? I call BS

[@burbman60]

Its insane, 30 min to rough it out is incredibly awesome. Prob take 30 min to prepare a sand mold for something like this with uncertain results ahead, casting imperfections etc.

[@s.s.9627]

Sorry to burst the bubble but 30mins is complete BS. I count 55 step downs with the 4in HFM which takes 8 seconds to do ~1/4 turn of the part (from 0:28-0:36), do the math and its 29mins just for that single tool! the 2 in runs at 50% the feed of the 4in so add another 44mins and you're already over 70mins for just 2 tools. 30mins is a complete lie. Sad to see them say something so egregiously wrong. I thought titans was more honest than that.

[@CNCAddictGR]

@@s.s.9627 you're probably right,i dont get why would they lie like that

[@mohammedalbattal77]

Yesssssss 30 minutes HELLER 🔥🔥🔥🔥 Barry is the jockey and Heller is the great horse BOOM 💥

[@blueridge_ogre1714]

I have been out of school and in the field now for right at 4 years, I honestly wish all American machine shops and manufacturing shared the same level of enthusiasm, and pride in their trade, as you all exhibit on this channel. I can honestly say that my experience in machining has been the complete opposite. Everyone has an "its good enough", or "not my problem" attitude, and they lack the desire to be better at the trade or teach anyone anything. Despite feeling like Ive wasted my time in school and the last 4 years, I guess I will just have to suffer through and hope for the best. Thanks for atleast giving me hope that I'm not alone in having pride in my work. This really is an enjoyable trade, its just too bad that companies no longer embrace and appreciate the good machinist or the green ones still eager to learn, get better, and earn their pay. Keep up the good work, I definitely want to see the finished piece.

[@ms.informed]

It's the same elsewhere, even in Germany, the land of engineering. Not every machinist got into the field because they were always enthusiastic about the trade. And not every aspiring machinist/engineer get to do what they love as a job. Additionally not every company provides enough resources and benefits to attract competence, but they stay afloat, just because they're cheap and make parts that are "good enough".

[@jthewelshwarlord6331]

I apprenticed for a company that only kept me around as cheap labour. The only one who actually wanted me to do well was a coworker, who mentored me for most of my time there. Sometimes my manager could be supportive but never there to teach me. He and my boss kept saying I was "going backwards" and the lack of support and help, coupled with the filthy environment and lack of sunlight spiralled me into depression and anxiety. Isolated myself, cut out things that could have helped me long-term, and after Christmas 2019 I had a panic attack over returning to work after the holiday. One phrase my boss burned into my head was "the only thing lower than an apprentice is the ground under their boot" which summarises how I felt most of the time I was there. Eventually I just fell into mediocrity and was only staying for the pay and job experience, not to impress or progress. Just go in, get paid, get out. I was there for a year before I was made redundant by company losses, and 2019-2020 was the worst year of my life. 3 years later and I'm still suffering from depression, anxiety and perpetual burnout. Been trying to take steps to break it but I find myself still falling into the habits. Would I try it again if my current aspirations fail? Maybe. Would I be willing to work in an environment like that again? No. Should I have sued for the damages? Maybe, but it'd probably end any future career opportunity in machining.

[@jestonporter5049]

The fact that shop owners and leaders are still this way is ridiculous. This has to change. There are some shops out there that are embracing the way things should be, but they seem to be few and far between. Hopefully, the right ones will take over and the others will be left in the dust.

[@jestonporter5049]

@@jthewelshwarlord6331 I'm very sorry to hear about your experience. That kind of mentality makes me furious. I hope you can find peace and have better experiences in the future.

[@truegret7778]

It hasn't helped when so much outsourcing started in the late '80s. From manufacturing, to materials (iron/steel/aluminum mills), to software development, and food. The "it's good enough, or not my problem" mentality has permeated throughout America (and from some of the comments, just about everywhere). And in my opinion, unions have hurt more than they have helped. I learned from my father when you are on someone else's nickel, you give them 110% and take pride in you work. I hope the situation turns around this election cycle.

[@cdmChase1]

Haha!! "Look at that cut it's BEAUTIFUL"!! I thought it was just me who is mad!! Love machining.

[@trevorgoforth8963]

Awesome video Barry. Love the explanation of the thought process behind the programming strategy. That part is sick too!

[@dougthomson5544]

You guys say you are machinists, but I beg to differ; you are much more. First, you are a special brand of computer programmers. Second, you have exceptional understanding of aerospace metallurgy. Third, you are expert mechanical drafts people. So, you are souls who have embraced new technologies and have run with them very, very fast. Good on you.

[@leanderfaurholt7118]

I love Barry just waving the part goodbye here 6:47 😂 I swear something is wrong with this man, and i love it.

[@barrysetzer]

Hahahaha I was starting to think noone was going to notice that! You're the first LOL

[@Kardos55]

Love that sound . . .

[@robertkylethomas173]

I have no idea what's happening but this is awesome

[@archie3537]

Barry Givin it Hell,! On the HELLER

[@chudyhun]

we need more videos for this!!!!

[@user-sz6iz9yh8b]

30 MINS? Now that's HELLER impressive!!!. In rough stage, it resembles art deco sculpture. Very cool!.

[@craiger8484]

Can't wait to see more

[@jeremymatthies726]

Barry, that was awesome. I like watching the milling, cant wait for the next vid.

[@barrysetzer]

Hey thanks Jerm!

[@Sebastian-ed5kt]

@@barrysetzer hey Barry, wouldn't it be faster to rough the big hole in the middle with a smaller (63-85mm) high feed mill? we did it like that in my old company in the horizontal position with 0.3-0.5mm doc, 750 rpm, 7100mm of feed and air a hole like that would take maybe 10 minutes

[@alex_yates]

Nice work Barry

[@barrysetzer]

Thanks!

[@kevinedwards7079]

Viking music sound like you on a conquer binge stay calm and carry on

[@williamlind2843]

I totally respect the big part makers, but I need constant gratification!! Parts under 2" that are 4 axis mill/turn get me pumped. I love showing what a lathe with live tooling can create. But for me it's job specific and I'm in my wheelhouse. Win, win!

[@skozzy1968]

Ive never seen something like this in real life, and seeing it so close up and clear makes me wanna watch so much more.

[@ronjlwhite8058]

We are all happy now, Barry.

[@barrysetzer]

Mission: accomplished

[@FiglioBastardo]

😂

[@MrChevelle83]

roughing is the worst part for the machine because of major tool load so i think its cool that titan is detailed on hogging the metal off using the machines strengths then speeding it up on the light tool load cuts. excellent work.

[@barrysetzer]

Hey thanks bud, just talkin about what ive seen and done! Thanks for the support!!!

[@JamesWatts-ik8fe]

Killing it Barry - love all the detail on the Rotoclear as well, cool stuff!

[@I_________I]

DONT FORGET TO DROPP THE REST PLZZZ? IM WONDRING HOW YOU GONNA MAKE IT WITH THE BACK OF THE EXIT TUBE

[@simsonlaikongleong3785]

Barry rocks. Spin us more video.

[@barrysetzer]

Why thanks Simson! And I sure will!

[@benjaminordonez779]

YAASSSSSSSSS!!!! BERRRYYYYYY MOOOOREEEEE CHIPPPSSSSSSSSSS! BTW, GGRREEAAAAAAATTTTTT VVVIIIIIDDEEEEEOOOOOOOOOOOO

[@TITANSofCNC]

YAAASSSSS

[@mnstrxj3280]

I enjoy doing all the CNC work,but come my days off or the weekends. You'll find me at my 40's vintage south bend heavy 10L's & Bridgeports, sometimes you just have to go back in time & sling chips.

[@aimlessdude9735]

You should take those monster chips and cast them into epoxy round bars for tool handles

[@barrysetzer]

That is actually a cool idea!!

[@Avodea]

Good job, regards from switzerland!

[@lllllMlllll]

What a beautiful piece

[@swikocki]

Great job! I always like machining ductile iron, its usually kind on the tools. Just got a new horizontal delivered at work, looking forward to the increase of memory and now being able to use modern tool paths.

[@jackjumperx4441]

Depending on the quantity of units being made, you either cut from solid chunk of material or make a rough cast and machine that down on critical areas only

[@MarioAPN]

Based on quality also. And its geometry. Sometimes you just have to use molding, it is chepaer, you can cast crazy geometries, but you can lack in terms of porosity, for example. You can compensate that and everything else, it isa beauty of this work. A lot of pain for the average human tho...

[@misfit3050]

On the second note about having to pick up from the beginning. Hermle 5 axis machines have this AMAZING feature called block scan. You can pick just about any line in a program. It will scan everything in the program up till that point, figure out which codes were active etc etc and start you again right from that point.

[@misfit3050]

I also freaking love durabar. We use it all the time

[@ecogames7165]

I think this is not directly a feature of hermle but from the control Siemens/Heidenhain

[@andrewhorlock7744]

Even haas have this feature. The bigger issue is knowing where to start and find that easily on a program that might have a million lines of code

[@raider1628]

hope you guys actually show the fixture set up for the 2nd op! would be cool and educational if you guys showed how you guys programed the more interesting parts!

[@danb3122]

I like the energy!

[@kingofherdaz]

I'm very curious how you will machine out the hollow part of the spiral

[@bigcat.3256]

HECK YES BERRY!! 30mins is insane! That Heller is so BADASS!!!

[@bigcat.3256]

Also I’m totally a lathe man at heart so I better see some damn turning!!

[@vadmalski]

Hypnotising

[@4DModding]

This would be a casting in production - I would hope :)

[@phillhuddleston9445]

Probably but for a one off part or low production part casting it even more expensive than machining out of solid stock though neither is cheap.

[@harryho9097]

4:51 that tunable holder sounds interesting. Can we get some more details about this holder? Like how it works? 😅Also, it would be helpful to see a comparison between this holder and a regular holder❤

[@stanislavalekseev9625]

I would like to do something similar, for example, during planning, to have the table rotate instead of the Y-axis.

[@piratiniwood547]

Nice video Berry, this is some great chip making, cool.... Next video please😊

[@tonyjesuslover]

Great job.

[@warehouseman6325]

That's awesome

[@frankensteincreations4740]

Damn! You know you’re watching some good sh*t when your eyes are dried out, and your chins wet lol. Unreal what these machines, with the proper user can do… unreal! 👍🤘👏

[@Honzishek]

that is really good strategy to rough that part . ! cool.

[@Peter.S96]

Damn we use oil to cool our tools always. We never work without cooling but u use kennametal carbid ones without any cooling :o really awesome

[@phunter198142069]

Can you 5 axis drill in Mastercam like you can in Hypermill? (Use a shell mill tilted to plunge will rotating the part to bang a big hole in)

[@Stylesidetruckguy]

Just a video idea. Try to show up the 3DP-ing community by machining a benchy.

[@brandonrenwick9125]

how did you get it to favor the rotary instead of the x,y on the 3d optirough? is that a custom post switch or simple toolpath setting?

[@CalvinEdmonson]

At any point did you find it necessary, or just reassuring, to check the clamping pressure on your jaws? Stout set ups, the best tools, excellent programming, all add up to quality parts. Well done.

[@sobocinski123]

why not use a high feed mill to open the entire cavity? then come back to finish sides with solid carbide..or am I getting into practical vs. marketing?

[@ryandarrah4247]

mill v turn, machinist handbook says turn if you can because turning with a $5 edge can remove as much material as a $80 end mill

[@suvajit_Dutta]

Ya just do it

[@rofltechniker]

In the thumbnail it looked like an additively manufactured part, like with WAAM

[@denalozecon9074]

That is super impressive to do that much in 30 minutes. I betcha it took two or three full work days to decide what instructions to give that machine. I don't mean only one person working that amount; any number of people working a total of 16 to 24 hours doing lots of math and geometry, deciding which tools for each step, and many more details I cant describe. I really am just guessing on this, but what I describe is worth it to avoid ruining a part; if that part was ruined and they had to do it again it could cost them over $30,000 as a guess.

[@ytfan3815]

Just forget it, not in 30 minutes.

[@saumyacow4435]

Oh dear, this guy is going to be making love to the machine in part 3...

[@joemattes8389]

Cool video Barry. Curious, why not rough all the ID with the feedmill after drilling?

[@MakeItWithCalvin]

Or plunge rough it?

[@nikolaishriver7922]

Two thoughts that really aren't relevant here, but I'd love to see Titans dabble in: Rotary table on the Blohm, and an actual HSM milling department.

[@supremecommander2398]

how long until the subtitles for metric numbers are ready :D ahh, can't wait for the 5-axis action

[@jerriayzac8711]

Que estrategia usaste para el desbaste, me lo podrías compartir 😮

[@virtuosisimo]

I once snapped a high feed endmill just after five parts

[@killerterreur25]

Tornos Swiss Nano at 6:54 😉

[@donniehinske]

Nice!

[@hamzanawaz7945]

Berry destroying Trever, Donnie and all others in the famous #Titans style.

[@ronakzare655]

افرین کارت خیلی عالیه

[@Renegade48445]

Love machining cast iron, hate the mess it makes of the coolant and the dust on everything. But Barry I have to ask, why not rough the id with the high feed mill?

[@barrysetzer]

TBH I didn't think the dampened holder was going to help as much as it did, so I expected it to sound rough. But, it ended up sounding great, so if I could go back I would've skipped the endmills.

[@Renegade48445]

@@barrysetzer Fair enough... ive found the hf mills push up so hard that even extended they don't bark nearly as bad as a standard shoulder mill. Thank you for your reply.

[@dakotareid1566]

I’m calling bs on that taking 30 minutes, post the full video of the machine process without editing

[@rf11423]

Really cool Vido, but i have a question. Why you dont use the 9 axis Turn Mill for this Part. The od and id roughing goes so much faster. Or you did it just like you said you are a mill guy? :D Anyways i like seeing mills working as a lathe guy :D

[@EvoKey]

Is it really necessary to machine down the steps on the outside? I would think it would often not matter if the part is visually clean outside, as long as the critical measurements are correct. Because then it is just extra time spent on niceness, and is that extra time spent paying off for both the costumer and you?

[@wildin13]

Depends on customer and application. All those steps can be stress points and some customers like parts to look clean others just want it quick and/or cheap

[@phillhuddleston9445]

@@wildin13 With all the time roughing it doesn't take too much more time as a percentage to make a part look ten times better and finish it correctly.

[@wildin13]

@@phillhuddleston9445 well it depends really. As a tool and die maker I find 30min roughing to 2" on this is shifting, considering that inside bore. I also imagine it needs roughing down to a 3/8" tool in places so those steps don't matter 1 bit yet. Just focusing on the outer shape (none of the important features) I'd bet there's another 45-60min of roughing then an hour or 2 of finishing. But thats assuming its finished with 1 tool which I actually doubt highly. Typically when we do the "lightening out" on the back of gravity dies we use high feed roughing tools to "finish" with a smaller Ap than usual to reduce stress risers

[@jakebpau2396]

The Setz!

[@robertomurillo340]

So, where is the finished part...?

[@brentnicol6391]

As a manual machinist, I would like to say to the world, real men play with chips.😅😅 Impressive machining there.

[@garethbaker5179]

Why wasnt the part cast beforehand so that there was a lot less material to machine, therefore saving material costs and the time taken to rough and profile?

[@89RASMUS]

Probably a one-of part, making it more economical to machine it out of a billet over spending 100-150 hours to make the pattern and casting. Cheers.

[@koenig]

Can you share the mcam program? Thanks!!

[@adammiller4879]

7:35 for a nice classical Barry face😂

[@barrysetzer]

Lmao its always great when the film crew says “make faces.” Like wth am i supposed to do!??! So? I just be me.

[@adammiller4879]

@@barrysetzer looked like an orgasm face to me LMAO

[@paulmorrey4298]

Cheers

[@GrumpyMachinist]

Nice. I've been anxiously waiting for more content on this part. I would have processed this part by machining the I.D. work first. Does it matter?

[@travisjarrett2355]

Good video. Better tips. Should of turned some of it 😉

[@barrysetzer]

Blasphemy LOL

[@amalfi460]

New sub here, so what is the part you are making…if you said it i missed it, or do you guys just get told to make this with no explanation?

[@barrysetzer]

Hey Neil! I actually couldnt tell you what it is. It’s obvious some type of pump, that we were told was “difficult.” Soooooo we wanna make it easy

[@CTLanni]

Looks like fun! What I don't understand is why the billet can't be (or isn't) created with a basic shape to reduce the amount of milling necessary. Is the billet cast or forged?

[@flyingjeep911]

Where is the rest of this part being made?

[@jonbaker3728]

Does that beast need to be stress relieved, or allowed to spring a little bit, or do you just keep milling in one chucking?

[@machinetoolswarehouse]

How much did the billet cost? How much would is cost to have that part machined?

[@barrysetzer]

The billet was around $800, and machining it will take around 15 hours, so around $2000

[@MrChevelle83]

ive removed well over 1000lbs of steel and iron on one part on my job :-). in under a 12 hr shift

[@barrysetzer]

YESSSSSSSS I Hope you love chips as much as i do

[@mehmettemel8725]

Yes you sure can if you have a monster of a machine and a programmer like Barry.The bit I don't understand is how do you have steel and iron on one part?

[@MrChevelle83]

@@mehmettemel8725 some of the parts are adamite steel and some are nodular iron.

[@MrChevelle83]

@@mehmettemel8725 I run a 150HP lathe that can hold a 20 ton part, our roughing tool is 1-1/4 or 32mm ceramic inserts,

[@mehmettemel8725]

@@MrChevelle83 Yea you reminded me when I was an apprentice at steel works machining back up rollers up to 60 tons with ceramic inserts,watching the roller go round and round for a whole shift falling a sleep.🥱

[@pozalujstapodpishus3062]

how you convert 3axis strategies to rotate axis?

[@Hani13ful]

Post processor for that type of machine nothing science

[@thni1703]

Crazy

[@TobiasKornmayer]

thought you WAAM'ed it when looking at the thumbnail, but it was only the roughing m)

[@brianropel]

I really hope he gets the same enjoyment out of greeting people at Walmarts door as he does with his machining 😂

[@mehmettemel8725]

Is that his second job?

[@brianropel]

@@mehmettemel8725 in the future we all hope it is. He’d be amazing at it. Until then he’s just going to have to keep making great machining videos

[@strange_weird]

What do you guys do with all of the chips? I’m really interested

[@barrysetzer]

recycle, for the most part

[@TechTomVideo]

The thing ist, that it took 30 minutes so far... but now come 4 more hours to make it smooth

[@_BarabaSHka_46]

foundry production no I haven't heard

[@importanttingwei7747]

Where is makino horizontal machine from 2 years ago

[@user-pw1sb5co7c]

Звук обработки как песня. Круто.

[@tubbytimmy8287]

Can anyone get this to work on HLE? I assume I just go to "Rotary Axis" and then "Rotate about Z axis" ?

[@barrysetzer]

Yeah, assuming your post is set up for it, you would select 3 axis and rotate about z. You can also change your backplot settings to simulate rotary motion.

[@theofficerfactory2625]

Are you guys gonna show you you will aug out the pipe?

[@alexbireta4668]

Though I am curious about why you used polar interpolation rather than the three linear axes…

[@barrysetzer]

Because the head can only go a few inches past table center, so it's really the only way to do it in this case

[@bschwand]

Why not cast to approximate dimensions then machine ?

[@MWL4466]

Why would that part not be cast ? We machined volutes for years and they all were cast in a foundry.

[@mehmettemel8725]

Barry before you start machining you should explain why you wouldn't 3D print or cast the part.Reading the comments there is dozens of them asking the question.

[@barrysetzer]

I actually did, but it ended up on the editing room floor. It's a prototype which would be cast in production

[@toolmakerdave5287]

so gonna try some of this shit on my UMC 500 tomorrow. how you think it'll go?😎😎

[@olafmaestro]

If I see it correctly I assume that the part has a tube that goes around, but with what sorcery other than additive or casting could you machine this from raw stock?

[@niclasstorm8192]

Must be a showpiece of sorts

[@alexbireta4668]

If the bottom plane cuts through enough of the tube, you could access part of it through there, and the rest from the opening on the top

[@user-ur2kj4lf7l]

They made a rough draft, and then, there's still a lot of work, all the main work is ahead, judging by the 3d model...