How to Machine the PERFECT BALL in a BOX | DN Solutions DNM 5700L Mill

Barry uses the DN Solutions DNM 5700L Mill to Machine the Perfect BALL in a BOX. He reveals his secret method of machining a free floating object. Trevor helps out by printing some custom jaws on the Markforged 3D Printer.
Help us fund FREE Education by purchasing tools seen in our videos here:
TITANSofCNCTooling.com
FREE CNC Machining Academy:
rebrand.ly/TiAcademy
FREE Aerospace Academy:
rebrand.ly/TiAero
Subscribe for daily content and expert knowledge: rebrand.ly/SUBTITANS
___
___
FREE CNC Machining Academy. Join the Revolution:
rebrand.ly/TiAcademy
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
Doosan - bit.ly/DoosanTiYT
United Grinding - hubs.ly/Q013zHpC0
Mastercam - rebrand.ly/MastercamEDUTiYT
Blaser Swisslube - rebrand.ly/TiBlaser
Tormach - rebrand.ly/TiTormach
Solidworks - rebrand.ly/TiSLDWRKS20
Trumpf - rebrand.ly/TiTRUMPF2022
Trumpf TruMark - rebrand.ly/TiTRUMPFTruMark
Trumpf TruPrint - rebrand.ly/TiTruPrint
Markforged - rebrand.ly/TITAN-Markforged
Tyrolit - rebrand.ly/TiTYROLIT
Mitutoyo - rebrand.ly/TiMitutoyo
Haimer - rebrand.ly/TiHAIMER
LNS - rebrand.ly/TITAN-LNS
FANUC America - rebrand.ly/TiFanuc
Schunk - rebrand.ly/TiSchunk
ONA - rebrand.ly/TiONAEDM
#CNC #Machining #Machinist

[@Kardos55]

The importance of a foundation. Making a perfect cube is a challenge to many experienced machinists. Nicely done Barry!

[@TheyForcedMyHandLE]

Right! Folks think the ball is hard, then realize 2/3 of the video is just making the cube.

[@majorva2653]

leave 2mm to clamp on the bottom, machine the plane on top and around with a endmill, 5 perfect to each other faces if your endmill doesnt flex, which doesnt happen with a sharp good tool saves you like 1.5 hours in his case

[@mrfinder18]

Basic AF. If making a cube was hard, you came into the wrong field then.

[@mgk1397]

@@majorva2653 Only if you can get an endmill long enough to side cut the entire block, so it depends on how big you want the cube. Either way you are right, it is much faster.

[@JohnBlaze505]

Making a square cube is day one stuff.

[@gofirst501]

This guy’s presentation and teaching skills equals his engineering skills. Impressive guy.

[@allentastic]

Both are somewhat rare talents, I was thinking the same thing.

[@machocamacho9544]

When I did my ball I used two bottle caps to hold on to the last side. It wasn't the best, but it was the only thing I could think of as a 19 year old machinist.

[@barrysetzer]

Hahaha that's actually pretty smart!

[@haydenberndt4835]

I used a flat piece of hardwood that I cut to the correct square size, rounded the corners, and used a large drill to make a pocket in the centre. It wasn't the most stable, to be sure, but it did the job. Now that I have a 3d printer, I'll have to give this method a go.

[@andyloney777]

I was just wondering how an apprentice was supposed to do it if you didn't have a 3D printer.

[@barrysetzer]

You can also machine these exact jaws out of aluminum!

[@tylerchiu7065]

@@andyloney777 i mean, he did say that you could mill a holder too

[@blaynheimann3423]

Barry is such a trip. I loved the years i got to work with this guy, he was by far one of the best Programmers i had the pleasure of working with and before he came along my company had never run anything high speed. also his singing about everything he did was classic and his sayings were top notch.

[@mvpolo2k3]

we used to just freeze the cube in water, or dip it in wax, then hit the 6th side. we didnt have 3d printed jaws 20 years ago lol

[@unclelar53]

Cool stuff. I'm retired now, but was a machinist/toolmaker/CNC programmer for 50 years and still a bit surprised at the simplicity of this project, yet the final product looks very complicated. It reminds me that it is always best to, first, look for the simplest way. Back in the 1970s, it was just "NC" not CNC, and we ran on punched paper tapes. We would refer to it as "no control", lol. Fun, fun.

[@levihoff7923]

Video quality is through the roof today. Love seeing machining on KZbin!!

[@elliottanderson9507]

the heretical part of me just thought "shrug cut box in half, insert ball, weld box back together, mill welds flush..." but this is much more technically impressive

[@thebeverageman2982]

Who edited this video? I really enjoyed all the little things sprinkled all over it, like the MLG hitmarker. Excellent

[@austindavis2406]

"Using nothing but a 3 axis mill" What a humble and lowly piece of equipment you're using ;)

[@NegativeROG]

That 3D fixture was BRILLIANT!

[@MrScienceMaths]

Barry your a genius. Excellent work, another great example of the integration of subtractive and additive machining. Love you Barry!

[@barrysetzer]

Hahaha thanks, this is one of my favorite projects, glad you liked it too!

[@ricosuave3565]

Barry. I dont know anything about machine ing. But I know you're a Genius. LoL 😅😆🤣

[@mount.sinai.5295]

Man its something else watching this as an european.. Your AMERICAN energy is something else. I dont know why but i have huge respect for this guy and i dont even know him :D I love the accent, makes me want to listen more

[@barrysetzer]

Hahaha glad you liked the video, brother! Thanks for watching!

[@mount.sinai.5295]

@@barrysetzer Amazing content bro! Its just what this industry needs, content like this

[@lsfloro]

Namaste! I'm a retired (primarily manual) machinist and really enjoy your videos. The perfect ball in a box is a classic.

[@SameerKhan-xn9gn]

I need to try to make one of these before I die, Thanks

[@JoshBelowKnee]

Whoever is doing the sound effects is doing a bang up job!

[@johndennis3181]

I use this method for getting some very square (no such thing as perfect) but when I need the best I can get I clamp the part to an angle block, this always yields better perpendicularity.

[@shaniegust1225]

Great video Barry! And I love how the editors are getting HUGE credit on this one! BOOM!

[@barrysetzer]

Thanks Shanie! And yeah those guys deserve way more credit than they usually get!

[@BrilliantDesignOnline]

Awesome editing and use of AfterEffects, like where he says in X and In Z and the screen labels track his hand.

[@peterchindove7146]

How much would this cost? The ball in the box?

[@STUNRICK]

I might be slightly drunk and have nothing to do with CNC machining... but I admire technology and the art of it. Thumbs up, great vid.

[@onepairofhands]

that surface finish when you were squaring the stock is amazing

[@joewoods9909]

Fantastic video, I like the longer and more educational ones!

[@trevorgoforth8963]

I gotta say Barry, you really know how to put the FUN in fundamentals 😂 #dadjokes

[@ascobie22]

Great demonstration on squaring a block

[@travisj.3994]

Solid video brother. Really enjoyed the tutorial embedded in a super cool project.

[@KeithAlumbaugh]

I use a ball bearing instead of a half round rod to square up stock.

[@TheExplosiveGuy]

I've always loved doing tight tolerance work, everyone else always seems to hate it or aren't very good at it but I think it's rather fun. I've always dialed my vises in as tight as possible until my .0001" gauge dial stops moving, if I had a dial indicator that read in .00001" increments I would use that instead lol. My boss always gave me the stuff that we couldn't afford to mess up and had extremely tight tolerances but wasn't in a hurry either, he knew I took my time dialing things in as tight as possible even when I had a mile of tolerance, I was never the super fast get it done in 20 minutes kind of setup guy but he appreciated my attention to tolerance all the same, I even set all my tool height offsets down to the tenth, and would also run every new cutter through a piece of test material to establish my diameter offsets down to the .0001" as well. Takes a lot longer to set up but when your first part buyoff comes around and you've nailed every single dimension down to one or two tenths, it's a pretty good feeling and it impresses the hell out of the inspectors as well.

[@xl000]

Meh. Machinist is an easy job. Why do you think it's taught to kids in trade schools, I think it's a cool hobby though. With a CNC, some woodworking and 3d printing skills, I can repair almost anything

[@Joshua-YeetRat]

@@xl000 it's not easy man

[@CaskStrength777]

​@@xl000it's taught to kids in trade schools because it takes a very long time to get truly good at it, and the people who make things like space shuttles and parts to crazy tight tolerances in millionths of an inch, microns, like I'm doing, you don't pull that off just coming out of school. For someone to say it's an easy job you obviously have no understanding of anything related to machining or how difficult it actually is to make something complex let alone this properly. Some of the most brilliant people in the world are really skilled machinists. This guy was fine with a thousandth of an inch variance in the cube and I laugh at that. I would have made this 10 times better, and I would be splitting tenths. Because when you get good at it it's not difficult to do that rather quickly. But it takes a long time to get to that point where you understand all the intricacies of variance that can come into the setup. He was fine with 0.0002" variance on his paralellism, I would have quickly had the vice parallel to millionths. The hard part is getting the vice bottom perfectly flat because there are always micro burs on the table, slight imperfections on the vice that you use precision ground flat stones to take off and clean meticulously before you even put the vice down. If you do it correctly you can do much better than this much quicker. There are people who can do tight tolerance work but take forever and they don't make money, the key is being able to do very high accuracy quickly and efficiently. Machining is the only career I can think of that develops a hands-on experience with geometry and physics when you get to the high levels, and it promotes a comprehensive understanding of physical natures of force. There's nothing easy about it, your conception is shallow at best

[@maikel371]

all hail to the video editors! what a great video y'all

[@barrysetzer]

Yeah those guys do a fantastic job!!

[@maikel371]

@@barrysetzer you also did a amazing job :) i just found another use for my army of 3D printers. thanks barry! what a great job you have

[@beckoningjinx1119]

This reminds me of a production part that I used to run. Milled all six sides, starting the saw cut up and rotating the fresh faces toward the stop. On the fourth side, there were 1.25" drilled holes with less than .050" wall left from the previous milled ends. If you didn't get it squared good enough on the first side, those holes would be out of tolerance. Then, rotated forward and back to finish the block out. The last side had milled ports that intersected those 1.25" holes and 1/8" holes with about .040" walls that went through over 2" of material. Being a production part, we didn't have the luxury of getting it all square before features were added, but they weren't bad if you got it square to begin with and kept a handle on it.

[@Atlas.Brooklyn]

Ok

[@paulkraus4799]

That’s one of the coolest parts I’ve seen made in quite a while. One of these years I’ll have to try that . Great job Berry

[@barrysetzer]

Hey thanks Paul! This is one of those projects that I always liked because it keeps the new guys interested in machining. Everyone likes having a conversation piece for their toolbox or desk!

[@mrbmp09]

bArry not bErry were not fruits.

[@Sara-TOC]

@@mrbmp09 Good ole' auto correct...will get some every time ;)

[@horseshoe_nc]

@@Sara-TOC or as I like to call it, Auto Incorrect. 😜

[@ChristianZenker]

Long time agao i learned to use this machines, but i never had an project awesome like this. Thanks for showing

[@patpalermo7629]

I never clamp anything offset that much in a vice - it will not be square - at least not in the vices I have. The fixed jaw is fine, but the moveable one will cock. Putting it near the center of the vice, or using a spacer on the other side of the vice will fix it. Evrey vice I have does this. Check yours. If it is still within .002 when clamped this way, then I want one. Been machining for 30 years.

[@KimbrellBrad]

I've done that in wood before on my PowerMatic lathe but wow in metal! Super cool idea on those vise jaws! I need to get a 3D printer anyway...great reason just thinking about not having to machine soft jaws on my manual metal lathe!

[@mohammedalbattal77]

Ohhhhhh man we have a ton of new information here I like that one when you check the square with v block it so fine and we can save alot ov time with this way Thank you Mr Barry for this video and thank you for your time 🔥🔥🔥🌷🌷🌷 Boom

[@reidklassen5096]

I can't wait to try this!

[@jimderino]

DESPITE ALL MY RAGE IM STILL JUST A BALL IN CAGE

[@tdg911]

You guys are badass, period. Just saying. Much love and gratitude.

[@user-pr2sn8oo4j]

Barry!! I NEED MORE BARRY!!!

[@barrysetzer]

Hahaha thanks for watching, brother! 💪

[@christophervillalpando5865]

Awesome Video Barry! Very informative!

[@Jatsekusama]

Great work!!! Next video on CNC turners cube plz!!! :D

[@jackthayer904]

That’s awesome takes me back to high school where we did a cube in a cube at a way simpler level

[@marcabrams6087]

Have to remark on how much has changed and how much IDK since my programming and CNC (G & M code) and operation days in the 80s on an Ikigai 3 axes. So far above what I learned. Know JUST ENOUGH to be amazed! I so love seeing how technology and hardware has so advanced. waent the dark ages, lol, Still had inserts.

[@bobbymelehes732]

Loved the editing! Keep it up!

[@markhill2489]

great stuff guys ! i really appreciated this. thank you

[@timbaer8525]

Best practice would definitely be using more of the fixed jaws and reference surfaces for keeping square. If you have more surface easily available to use, use it. Only going to make better square easier.

[@duffmanmark]

Stepping it up a notch would you do a ball in an octagon that would be cool to see

[@frankensteincreations4740]

Absolutely nuts! Crazy where technology has taken us…

[@VikingRul3s]

Well done!!! I don't think I've ever made a box that perfect, old school style, but frankly I'm too lazy and would just include the "squarness" as a part of the first 2 CAM programs

[@moodberry]

Dude!. Oh how I wish I had a teacher like you in high school!

[@EdTube444]

I have never done machining, which now makes me realize I wasted my life because it looks cool AF, but as a carpenter and builder I see the same methodology applied. Achieving "squareness" and approaching a build with "forethought" like "okay my 6th side was holding the ball so how do I get the 6th side without goofing it up". I get crap from other workers I have worked with for being OCD. And when its all said and done their product is, in their words, "good enough". I've been hearing this for 30 years. I see I should have been a machinist. You all seem to understand perfection is a worthy goal.

[@tommasu5391]

Awesome video guys! Is it possible to share the steps done in master cam for people to follow along and Try to make it as well?

[@humancaos]

you present it as like everyone just has a cnc machine in their kitchen

[@duyle7031]

I'm try this on the weekend

[@sjorsangevare]

I found the edits quite hectic. I wouldve loved to see more of how the machine machined the ball, I didnt know you could make perfect spheres like that!

[@JGV_IX]

Insane!! Great work!!

[@kokonisayg6567]

GREAT WORK+IDEA

[@stevebell5231]

Now that was bloody cool

[@tj9382]

Splendid stuff

[@bjmckay3]

Good job👏 pred straight forward for experienced cnc lads

[@ProjectShopFl]

That was Awesome! 😎 I want to make that out of copper.

[@chicoxiba]

I guess misalignment would have been in the order of 100 microns. 3d printed mould the weakest link? None the less. this is a cool one. Take it back 50 years and show it around;

[@ELITEWELDER1]

Thanks for the entertainment I’d love to come be an apprentice and learn how to operate and maintenance all these amazing Rocket creating machines! So cool how I feel watching this amazing skill. U guys rock’.

[@satyajeetsahoo1073]

Ohh man... it was really amazing 👏

[@Beaches_south_of_L.A.]

That was really cool and I like this guy he's really cool too.

[@jeanyonsei2318]

Mind blowing!

[@jtrent3960]

Great fundamentals video, and Barry is the fn best.... Cheers

[@barrysetzer]

Why thank you! I will make sure that I rub this in Jessie's face HAHAHA! Seriously though, thanks for watching, and for the feedback brother!

[@philipp__5106]

Thats verry nice🙏🏼

[@MagnetOnlyMotors]

If you had your vice a few degrees out of alignment, you would have a wonky looking cube, which would also look very interesting.

[@TommiHonkonen]

We did one with a cross inside at school 10 years ago. Wanted to do one with a ball inside for years. You should have had Travis cmm that block for squareness.

[@e2jw]

Sure, you can do it THAT way - but I just get a large ball bearing and cut the cage, soak them both in vinegar overnight, push them together in the morning, rinse and dry. Works about like you'd expect... not at all LOL! But Seriously - Great job with this! (i did put an egg in a milk bottle once in a similar way)

[@LU-D1GITAL]

One thow… so cool I’m gonna use it

[@coyleboyd4882]

I wanna try this so badly

[@lidarman2]

I'm an optomechanical engineer and I giggle when machinists equate spotless clean with rubbing surfaces with their fingers. It's an interesting relative perspective. :)

[@davidsnyder2000]

Super cool teaching 👍🙂

[@funnyanimalworld7579]

Probably most people learn this in companies because of high cost of equipment but either way this looks like a great profesional video👍

[@Metaldetectiontubeworldwide]

" MAGICO THE MACHINIST " AWESOME ☆☆☆☆☆

[@iamtyzed]

From Switzerland I first learned that in my first year on a conventional mill 2:40

[@cgdrider]

Nice work. As a retired 50 year CNC Machinist, Once I saw the project I immediately knew how it was done. The only thing I would have done different would be to make the Ball capture fixture aluminum soft jaws and as a former GibbsCam Sales engineer/application engineer, I would have used GibbCam to program the CNC and Solidworks to create the part model.

[@princebhuhi1764]

Wow amazing 😮

[@user-yi4qm2mr2z]

great job I love it ❣❤

[@mg.2187]

Work holding and badass cam software

[@chraven69]

You can use the same ish process to make a cube with in a cube which it self inside a cube on a lathe. You can also manufacture the same effect on a manule mill but using form tools to manufacture the shear in the middle 😉 Great video boom 💥

[@hunlee7521]

오~이런식으로 해야 하는군. ㅋㅋ 저도 한 번 도전 해봐야 겠네여 ㅎ

[@Nextlevup]

Nice. I like it.

[@filippaoronto3880]

To me you guys are great teachers and a great source of inspiration 💪💪💪! Wish to see a lot more from you in the future! That 3D printed parts ,what tolerances they got ?

[@mgk1397]

Depends on your printer and many factors including material. For the most part thought tolerance doesn't matter that much for this application because the plastic squishes a little bit when you tighten it down in the vice. My experience with 3D printers has shown down to less than +/- 5 thousands of an inch with a well setup printer.

[@brianw572]

That is very cool and would make a great conversation piece. Thanks for showing how to do this.

[@barrysetzer]

Yeah i always like having people guess how I got the ball in there 😂

[@bensonburner8435]

I've done Turner's cubes where for the final side you tape up the cube with tinfoil tape and then fill it with melted paraffin wax. Let the wax harden then machine the final side. Use a heat gun or low temp oven to melt out the wax. Perhaps not nearly as accurate but definitely still a great result. This video was great and I want to try and make one of these now! Also wondering if two pieces of round stock and a counter sunk set of holes in the ends would maybe work ok for holding the sphere on the final side. 🤔

[@dekebell3307]

Very, very cool.

[@RogerBarraud]

Cylind*e*r... Amazing vid, thanks heaps!

[@ericmatthews7652]

Did mine on a manual lathe after seeing another video.

[@arturmelniczenko3611]

It's a great thing to try to do it at home at the physics institute, but in the metric system we'll see if it will work. Well done

[@Make-Asylums-Great-Again]

Ok

[@rollbot]

tenths indicator? lolz!!! love your vids !

[@bruderschwester903]

New Videos editing is awesome!!!

[@lucasluiz8735]

Looks cool, not gona lie.

[@DiegoLopez-sg5bs]

Very very very bright 👍

[@funnyanimalworld7579]

You have whole door covering you from hot metal scraps ,in my time working with some ancient equipment i had only my skin covering me from them😅

[@aaronczarnecki1403]

Great stuff! What Ball End Mill are you using? Thanks

[@alegermani1981]

La lavorazione in trocoidale per fare la gabbia è eccezionale... complimenti veramente

[@DumfriesDik]

That was a great video, thank you.

[@buiucgiau2664]

That's great! What is your this tools of rough operation?

[@yogeshkumar7402]

Good work