INCREDIBLE Techniques Behind Machining Long Spline Shafts

This is game-changing technology that made cnc machining this part on the Tornos GT32 Swiss lathe so much easier. The tools used in the machine made cutting through steel a breeze, a must have for any job shop.
titansofcnc.com
00:00 Machining
00:22 Introduction
00:44 kennametal's Cermet Tool
01:31 Tool by Horn
02:01 Programming in Solidcam
04:32 How to eject your finished parts
06:12 Outro
#Machining #Machinist #Engineering

[@Jessie_Smith]

Great video Donald. I always appreciate the step-by-step process and not only seeing the process from start to finish but hearing the little considerations all along the way.

[@SolidCAMProfessor]

The flexibility that SolidCAM gives you lets you be as innovative as you want. Very well-done video.

[@donniehinske]

It’s crazy to me how with the right tools things can be so much easier! From the Machine, tools and software you can make parts like this a LOT easier to tackle! Good job on the edit Ben! This was a fun one to make!!!

[@raguramspace]

Beautifully machined Donnie!

[@donniehinske]

@@raguramspacethank you!

[@oberender64]

Its weird that you always praise yourselfs in the comments to generate traffic or why?

[@DCT_Aaron_Engineering]

That was an excellent video. Well filmed, documented and explained. Thank you for showing us. Cheers, Aaron.

[@Dyna78]

Now all we need is another video showing inspection of total runout from the pitch diameter of one spline, to the pitch diameter of the other. :)

[@dannymitchell6131]

The videos are so much better over the last 12 months are so. You all do a great job on camera. I'd like to see some introductory videos, I do 3D modeling for work but nothing like you guys do. I'd like to see if it's something I can get my head around and maybe one day take your classes.

[@williamlind2843]

I love it!! I'll be on the Horne website 1st thing tomorrow morning! I have a lot of spline shaft work.

[@shaniegust1225]

Very informative! Great job Donnie 🔥

[@drewbush2163]

I need to get my hands on a Swiss lathe and deep dive the capabilities. They absolutely fascinate me as a normal lathe hand. HAAS ST30Y here.

[@michaelpawluk6791]

Awesome video. I did something similar on a DMG Sprint 32/8 I had to mill between spindles. It was a rectangular part, and I had an extended nose collet on path 2. It ended up stress relieving too much ( 316 ss ) so I had to shelf it for now. But I will make that part

[@blackshadow772]

Great video Donnie!

[@gogelgebenec5270]

Great video Donald

[@markdavis304]

Good info Donnie👏

[@Squid15ncali]

love the no brass material boyzz!!! 👏🏽👏🏽👏🏽

[@ytfan3815]

We use this tool for involute gear Module 1 on a 10 mm shaft two sides, HORN toolholder 313 with special ordered/grinded inserts, our geometry was not available as standard insert, they where over €120 apiece, first minimum order is 10 pieces, second order was ( a bit ) cheaper. That's a big plus of HORN that they can provide your own profile/shape.

[@GarageWorx]

Pretty cool 😊

[@alinaveed1895]

Blown away

[@allenbrown7820]

“Don’t ask me how I know!” A true sign of first hand knowledge! Be Safe!

[@ttools_professional5173]

Swisstype + CAM = weapon😅 please do more Content abot how to programm a swiss lathe by SolidCam

[@jackofalltrades3654]

Wicked cool

[@user-dv5ej7un7o]

Nice

[@ernest6980]

if you’re running a bar of material thru a guide bushing how are parts ejected thru that same tube with bar stock ??

[@barhoecs5250]

programed with SolidCAM

[@skenzyme81]

5:34 🔥🔥🔥

[@willmc11]

How do Swiss machines perform with high tolerance parts the require a high surface finish when a large doc is required For example, a 1/2 in part in copper 3in long with a 1in step at the back and a 1/4 in bore The tolerance on the 1/2 in is +/- 0.0001 the bore +/-0.0001 and the bore concentricity of ID to OD 0.0005 max I’m currently using a Hardinge wanting to go Swiss to expand capacity but not 100% confident the tolerances especially the concentricity as I’m reaming due to the material (copper and 3% nickel alloy) and volume

[@garyhenry1773]

Wow hard to believe that you can keep those tolerances

[@mgk1397]

They work quite well, though I won't say it's easy. I've run a part with similar tolerances in copper and it worked fairly well, though it depends a lot on tooling, order of operations, and possibly most of all, how accurately and carefully it was setup. I've heard it said that in Swiss Machining "The process is the product" and I would agree. I run Citizen machines, and tight tolerances are not too big a deal, usually you fight tool wear the most, and warmup for maybe the first half hour of running. I would do your research, but Swiss would likely be a great option for you.

[@yak-machining]

Can someone explain to me how it can simultaneously push the stock out while spinning?

[@QinX81]

Behind where the stock comes out is the actually motor, it grips and holds the stock. The part where the stock comes out is not actually gripping or spinning the stock. It is only supporting it.

[@donniehinske]

What you are seeing the material feed through is a guide bushing. Basically it is just a steady rest for the material. The spindle driving the material is actually behind the guide bushing so you don’t see it

[@danielczoller3395]

Wher kennametall?

[@Innovativeindustries]

Awesome video!!

[@mp5kfisher241]

Lord i wish i was still in the game. Who out here remember punch tape and tape twin?

[@sferg9582]

Ah yes..... punch tape and trying to make any edits to the program....😡

[@mgk1397]

I'm too young to have ever seen it, but it is not entirely forgotten! That technology and the transition from no computer control to all computer control is very interesting to me. Periscope Films has a channel here on KZbin with some old product advertisements from when that was brand new technology, very interesting to watch.

[@PacoOtis]

Greetings! An excellent video by a very fast speaker! LOL What about lubricant? When is it used these days? Thx

[@VeryDramatic]

Cool

[@mikeandcolleenk9831]

What the omg. Id just settle for an older lathe so i could do some work for alittle money . Unreal wow

[@timothyearp631]

Could you power feed like that, and power skive at the same time?

[@Everything_Engineering]

What stops an unclamped part in the sub coming flying out the end of the sub spindle liner just centrifugal force?

[@anderspettersson7580]

The inner tube is not rotating, only the chuck.

[@Everything_Engineering]

@@anderspettersson7580 That makes sense

[@nathanthomas8184]

Very quick, Donnie your given a drawing & BOOM in your head its made , transferring that to language for mach in how many steps do you get IT & history of mach you can extract from previous to One off , Donnie keep BOOMING & soon triple888 subs

[@danhnguyen435]

Boom !

[@malzahar33]

By holding the part on its casting surface, how to make sure it is well centered/balanced so when it goes out of the holder, the runout is still good?

[@HuFlungDung2]

The original stock might have to be stress relieved to prevent warping. It must also be perfectly straight before machining because it's cantilevered behind the guide bushing and the driving spindle (which you cannot see from the front).

[@supremecommander2398]

nice... and next time you show us how to deburr that part flawlessly with a ceramic brush in one of those tool-holders, right? :D

[@mgk1397]

I'm not familiar with a ceramic brush, sounds interesting. Of course ideally there are no burrs. You might be surprised how often deburr is unnecessary in Swiss Machining. Burrs are inherently contrary to the idea of Swiss Machining and lights out obviously. Order of operations makes all the difference!

[@hinalmahera5298]

Which tool you used, please share the part name of PH HORN tooling

[@nhathuy1503]

Please tell me what name of the machine ?

[@seancollins9745]

I'm thinking i want these tools for my regular lathe

[@snowfall3034]

I've never ran a machine, so dumb question, Say your going from this ~12in part to say 3in parts. How would you get the old parts out of the tube?

[@mgk1397]

If they are magnetic it's easy with a magnet wand. Otherwise you have to use something like a smaller piece of bar stock, coat hanger, etc. and poke it through. Usually not too big a deal. Good question

[@johnnycomelately6341]

Is that a gear (involute) profile instead of a spline ?

[@Dyna78]

I was thinking the same thing, way too deep for a spline, at least any I have ever seen or worked with.

[@HuFlungDung2]

Common splines are involute designated by 16/32 for example. That would have the circumferential spacing of a 16 DP but the height characteristics of 32 DP. In this instance, he has to have extra depth to fit the guide bushing with standard stock diameter, then machine the actual part OD after the part no longer needs support at the original bushing ID.

[@ndpesicgroup]

Wow....

[@benhardy172]

We need to know about the fire 🔥 🔥 📛 👩‍🚒

[@carlroy1865]

That was safe and effective! unlike other things they told us.

[@wst2663]

Why would you want to use solidcam over MasterCAM for programming something like a Swiss?

[@michaelwybert7833]

SolidCAM excels in Swiss-type machining with its advanced Swiss-type machining module, supporting an infinite number of channels, unlike MasterCAM which is limited to just two. MasterCAM only recently added Swiss support, while SolidCAM has long provided robust capabilities tailored for Swiss machines. Additionally, SolidCAM's Machine Control Operations (MCOs) allow for precise control over machine movements outside of normal toolpath commands, essential for operations like bar pull and spindle transfer. These features, combined with seamless SOLIDWORKS integration and iMachining technology, make SolidCAM the superior choice for efficient and precise Swiss machining.

[@michaelpawluk6791]

You actually want to use Esprit. Part maker is another good option, but it's no longer supported. Esprit is THE swiss CAM software. It makes syncing operations between two or more paths very simple. On a swiss or most mill/turns you have a separate program for each path. You might not want sub spindle to be near the main spindle until the cutoff cycle. The only way for both paths to know when to proceed is with a "wait code" and that's exactly what Esprit and part maker do the best. Other CAM softwares can provide a solution, but it's nowhere as streamlined. Maybe SolidCam is now, but I haven't heard of people switching

[@michaelwybert7833]

SolidCAM now far surpasses Esprit. Channel synchronization is incredibly straightforward with SolidCAM, and it offers significantly greater control through the use of MCOs. Plus, there's a dedicated post team available to integrate any custom MCOs you require.

[@michaelpawluk6791]

@@michaelwybert7833 I'd love to get my hands on it.

[@apr8386]

what does he mean the stock is the work holding? I don't understand how that doesn't allow you to take depth cuts

[@verakoo6187]

Unlike a lathe that moves the tool along the part, a swiss moves the part along the tool, constantly bringing it in and out of the chuck. So if he turns it to size first when it moves back into the chuck to start each spline. it wouldn't be able to grip onto it.

[@HuFlungDung2]

The front 'chuck' is not a chuck but a bushing. The real gripping chuck is behind, and it does not release the stock at all during the machining of a single part.

[@wildboyz5736]

Thought he was making a reamer for a second haha

[@thefabuloussaneone]

I seen where they make these in Pakistan with a lathe and an Arc welder while wearing an evening gown and sandals. You guys at cnc take too many credits.

[@sferg9582]

LOL! All while squatting on the dirt floor.

[@MillTurnBR]

Chity comment

[@flikflak24]

I have played with the though of makeing a manual Swiss type lathe that works the same way that the cnc does ( mostly cause I couldn't fine anything on the market like that ) since if you do need to make a long thin/skinny part with high tolerance ( like 3mm h4 in diameter and 40mm long. Good luck makeing that on anything other then a swiss type machine ) but only like 1-5 of them then setting up a cnc for it is just a complete waste

[@duncanhalliday3655]

Drill a hole through a traveling steady pad, works really well. Got to lock the 2 pads together for rigidity and drill it with a the drill held in the lathe chuck but it works well

[@flikflak24]

@@duncanhalliday3655 i see what you mean but if i have to set up a lot of diffrent size's in a shot amouth of time then it is al little unhandy ( at least in my eyes) plus how cool wouldnt it be to be able to say that you have the first manual swiss type machine. plus if you make it primarely as a project and seeing if its even posible

[@scotte2815]

Well, I guess that's sort of an OK way to make a spline, if you like wasting time and material and can accept second rate parts. Or OR, You can get a spline rolling machine that does the whole thing in less time than you take "RIPPING" through the first spline cut.

[@easyBob100]

If only the central bank didn't constantly devalue our currency, so many things would be so much more affordable. These tools make you so much more productive, and all the value that you create by being more productive is sucked away, and given to the rich and powerful. Keep up the good work! :)

[@13orrax]

i watch this channel to balance out any pakistani manufacturing videos i watch

[@Defender_928]

I think Manufacturing is cool no matter from old school or new school...!!

[@CNCMatrix]

Wait...wait...what happened to MasterCrap? And those gears are very specific too. The inserts are extremely expensive and absolutely not off the shelf and readily available. There's nothing special going on here as far as the part ejection system is concerned either, we were pooping long parts out the back of a Star (🤮) nearly two decades ago.

[@CaptnHampton22]

What does break the chip mean….? A quick explanation would have made this video more accessible

[@mgk1397]

Put simply, it refers to the size/length of the chip. You want the short curls that easily fall out of the way and don't get tangled and wrapped around stuff. If you can't get the chip to break you get long strings of chips and they get tangled and wrapped around tools and parts causing dents in parts, scratches and rub marks on parts, broken tools, and crashes. Depending on how fast the cutter is moving into the material (feed) and how fast your material is spinning (speed) the chips coming off vary in size shape and length.

[@DoKabaddi]

Big Problem of collet slipping, results shorter length, fail, Only get 60 pcs per day only.

[@ardennielsen3761]

wonder what those are for... as if one has to worry about making parts for a machine to replace its self rather quickly? just like the south American bearing in the old English massy tractors tiller, nearly the same size as the bearing in a Ford 8.8 differential... except, the ford bearing has a 5500lb-ft 650hp ratting... as the mid 1990's made Columbian bearing rather did fail at a load less then 23hp. the difference holds around using sustainably recyclable chemicals to process metals into singular elements... table of 12 had to switch to wood spoons to make that bearing, didn't last to long ether. machining AR600 bearings?

[@ardennielsen3761]

nothing in the existence of their world can machine that material. T700 as AR700, +340ksi... making things like worm gear hypoid automatic lockers in axles posable.

[@ardennielsen3761]

wire EDM to make those...

[@David-yy7lb]

Rolled splines are stronger because it doesn't take material away

[@fc3srotory370]

Correct, but, it's not about "taking material away" it deforms the lathis of the crystalline structure of the material instead of destroying the structure.

[@daynosdr]

that machine literally shits money

[@dukenukem8381]

Seems to be very complicated. Good for mass production I guess.

[@mgk1397]

It's all about the process. These machines are great for high production and high volume/long runs. 8-12 hours of setup doesn't matter if you then get to run for 100+ hours nonstop. It does take a while to setup, and the machines tend to be more cramped than a conventional lathe, so chip control is more important, but once it is setup all you have to do is keep the barloder loaded and tools changed.

[@clintwestwood2731]

If you remove the word really from your vocabulary, your ability to make videos really goes away