Complex Aluminum Part on the Mori Seiki NTX. 97.5% Material Removal in 1 Single Setup.

Machined these crazy thin wall Aerospace parts for a customer recently. Went from 23lbs stock to 8.8 ounces finished part. Overall took about 3 hours using 13 different tools. Took me about 60-80 hours of programming and set up to get everything running smoothly. One of the more complex parts I machined. Customer was making these for 40 years using 3 different machine and 4 different set ups. I took it and got it done in 1 5 axis set up.
Let me know what you think, and if you have difficult parts send them my way.
Difficult 5 axis machining at Zala Machine in New Jersey USA.
USA Machining.

[@Kizmox]

Coming from aviation company I used to work on parts like these daily. Very well done! I can imagine the annoyance and cost of having to fixture such a flimsy part 4 times.

[@zalamachineshop]

Yea it seems almost impossible to do in multiple setups. For sure more difficult than the way I managed to get it done. The machinists that figured it out working with 3 and 4 axis on old machines were the masters. I had it easy compared to those guys. Even though I admit it was a nightmare and pushed my skills to the absolute limit.

[@Sebastian-ed5kt]

@@zalamachineshop could it be that they glued the part down in any way on their multiple set ups?

[@TROdesigns]

Incredible work getting all that machined accurately in a single setup! Subscribed

[@mannycalavera121]

A lot of rough, semi rough, semi finish and finish when into those long overhangs. This is a real impressive part. The parts you churn out on your NTX2000 is always impressive.

[@zalamachineshop]

It wasn't perfect and I was constantly fighting vibration but when I dialed it in the machine ran complete parts in around 3 hours cycles unattended. Nothing more satisfying than peeling off a beautiful and expensive part every single time.

[@alexgregg2466]

Finally, been waiting ages for another video from this channel

[@aly-tek7190]

Looks awesome. Why is that that you didn't debur it as well?

[@TheFeller1554]

That's pretty incredable. I am going to incorporate the dovetail workholding method into some of my machining.

[@frankr608]

that’s awesome thanks for sharing i would be ok with seeing the roughing process and more of the finishing

[@zalamachineshop]

Most of the roughing I had to run with coolant and didn't get any good shots. I was going very aggressive and needed the coolant or I woulda started melting aluminum together.

[@tomwolf4148]

@@zalamachineshop Damn, that's to bad, the roughing would be interesting to see.

[@vishalpal6265]

Which software use for programming

[@davidl.579]

Nice for a mornings work.

[@thedude5869]

Daaaannng!! Now thats a crazy part. How do you guys even quote that?

[@zalamachineshop]

I usually quote high and when I get the job I know I quoted too low.

[@thedude5869]

@@zalamachineshop haha, same, I’m in Jersey also, you guys sure do some nice stuff.

[@465maltbie]

That is an incredible part, thanks for sharing. Charles

[@BNEdynamics]

Is there a reason you used a mill boring head for the final ID versus a boring bar?

[@carltauber2939]

Thank you. I'd love to see more of the machining.

[@zalamachineshop]

Keep watching I got more coming.

[@vishalpal6265]

Excellent work

[@Cosmobrosomething]

Ya done good! Did you anneal it or no anneal?

[@shiro-r4m]

You never disappoint, awesome

[@obican]

Can't believe you skipped so much of the fun!

[@1AB09CC3]

At 1:36 what's the reason for the "rewind"? I guess it's some coordinate system mumbo jumbo i've seen from time to time. As I'm only working on 2 axis lathes / 3 axis vmc's I'm not sure if it's necessary or just easier to program.

[@zalamachineshop]

That's just a programming thing. The next operation goes back to C0 at the start while the previous wound up in the C1000s

[@ipadize]

@@zalamachineshop the machine counts more than 360 degrees?

[@rodneyeamon9876]

Pretty fancy candle holder.😁

[@owievisie]

Looks insane bro

[@makouille495]

damn you nailed it! nice job!

[@Hydrazine1000]

it's complex parts like these, with an insane start-to-finish weight ratio, that will be replaced by additive manufacturing. This particular part, with it's 40+ year design lifespan, will probably remain a legacy conventional part, but similar modern equivalents will be "printed" more and more, rather than machined from solid block. It's a Last Hurrah for conventional machining of really complex parts. But as a showcase of exceptional programming, this is mightily impressive!

[@ignacioaguirrenoguez6218]

Who knows, melting the 10kg of aluminum back into a block takes the same power as boiling 10 liters of water

[@Hydrazine1000]

@@ignacioaguirrenoguez6218 Well, to transition water from liquid to gas takes 2265 kJ per kg. To transition aluminium from solid to liquid takes just shy of 400 kJ per kg. Boiling isn't the same, in terms of transition energy cost, as melting. But melting 10 kg of swarf will, effectively, cost a lot more than just the energy to boil 10 kg of water fully into steam. It's not a very efficient process, with heat energy losses left and right, and due to oxidation, also some material loss. Plus a check, and a correction if needed, on alloy composition.

[@ignacioaguirrenoguez6218]

@@Hydrazine1000 Boiling as in making some tea, not making it gas, which would be several times more energy consuming, I don't think any of the processes are too important when it comes to large scale-aluminum melting energy wise, boiling water also has many losses so comparing it too deeply is highly pedantic. I just mean to illustrate that boiling water as you can do at home, takes a lot of energy too.

[@Hydrazine1000]

@@ignacioaguirrenoguez6218 Fair point, this was pretty pedantic, but I am a metallurgist, so I took it seriously. The whole point though, is that the part shown, with only about 1/40th remaining as actual part, could probably be made actually cheaper by additive manufacturing. Metal powder, suitable for powder bed selective laser melting will cost about 10 times as much, compared to bulk. The "toner" needed for the 8,8 oz part would be 1/4th the cost of the 23 lb billet block. (Well, ok, not entirely true, since 3D printing needs some support structure too.) And if you _are_ going to print, you can create shapes that are near impossible to produce by conventional machining, so you can optimize much more than by going it the oldfashioned way.

[@ignacioaguirrenoguez6218]

​@@Hydrazine1000 Great to agree!. Subtractive manufacturing can be inefficient, but sometimes it's more efficient to use it in the bigger scale, times change and metal additive manufacturing has come a long way, maybe in the future we can see more systems similar to the "DMG Mori Lasertec 65 3d Hybrid" Excuse the lenght of the name, but I recommend searching it up becuse the capabilities it has are amazing. As a metallurgist you will be amazed by the fact that that machine can mix two different metal powders to make some crazy stuff. Greetings!.

[@justindewoody]

What is this part for?

[@zalamachineshop]

All I know is that I didn't need to know.

[@TheFeller1554]

Thats my thought process as well. Only requirements are time and payment.

[@akfarmboy49]

Smart set up Good video thank you

[@zalamachineshop]

Excellent, Thanks for watching.

[@0ssaa]

Great work. I was working on NTX 2000 few years, and now I am programer for NTX (and other) machines. Which software are you using for programing?

[@ipadize]

is it dimensionally in tolerance?

[@crashfactory]

why cut those slots in the sides before finishing the bore? should be waaaaay stiffer, and less chatter from the interrupted cut when the slots are in there.

[@ChikitoPOWA]

Burrs would mess with the tolerance maybe?

[@qualified_monkey8813]

Extruded aluminium has a lot of surface stress in it. If you finish bore your part before removing supporting material, the bore is very likely to distort.

[@zalamachineshop]

That 100% the correct answer. I tried finishing the bore before the slots and after the bore would be out of round .010" or more. Only way it worked was if the finish bore was the absolute last operation before cutoff.

[@crashfactory]

@@zalamachineshop Thanks for the info! Makes sense in hidesight, though i would have tried the bore before the side slots (like you did?) first. The bore sounded chattery/noisy, but the finish looked ok.

[@missingno303]

i culd imagine even the cutoff changed the form a little

[@tommyzgb64]

work of art Nice one 👏🏻👏🏻👏🏻👏🏻

[@alexh6061]

Very Nice Work 😁💪🏻

[@Bigwingrider1800]

WOW....SWEET

[@abdalrohmanmousa7405]

How much does it cost

[@maciejgren3122]

Coś pięknego. Pozdrowienia z Massachusetts !

[@Cowboy-pb3mt]

I would like to see the programming. I do not know how to program these machines. I'm an old machinist now 80 year old

[@mattiasarvidsson8522]

that dovetail was smart.. makes it secure when u dont have much materal to spare.. .. I'm stealing your idea ;)

[@derxKai]

2:46 you wan´t to do this, before you cut the Pockets (2:00). We can clearly hear it ringing the first few millimeters.

[@Donkusdelux]

Beautiful stuff. As a 3axis hand programmer I can only dream of that~

[@zalamachineshop]

I suggest you get into a cam software even for 3 axis. A laptop next to the machine with a copy of Mastercam or whatever will expand your machining horizons.

[@Donkusdelux]

@@zalamachineshop agree completely, tho, it is hard to learn because the shop I work at does not use it.

[@ipadize]

@@Donkusdelux your shop does not use a Cam software or doesnt have one?

[@Donkusdelux]

@@ipadize we have some, but the guys barely know how to use it. And don't seem to want to train anyone how

[@ipadize]

@@Donkusdelux which software do you have?

[@jozekzala835]

Brawo Marcin piękna robota👏👏👍

[@zalamachineshop]

Dzieki wojek dajemy rade.

[@npinson90]

Awesome video, but the spindle bearings in the main sound pretty bad

[@machineworld1873]

You are creazy 😮😮🎉

[@alexd162]

Спасибо, повеселили! Дай Вам Бог здоровья! Удачи - она неизбежна!

[@zalamachineshop]

Спасибо, мой друг. Я надеюсь, что все хорошо с вами и вашей семьей.

[@alexd162]

@@zalamachineshop Я мирный атомщик и судостроитель. С волками не играю и их не выбираю! Быть добру! Всё нормально, нас не сломать!

[@MC_Motors]

Wow. I would have just said ‘yeah, there is no way’

[@zalamachineshop]

That was my first instinct as well, but then when everybody said I couldn't do it I had to do it.

[@ebrewste]

Factional kg and decimal ounces. Nice.

[@ensen89]

I gave you a thumbs down by accident, sorry. Changed it to a thumbs up of course :D

[@itz_lexiii_]

Forging or casting seems immensely easier and cheaper

[@anyah6204]

That’s my uncle 😃

[@MrReichennek]

Skipping all the roughing was unfortunate.

[@adillachgar4513]

☕😎

[@adammiller4879]

That’s a nightmare of a part I don’t think I could take on.would be a good part for additive manufacturing

[@svenkrause3433]

Your customer really needs a better designer...

[@zalamachineshop]

These parts been in service for decades I guess the design has to be what it is.

[@svenkrause3433]

@@zalamachineshop I know...I know such parts and everytime I wonder why the designer did this. Environmently friendly...not really...

[@Grazy1967]

Wahnsinn ;-p

[@antongyrt4814]

Хамут на канализационную трубу готов)