Who would have thought that the "Top 10 most dangerous crashes" ended up being a bunch of minor tool breakages and other generic crashes with very little in the way of actual danger
I have seen others that were way more extreme that these fluff pieces. The biggest expense was all those expensive end mill and maybe some raw material
In my experience I've learned to never ever trust your program on the first run. Always control your speeds and feeds. I've caught myself many times with something that would have been catastrophic. Every video in this tells me it was a first run and no one cared to be cautious. Telling the boss you destroyed the spindle without verifying the first run has gotta really HURT.
So true the program default speeds rarely work out the box so to speak they need tweaking, i think it depends on what grade of material you have and a cheap one means producing well lower quality parts, always check the speeds and never assume as you are to blame if you dont, if unsure ask setter or supervisor 👍👍👍
When I first started, I would do a dry run with no part or tooling, just to get a visual of my feeds and speeds. I went so far as to put my hold downs or vise in play without a part, using a pencil as my tool, just to make sure my rapids wouldn't conflict with items not shown in a program. Maybe I was a bit gun shy, but I caught a lot of mistakes that both the programmers and I made before, you know, destroying a $2k chunk of Elkonite or crashing a $900 tool. Did you see the one with all the hand tools laying on the bed? Yikes!
yea I always run my programs for the first time at 25% rapid after I double check all my tool paths and I make sure everything is going where its supposed to be going with my finger on the feed hold button.
reminds me of a saying that a guy at my shop told me, "don't you hate it when the machine does what you tell it to do, and not what you want it to do?" lmao
@@WonderfulMrWolf No question is 'stupid' if it's likely to save people from making a $100, $1000 or $10,000 mistake... such as not 'clearing the path' for an expensive machine head (as it slams into solid steel and snaps off like a twig, lol). NO basic question takes more than $10-$100 of time. Definitely better to be certain than to go broke making avoidable mistakes.
Reminds me of a guy that was always crashing machines. "That's not what I meant for it to do." (Read real dopey) I'd say " maybe you should have explained it better".
These are mostly due to poor machine programming, too fast of feed rates, not programming proper clearances, or a poor understanding of the forces at play
Yeah the feed rates they are using in some of these videos are shocking. I like the videos with the bad programming, that’s when you let out that “why did I do that” sigh.
Why would the axis even need to be that damn strong to apply such a force to break the damn machine? That is certainly more force than any of the cutting forces that machine would ever face.
20 years ago I worked in a massive machine shop making gas turbine parts. A huge VTL (15'+ wide) was making a pass and something was dramatically wrong. The casting at the top of the cutting arm broke with such a snap that people all the way at the end of the shop heard it. We're talking about a shop that is over 1/8th mile long full of running equipment. That machine was down for months and it took techs flown in from all over the world to fix it.
@Drew K well i work at a company of about 100 and i would say that not one person has not had a crash of some sort. Good machinists do crash but they learn from that crash. For instance we had a crash at work on machining centre ripping a part out of a vice and it turns out the problem was the material not being 100% flat and it creating a pivot point so i find it impossible to belive your statement. I also have a friend who works at red bull formula 1 team in the uk with some of the most highly skilled men available and all the best new machines and even they crash.
Boss: Can't you speed this up any? We're losing our ass on this job! (Ironically, every place I worked for in my 20 year machining career, they seem to have lost their ass on every job that went through the shop but somehow stayed in business. Go figure.) Operator: Sure, how much money you got?
@@Dani2wheels Sounds the manufacturing triangle. fast, cheap and good you only get 2. If you want something cheap and fast it wont be good. If you want something good and fast it aint gonna be cheap.
at my place of work, we turn 16" Ar15 barrel blanks between centers. it is really something when the roughing insert cuts the tailstock's live center right where its making contact with the work piece at 1600 rpm
@@Wulfjager I hear you man. We run AR parts too lol... With lathes it's way scarier because the lathe throws the part. With Mills, they throw the tool. Well, Mills throw parts but not like a lathe. Getting hit by a solid part that's all sharp and half cut is scary as fuck. I've heard stories of guys launching parts almost across the whole shop
@@swickens930 I'm actually now hired at a new shop exclusively on mills. Though I know what you mean when it comes to mills throwing stuff lol. We were running 12x18" sheets of aluminum and the first thing the program does is deck the sheet from .125 to .120 in a vacuum plate. my brainlet coworker stacked the .150 thick aluminum sheets there and ran those. The fly cutter handled it well until it got about halfway through the sheet and launched the thing at the glass; shattered the safety window and managed to ricochet off of the glass and put a dent in the back of the machine. No amount of safety glasses will protect you from _some_ crashes lmao
For 3 days I told my shift supervisor that the chuck in my CNC was not reacting normally. For 3 days he told me it was fine. The 4th day the chuck failed and came loose during cycle and wrecked the machine. I laughed at him then got to sit around for 2 days getting paid while the boss fixed everything that got broken.
You must be a weak as piss employee. Instead of using your brains or balls to man up and fix the problem you waited till it failed putting yourself and others in harms way. Glad I don't work with you.
@@dilligafmofo5921 i completely disagree with your take. He told them about it, he isn’t a certified technician, I’d rather he not touch a machine he knows nothing about and get hurt or wreck the machine. It’s his supervisors fault for not getting it fixed when the problem was brought up. They should have shut the machine down when they found out. Your mentality is what will get people hurt, not someone doing their job and taking the appropriate measures. If anyone got hurt it’s not on the operator, he was told it was fine.
@@knightfall7534 it's more the attitude of passing the buck and then laughing about it. Safety starts with the bloke pushing the buttons on the machine. You need to take responsibility for yourself. I would have tagged the machine out stopped operations on it. No job is worth your life because you wouldn't take appropriate action.
@@dilligafmofo5921 on the other hand the supervisor did tell him to carry on though, as a machine operator he isn’t qualified to say no or know if something is truly wrong or not. If anything that supervisor deserves a talking to because that is no way to treat an employee, clearly he was concerned, and yeah maybe the wording might have made it seem like he didn’t care but really I can see people getting fired for refusing to work like that especially if the supervisor says otherwise. Just another way to think about it, ofc safety starts with the machine operator but ultimately it is the supervisor at fault because he did express his concerns to them and they told him to proceed. I get what you mean though but some people just aren’t qualified to make that call especially if they don’t understand the machines inner workings and are told that it’s normal and to proceed working.
What's so dangerous about that? That's when the end sensors failed, and the 500 kg portal hit the limiters at full speed and flew off the rails... That's when I really got scared.
1:20 Half of these would be avoided if you *proof your program!* First run of a program you should ALWAYS ALWAYS ALWAYS stop the tool before it touches the piece, and check the “to go” distance on the Z axis. Youd be surprised how many thousands of dollars a mistake like these can cost.
It's not necessarily the program in a lot of cases and sometimes just the tool height not set correctly. It's still solid advice though. Generally you don't need to stop your machine but just turn the rapid down(a lot) before you hit the surface. To go is ok but it's also used during rapid movements. Programmed to or equivalent is better.
This video brings back bad memories from my last job as a Mastercam Mill programming engineer. The model shop ran parts overnight unattended. I had a lot of sleepless nights.
@@ssg5598 I’m a CNC Turner myself and until you’ve had a decent size steel billet come flying out your jaws at over 1k rpm you don’t know what a heart attack is🤣. Abs as long as the doors were closed none of these could really harm anyone. Just fuck up the tool and maybe knock the alignment out, or possible shag the spindle
I was taught to G0 in Z at first to clear ALL obstacles (if possible). The 0,2s it takes longer may add up in 100 or more parts. But that is cheaper than crashing once.
@@Man_Emperor_of_Mankind I was told (example): Z0 surface of the part. Milling dept Z-10; G0 Z150, G0 X(start position) Y(start position), G0 Z2, G1 Z-10, (G1/G3, etc...), G1 Z2, G0 Z150, (from there to tool change ..., etc). That was the easiest and safest way to clear all obstacles (like clamps ..., etc) even when we were milling between or outside the obstacles. However, we soon improved that to just measure the actual height of the obstacles (for example Z30) and added like 20mm in Z. To clear the milled surfaces we started to retract one mm in each direction (X0 Z-10 →X1 Z-9) in G1 and then G0 to Z2. The new machines are that fast in G0 that there is basically no difference if you G0 Z2 or G0 Z50. I mean there is, but you waste more time scratching your balls while changing the workpiece. However, that works very well when you are working three axis. As soon as you start in four or five you have to do all kinds of weird things that you are better of just using what is given from the control system.
@@lifepolicy Okay, so if I understand you correctly, you're talking about keeping Z way up above the part, rapiding to the X/Y approach position, rapiding Z down to a little of the part, and then start feeding down for the cut? That's pretty similar to how I was first taught, and is what I try to teach my students to do. If you're not going to cut something, keeping the spindle way up and out of the way is the safest thing to do. Funny enough I have to do the same thing with the 7 axis Mazak Integrexs that I run, except it's the X axis that needs kept clear. They have dual chucks (headstock and tailstock sides), which are and amazing feature, but if you don't keep X out of the way it's very easy to back the spindle into the tailstock side chuck
@@Man_Emperor_of_Mankind Correct. I just ignored that procedure when I was on a mill where rapid was annoyingly slow and I had to do more than one part and knew the path was cleared. However, I worked once on a CNC lathe where I produced a few parts, and then the machine decided to do a tool change while the tool was still cutting. So yes sometimes you can do everything right and still have a crash.
most of the time it is poor programming. and the feed rates all seemed very possible ngl where i work the drills almost shoot into the part just depends on how you write the programm
poor programming is one part, but wtf are this machinists doing?! I worked for a special steel company and every new program you drive only in safety mode for the first part. They go full power without thinking. Often i think by the broken drills and mills they took the wrong lenght for milling.
I find it hilarious when you can hear the tool failing as it’s cutting but no one hits the stop. I also laugh like a child when the chuck and drawbar crash, who tf is in charge of these multimillion dollar machines? Lmfao
I'm not a machinist, but even I know that most of these are probably due to operator error or stressed tools (probably stressed when the operator made it go faster/deeper than designed to).
If you maintain your machine properly, absolutely 0% of it is machine error. lol I've never had a machine breakdown, but I've definitely made my share of F'ups
That third one just hurt to watch... that was 100% avoidable. That material chipping off of the table like that should've warranted the good ol E-stop button.
I was a CNC Field Service Engineer for 30 years, now retired. Unless you see a spindle bearing come flying out of the end of the motor or a broken way bearing flying apart that really isn't a dangerous crash. Most of these just require a tool change and an adjustment of the CNC program. I have seen crashes that took me weeks to fix. Now if you can get an end mill to crash so hard it comes through the bullet proof glass on the door then it is dangerous. CNC coders that don't know what they are doing kept me employed for 30 years.
Nah.... I mean beginners that stuff, but so do the guys who have been machining for a long time. All it takes is one decimal or forgetting one offset, and then confidence telling you that everything is good to go
In my experience a lot of programmers and CNC machinists just drifted into the roles and have no formal qualifications in the field. Combine that with management not providing any training it's no surprise there are problems. As you can see there's a lot more to it than watching a cursor following lines on a computer or just clamping a workpiece and hitting cycle start! i've seen guys just standing there waiting for the machine to finish cutting a test piece to prove a setup and their hand is nowhere near a stop button.
Though some speeds/feeds/tool paths might have been wrong/miscalculated, I didn’t see anybody using coolant to prevent thermal expansion. Just plain air blast doesn’t do enough cooling from what I’ve experienced. When tools and work pieces heat up, nothing good comes of that.
Must be careful though, some materials and cutter combos need to be run without coolant. Intermittent cold coolant on a cut can lead to thermal shock and premature tool wear, as well as uneven surfacing. Cast iron comes to mind.
First week of my apprenticeship the guy said I'm gonna have a smoke just watch this if anything bad happens hit stop immediately. He didn't measure the depth of the 3/16 drill and that snapped but it was so quiet I couldn't hear it. Then the spindle smashed right into the side of the part fucking everything up. I didn't get blamed though. Costed like 2k in repairs.
I've been researching these devices, and am very tempted to get an entry level one next year. I really appreciate videos like these, as they'll make me that much more cautious. Thank you!
Right! A large VTL chucking something that wasn't clamped securely, makes everything in the video look like a joke. Or large OD grinders, 54in×4in wheels spinning at 700rpm, is like a grenade going off if the wheel lets go (I've had the honor of seeing the results of a bad run of large grinding wheels. First time operator error was assumed, second time the mounting of the wheel was thoroughly monitored and documented but still let go upon first time being spun up. The remaining 2 wheels from the batch were sent back, and the manufacturer admitted that there was a bonding issue)
Oh, as an old CNC machinist, you eventually learn (or try to run when nobody is watching) slower, safer speeds and NOT the tool holder literature/boss speeds' that are absolutely, insanely fast to SELL the machines'/ tool holders' in the first place....
Right? A couple of those aluminum parts I could see right away that the flutes would get clogged up and snap the cutter. Not enough coolant, too high RPM. No substitute for experience.
Dangerous? Most of these are just general dumbassery. I can't understand why people don't check the setup and sim stuff out better to double check. Also why are you running high rapids on setup/ first run parts. Prove it out folks.
We've all done it. The important thing is being able to learn from it so you dont do the same thing and laugh it off. Dwelling on it does nothing but cause you to make more mistakes.
@@AbeDorf18 , lol so true. I guess my point was that I don't think the average person watching this understands the costs for some of these mistakes. Cheers
I don't know why I clicked on this. A tool crash for me is worse than a punch in the gut. The Tormach one really hit home as I've had pullout and buried an endmill in the table before on mine
This gave me ADHD. I spent 2 and a half years working CNC machines Making helicopter parts and helmets. I remember driving the entire spindle into our jig. After that I didn't care how slow I was. I always made sure to watch what program and part was being cut.
Haha just had a drill break in a high speed machining center today, my coworker and I were chatting and we started hearing (and feeling) this bassy rumbling from one of the machines
If you ever hear a nested base cnc with a collet poorly grabbed, you'll never forget the sound of a lopsided chuck going 18k rpm. The whole facility will think a helicopter is crashing.
I only ran a CNC for 8mos, but we did a first run at 50% speed and finger on the Stop button to avoid crashes. Never had a crash After a few bit or end mill breaks while on lunch, I added tool length checks as needed
I run a full simulation on all G-code before it even goes to the machine. And then do a touchoff before cutting so the machine knows what Z0.0000 really/actually is in space.
@@OddlyIncredible Yah, we’d have the part in the clamps and then zero it out off wherever it’s supposed to be zeroed, be it the soft clamp or the part itself depending (rough cutting was off the clamp, finish details were off the part... most times)
Maybe someone will invent “backplot”. Anything involving computers, will eventually increase your stress-related vocabulary skills. I watch these, and flinch while smiling.
![Eminem - Fuel (feat. JID) [Official Lyric Video]](http://i.ytimg.com/vi/t5H_CewqpKA/mqdefault.jpg)
Gcode like: HaHa! U missed a decimal! Now i willdrive this spinny thing right into the center of the universe.
Or:
Haha do you remember the letter Z? You don’t?
Well F U then, now I will shatter the tool
Some operators never heard of the "dry run" function. Just put the end mill in and let her rip!
"Oh east?? I thought you said weast"
So true
14 inches? No 14 thousands. Dumb asf how that works. Learned that the hard way.
Who would have thought that the "Top 10 most dangerous crashes" ended up being a bunch of minor tool breakages and other generic crashes with very little in the way of actual danger
Yeah not sure WTF all the praise is in the comments. Pretty weak crash compilation.
Still hurts to watch! This is why most of them still only make $16/hr. lol
And ontop of that almost all of the fails are in a polycarbonate box
Some idiot looking for views.
I have seen others that were way more extreme that these fluff pieces. The biggest expense was all those expensive end mill and maybe some raw material
In my experience I've learned to never ever trust your program on the first run. Always control your speeds and feeds. I've caught myself many times with something that would have been catastrophic. Every video in this tells me it was a first run and no one cared to be cautious. Telling the boss you destroyed the spindle without verifying the first run has gotta really HURT.
I see ..
So true the program default speeds rarely work out the box so to speak they need tweaking, i think it depends on what grade of material you have and a cheap one means producing well lower quality parts, always check the speeds and never assume as you are to blame if you dont, if unsure ask setter or supervisor 👍👍👍
When I first started, I would do a dry run with no part or tooling, just to get a visual of my feeds and speeds. I went so far as to put my hold downs or vise in play without a part, using a pencil as my tool, just to make sure my rapids wouldn't conflict with items not shown in a program. Maybe I was a bit gun shy, but I caught a lot of mistakes that both the programmers and I made before, you know, destroying a $2k chunk of Elkonite or crashing a $900 tool. Did you see the one with all the hand tools laying on the bed? Yikes!
yea I always run my programs for the first time at 25% rapid after I double check all my tool paths and I make sure everything is going where its supposed to be going with my finger on the feed hold button.
1. Expectation of this video: Stolen video of crashes from 10 years ago
2. clicks anyways
3. Result: Expectations met 10/10
yeah
Could even see that he had mirrored some of the clips to avoid getting caught.
dont forget the shitty loud intro and outro music , that's the cherry on top
reminds me of a saying that a guy at my shop told me, "don't you hate it when the machine does what you tell it to do, and not what you want it to do?" lmao
THIS... is exactly why extremely advanced A.I. is very, very, very dangerous.
Exciting, yes. Important to adopt, probably. Dangerous? *Extremely*. 😕
As a machinist apprentice I was told, "I'd rather answer your stupid question than fix your stupid mistake." That stuck with me.
Kind of like learning how to bend conduit…. Bender does exactly what you make it do, not necessarily what u want it to.
@@WonderfulMrWolf No question is 'stupid' if it's likely to save people from making a $100, $1000 or $10,000 mistake... such as not 'clearing the path' for an expensive machine head (as it slams into solid steel and snaps off like a twig, lol).
NO basic question takes more than $10-$100 of time. Definitely better to be certain than to go broke making avoidable mistakes.
Reminds me of a guy that was always crashing machines. "That's not what I meant for it to do." (Read real dopey) I'd say " maybe you should have explained it better".
These are mostly due to poor machine programming, too fast of feed rates, not programming proper clearances, or a poor understanding of the forces at play
Are you sure?
Basically 100% user error.
no shit dumb ass. machines dont crash. operators do.
Yeah the feed rates they are using in some of these videos are shocking. I like the videos with the bad programming, that’s when you let out that “why did I do that” sigh.
@@arsonarson8364 every time. When it plunges at like 2in/sec and the feed rate is about the same, it hurts to watch but I have to!!! lol
1:20 When that happens, it's not just replacing a tool or scrapping a part. The whole spindle has to be aligned and maybe replaced. That is scary.
Spindles prb not to happy at 3:25 aswell.
@@TheRealMasshole I WOULD AGREE
Why would the axis even need to be that damn strong to apply such a force to break the damn machine? That is certainly more force than any of the cutting forces that machine would ever face.
@@warwolf6862 Dynamic load due to changing of direction during rapid movements is the reason!
the one immediately after that too! Holy crap!!!!! What are these people tinking? lol
20 years ago I worked in a massive machine shop making gas turbine parts. A huge VTL (15'+ wide) was making a pass and something was dramatically wrong. The casting at the top of the cutting arm broke with such a snap that people all the way at the end of the shop heard it. We're talking about a shop that is over 1/8th mile long full of running equipment. That machine was down for months and it took techs flown in from all over the world to fix it.
Scary also interesting
some crashes cause mini earthquakes
And bankers from all over the country to write the checks.
I've made those errors before too, but not doing them again is the key to keeping your job.
1:35 was pretty atrocious, that spindle head probably just took some serious damage and will more than likely need to be heavily repaired or replaced.
I felt the machines pain.
Oh that poor, poor machine head.
As someone who works with these machines on a daily basis it hurts as much as getting hit in the balls with a sledge hammer
@Drew K probably because your making simple parts and all programing done on line.
Its so so easy to say 01 instead of.01.
Now that, i'd like to see
@Drew K well i work at a company of about 100 and i would say that not one person has not had a crash of some sort.
Good machinists do crash but they learn from that crash.
For instance we had a crash at work on machining centre ripping a part out of a vice and it turns out the problem was the material not being 100% flat and it creating a pivot point so i find it impossible to belive your statement.
I also have a friend who works at red bull formula 1 team in the uk with some of the most highly skilled men available and all the best new machines and even they crash.
@Drew K or more likely your more deluded.
@Drew K well if your talent pool is anything like your lame arse machines Hass we no your statements are false.
Boss: Can't you speed this up any? We're losing our ass on this job! (Ironically, every place I worked for in my 20 year machining career, they seem to have lost their ass on every job that went through the shop but somehow stayed in business. Go figure.)
Operator: Sure, how much money you got?
As a welder/fabricator I always say "quick or quality, pick one"
QUALITY AT TOP PRIORITY!
@@HighAway but make it damn faster
@@JTKK9 patience is virtue.
@@Dani2wheels Sounds the manufacturing triangle. fast, cheap and good you only get 2. If you want something cheap and fast it wont be good. If you want something good and fast it aint gonna be cheap.
As a machinist for 15 years none of these would be on my list for dangerous or high risk.
as a 3 year machinist I seen more dangerous machine crash and part holding fail
it's always so hard for me to understand why someone would run an unproven program at 100% rapid
ignorance is reckless
Now if you want some dangerous fails,
_LATHES_ are where it's at
at my place of work, we turn 16" Ar15 barrel blanks between centers. it is really something when the roughing insert cuts the tailstock's live center right where its making contact with the work piece at 1600 rpm
I used to run lathes back in the day. I actually prefer then to the mills.
@@Wulfjager I hear you man. We run AR parts too lol... With lathes it's way scarier because the lathe throws the part. With Mills, they throw the tool. Well, Mills throw parts but not like a lathe. Getting hit by a solid part that's all sharp and half cut is scary as fuck. I've heard stories of guys launching parts almost across the whole shop
@@swickens930 I'm actually now hired at a new shop exclusively on mills. Though I know what you mean when it comes to mills throwing stuff lol. We were running 12x18" sheets of aluminum and the first thing the program does is deck the sheet from .125 to .120 in a vacuum plate. my brainlet coworker stacked the .150 thick aluminum sheets there and ran those. The fly cutter handled it well until it got about halfway through the sheet and launched the thing at the glass; shattered the safety window and managed to ricochet off of the glass and put a dent in the back of the machine. No amount of safety glasses will protect you from _some_ crashes lmao
@@Wulfjager right especially on like, an open lathe lol. Throw something so far and you'll probably be close to being in it's way
I own a small CNC and looking at these situations I feel like real body pain.
For 3 days I told my shift supervisor that the chuck in my CNC was not reacting normally. For 3 days he told me it was fine. The 4th day the chuck failed and came loose during cycle and wrecked the machine. I laughed at him then got to sit around for 2 days getting paid while the boss fixed everything that got broken.
You must be a weak as piss employee. Instead of using your brains or balls to man up and fix the problem you waited till it failed putting yourself and others in harms way. Glad I don't work with you.
@@dilligafmofo5921 EXACTLY... people like this Captain WasteOfOxygen guy- far too many.
@@dilligafmofo5921 i completely disagree with your take. He told them about it, he isn’t a certified technician, I’d rather he not touch a machine he knows nothing about and get hurt or wreck the machine. It’s his supervisors fault for not getting it fixed when the problem was brought up. They should have shut the machine down when they found out. Your mentality is what will get people hurt, not someone doing their job and taking the appropriate measures. If anyone got hurt it’s not on the operator, he was told it was fine.
@@knightfall7534 it's more the attitude of passing the buck and then laughing about it. Safety starts with the bloke pushing the buttons on the machine. You need to take responsibility for yourself. I would have tagged the machine out stopped operations on it. No job is worth your life because you wouldn't take appropriate action.
@@dilligafmofo5921 on the other hand the supervisor did tell him to carry on though, as a machine operator he isn’t qualified to say no or know if something is truly wrong or not. If anything that supervisor deserves a talking to because that is no way to treat an employee, clearly he was concerned, and yeah maybe the wording might have made it seem like he didn’t care but really I can see people getting fired for refusing to work like that especially if the supervisor says otherwise. Just another way to think about it, ofc safety starts with the machine operator but ultimately it is the supervisor at fault because he did express his concerns to them and they told him to proceed. I get what you mean though but some people just aren’t qualified to make that call especially if they don’t understand the machines inner workings and are told that it’s normal and to proceed working.
I can't watch this , it hurts too much .
I'm hurt too
What's so dangerous about that?
That's when the end sensors failed, and the 500 kg portal hit the limiters at full speed and flew off the rails...
That's when I really got scared.
1:20 Half of these would be avoided if you *proof your program!* First run of a program you should ALWAYS ALWAYS ALWAYS stop the tool before it touches the piece, and check the “to go” distance on the Z axis. Youd be surprised how many thousands of dollars a mistake like these can cost.
It's not necessarily the program in a lot of cases and sometimes just the tool height not set correctly. It's still solid advice though. Generally you don't need to stop your machine but just turn the rapid down(a lot) before you hit the surface. To go is ok but it's also used during rapid movements. Programmed to or equivalent is better.
Amen to that 👍
Bro the one at 1:50 got me enraged asf like thats a moving part that can take your fingers off. Don't put your hand in there when its running. 💀
Doesn't stop the operator from entering -.3 instead of -.003
I left programming 16 years ago still while watching this video feeling scared as I use to do that time while running my program on machine
What did you leave programming for?
Most of them don't predict their linear movements and go too fast with G00.
most likely they did not set correct safety height because of nuts or other thing in workpiece
@@uknownperson5549 Also could be this one.
There's a universal special term used worldwide if this happens: "F*CK!" 🤣
This video brings back bad memories from my last job as a Mastercam Mill programming engineer. The model shop ran parts overnight unattended. I had a lot of sleepless nights.
Good thing you gave up on living in danger :)
“Dangerous” yeah ok🙃
So you are saying it's not?
Those guys have another definition for dangerous😂
@@ssg5598 I’m a CNC Turner myself and until you’ve had a decent size steel billet come flying out your jaws at over 1k rpm you don’t know what a heart attack is🤣. Abs as long as the doors were closed none of these could really harm anyone. Just fuck up the tool and maybe knock the alignment out, or possible shag the spindle
It's just a clickbaity stolen clips flipping them left right vid
Most of these have the potential to be very dangerous if someone is around while the machine is at work
I was taught to G0 in Z at first to clear ALL obstacles (if possible). The 0,2s it takes longer may add up in 100 or more parts. But that is cheaper than crashing once.
You mean G01?
@@Man_Emperor_of_Mankind I was told (example): Z0 surface of the part. Milling dept Z-10; G0 Z150, G0 X(start position) Y(start position), G0 Z2, G1 Z-10, (G1/G3, etc...), G1 Z2, G0 Z150, (from there to tool change ..., etc). That was the easiest and safest way to clear all obstacles (like clamps ..., etc) even when we were milling between or outside the obstacles. However, we soon improved that to just measure the actual height of the obstacles (for example Z30) and added like 20mm in Z. To clear the milled surfaces we started to retract one mm in each direction (X0 Z-10 →X1 Z-9) in G1 and then G0 to Z2. The new machines are that fast in G0 that there is basically no difference if you G0 Z2 or G0 Z50. I mean there is, but you waste more time scratching your balls while changing the workpiece.
However, that works very well when you are working three axis. As soon as you start in four or five you have to do all kinds of weird things that you are better of just using what is given from the control system.
@@lifepolicy
Okay, so if I understand you correctly, you're talking about keeping Z way up above the part, rapiding to the X/Y approach position, rapiding Z down to a little of the part, and then start feeding down for the cut?
That's pretty similar to how I was first taught, and is what I try to teach my students to do. If you're not going to cut something, keeping the spindle way up and out of the way is the safest thing to do.
Funny enough I have to do the same thing with the 7 axis Mazak Integrexs that I run, except it's the X axis that needs kept clear. They have dual chucks (headstock and tailstock sides), which are and amazing feature, but if you don't keep X out of the way it's very easy to back the spindle into the tailstock side chuck
@@Man_Emperor_of_Mankind Correct. I just ignored that procedure when I was on a mill where rapid was annoyingly slow and I had to do more than one part and knew the path was cleared.
However, I worked once on a CNC lathe where I produced a few parts, and then the machine decided to do a tool change while the tool was still cutting. So yes sometimes you can do everything right and still have a crash.
It's a similar situation with engines.
"How much horsepower can it make?"
"It depends: how long do you want it to run?"
I'm no machinist but...a lot of these feed rates looked way too aggressive....like retardedly aggressive. Not even crashes, just poor programming.
most of the time it is poor programming. and the feed rates all seemed very possible ngl where i work the drills almost shoot into the part just depends on how you write the programm
poor programming is one part, but wtf are this machinists doing?! I worked for a special steel company and every new program you drive only in safety mode for the first part. They go full power without thinking. Often i think by the broken drills and mills they took the wrong lenght for milling.
But the operator has always the power to reduce the feed rates manually. It is also his job to be cautious with the feed rates.
I find it hilarious when you can hear the tool failing as it’s cutting but no one hits the stop. I also laugh like a child when the chuck and drawbar crash, who tf is in charge of these multimillion dollar machines? Lmfao
I'm not a machinist, but even I know that most of these are probably due to operator error or stressed tools (probably stressed when the operator made it go faster/deeper than designed to).
If you maintain your machine properly, absolutely 0% of it is machine error. lol I've never had a machine breakdown, but I've definitely made my share of F'ups
The machine does exactly what YOU as in the operator tell it to do, so yes the machine is rarely if ever at fault
When programmers have never machined or when operators have never programmed.
"Machine has no brain, use your own".
That third one just hurt to watch... that was 100% avoidable. That material chipping off of the table like that should've warranted the good ol E-stop button.
Someone who doesn't make mistakes is someone who doesn't make anything
I was a CNC Field Service Engineer for 30 years, now retired. Unless you see a spindle bearing come flying out of the end of the motor or a broken way bearing flying apart that really isn't a dangerous crash. Most of these just require a tool change and an adjustment of the CNC program. I have seen crashes that took me weeks to fix. Now if you can get an end mill to crash so hard it comes through the bullet proof glass on the door then it is dangerous. CNC coders that don't know what they are doing kept me employed for 30 years.
Some of these guys fails come off like they never touched a mechine before. Droping the spindle through your stock is just madness.
Top 10 dangerous CNC fails
Lathes: amateurs *pulls man in by the sleeve*
Most of them seems like beginner mistakes😂
Nah.... I mean beginners that stuff, but so do the guys who have been machining for a long time.
All it takes is one decimal or forgetting one offset, and then confidence telling you that everything is good to go
@@Man_Emperor_of_Mankind your right its is so so easy to miss a decimal point.
Most of this are avoidable if you use the failsafes, and always add the supports/bolts/fixtures. You only need to design the fixtures once
Complètement d accord toujours faire attention pour la 1ere pièce aux approche outils et d anticiper les déplacements dans le programme en cours
I realized I've never seen one of these machines fuck up, it's just as satisfying as I hoped.
Thinking to myself after hitting the GO button, "That was metric, right? Or was it imperial?"
Remember, s rocket launch failure occurred a few years back because of a data mixup between imperial & metric , big money burned up.
Looking after drill bits seems to be an art
In my experience a lot of programmers and CNC machinists just drifted into the roles and have no formal qualifications in the field. Combine that with management not providing any training it's no surprise there are problems.
As you can see there's a lot more to it than watching a cursor following lines on a computer or just clamping a workpiece and hitting cycle start! i've seen guys just standing there waiting for the machine to finish cutting a test piece to prove a setup and their hand is nowhere near a stop button.
Though some speeds/feeds/tool paths might have been wrong/miscalculated, I didn’t see anybody using coolant to prevent thermal expansion.
Just plain air blast doesn’t do enough cooling from what I’ve experienced.
When tools and work pieces heat up, nothing good comes of that.
Must be careful though, some materials and cutter combos need to be run without coolant. Intermittent cold coolant on a cut can lead to thermal shock and premature tool wear, as well as uneven surfacing. Cast iron comes to mind.
@@Nathiuz interesting. Thank you for the knowledge. I’m used to materials such as A2, S7, D2, 8620, 4140 etc.
0:31 that one made my laugh a lot lol
First week of my apprenticeship the guy said I'm gonna have a smoke just watch this if anything bad happens hit stop immediately. He didn't measure the depth of the 3/16 drill and that snapped but it was so quiet I couldn't hear it. Then the spindle smashed right into the side of the part fucking everything up. I didn't get blamed though. Costed like 2k in repairs.
I've been researching these devices, and am very tempted to get an entry level one next year.
I really appreciate videos like these, as they'll make me that much more cautious. Thank you!
Good luck. I have a 3d printer, it's already a learning curve, but this is something else.
@@pierrex3226 Somewhat familiar with computer code. I've also thought about 3D printers. If only to help out my family members that want one.
To save you time and money, maybe lookinto creality ender 5 printing at .6mm.
CNC: wanna see me make this drill bit disappear? Wanna see me do it again?
That's why you always see the CNC guys with their forehead against the door and their thumb on the stop button.😂
You mean the "Oh Shit" button.
As we say at work "white knuckling the chicken switch.
@@triumphdave2449 😂
So you just reposted an old video, mirrored?
That's low.
Shop manager - what plunger depth did you set it at ?
Guys last day at work - Yes
Honestly, how quickly would they fire you over mistakes like this? I don't know how the field works.
@@BuzzingGoober probably not that quick but if you did it again then I bet you're out the door
@@BuzzingGoober Depends who loses an eye or hand I suppose :)
The good thing is: You will know fast that you've chose the wrong program. The last fail was the best. Couldn't see shit cause of all the symbols XD
Top 10 where? When?
Boss: "we're starting to lose money on this job, could u speed it up a little?"
Operator: "sure, how much more money would u like to lose?"
This makes machining look safe, where are the parts flying through buildings?
Right!
A large VTL chucking something that wasn't clamped securely, makes everything in the video look like a joke.
Or large OD grinders, 54in×4in wheels spinning at 700rpm, is like a grenade going off if the wheel lets go (I've had the honor of seeing the results of a bad run of large grinding wheels. First time operator error was assumed, second time the mounting of the wheel was thoroughly monitored and documented but still let go upon first time being spun up. The remaining 2 wheels from the batch were sent back, and the manufacturer admitted that there was a bonding issue)
Alles bloß kopierte und gespiegelt
I do not have the patience cnc machining, I wish I could switch back to manual 🙁
Oh, as an old CNC machinist, you eventually learn (or try to run when nobody is watching) slower, safer speeds and NOT the tool holder literature/boss speeds' that are absolutely, insanely fast to SELL the machines'/ tool holders' in the first place....
Right? A couple of those aluminum parts I could see right away that the flutes would get clogged up and snap the cutter. Not enough coolant, too high RPM.
No substitute for experience.
1:34 goddamn dude.
I had to grab my safety glasses to watch this...
Dangerous? Most of these are just general dumbassery. I can't understand why people don't check the setup and sim stuff out better to double check. Also why are you running high rapids on setup/ first run parts. Prove it out folks.
single block
and no 📷
Expecially doing vids when you're running the program for the First Time and going full Rapids
& distance to go, basic stuff really.
As someone with a basic mill with no computer this makes me feel good. Yes I have had minor stuff ups and damaged a tool or part. But not like this.
Typically
Machines don’t fail unless you tell them to fail
We've all done it. The important thing is being able to learn from it so you dont do the same thing and laugh it off. Dwelling on it does nothing but cause you to make more mistakes.
this is my mentality as well, i love our profession
Some of them looks staged for video
As a programmer, I watch videos like these to remind me that my programs can always be better, but they aren‘t this bad😂
It would be nice to see a "failure price tag" on all of these.
That would be a monumental pain in the ass to source
@@AbeDorf18 , lol so true. I guess my point was that I don't think the average person watching this understands the costs for some of these mistakes. Cheers
Screw all these pompous jerks. Nice job! Thanks for the laughs!
These happen weekly at machine shops, still good job making the video
more like 'Top 10 Mildly Annoying CNC Crash Fail Compilation'
I don't know why I clicked on this. A tool crash for me is worse than a punch in the gut. The Tormach one really hit home as I've had pullout and buried an endmill in the table before on mine
Props to those guys who broke the probe though. That cycle requires balls of steel.
New program = one hand on federate and the other on stop lol
This gave me ADHD. I spent 2 and a half years working CNC machines Making helicopter parts and helmets. I remember driving the entire spindle into our jig. After that I didn't care how slow I was. I always made sure to watch what program and part was being cut.
You clearly just stole these clips from another channel and just reversed the video. Reported.
Legend has there are still people waiting for the dangerous part
i mean the ones that just broke the tool got away relatively scot free given how much the machine costs
Haha just had a drill break in a high speed machining center today, my coworker and I were chatting and we started hearing (and feeling) this bassy rumbling from one of the machines
My home made CNC catapulted itself into the wall yesterday. Way more terrifying that those tool breakage!
Half of these have so much feed it could end world hunger.
If very "F" bomb was a drop and all the "F" were collected soon after these fails.....you'd have a new ocean
If you ever hear a nested base cnc with a collet poorly grabbed, you'll never forget the sound of a lopsided chuck going 18k rpm. The whole facility will think a helicopter is crashing.
All those drills in the end are thousands , some machines can switch between up to 20 of them automatically
2 inches in the chuck, 10 inches sticking out. Not tailstock or steady rest. What could go wrong?
The CNC machine is never wrong, only the person imputing the program is.
1:09 I laughed way to hard at this simple mistake....
*calls machine supplier “the machine just stopped, nah no idea why”
1:15 had me laughing lol
Where's the coolant in 100% of those videos? Lmfao
I only ran a CNC for 8mos, but we did a first run at 50% speed and finger on the Stop button to avoid crashes. Never had a crash
After a few bit or end mill breaks while on lunch, I added tool length checks as needed
I run a full simulation on all G-code before it even goes to the machine. And then do a touchoff before cutting so the machine knows what Z0.0000 really/actually is in space.
@@OddlyIncredible Yah, we’d have the part in the clamps and then zero it out off wherever it’s supposed to be zeroed, be it the soft clamp or the part itself depending (rough cutting was off the clamp, finish details were off the part... most times)
Very funny fails ! This what happens when you give machines to amateurs.
Very funny CNC machines still scare me it's terrifying actually running one
I thought I wanted to see this, but it turns out I didn't.
I like how they mirror other peoples videos to avoid copyright strikes. It's not like we can see the text or anything lol
Maybe someone will invent “backplot”. Anything involving computers, will eventually increase your stress-related vocabulary skills. I watch these, and flinch while smiling.
"How high do you want the feed rate to be?"
-"YESSSS!"
That last one is why my instructor always says “RIGIDITY. ALWAYS HAVE RIGIDITY” that’s like his gospel
glad to know I'm not the only on e with a learning curve!
Wow... echte Profis bei der Arbeit
The one that gets me is the clown that sticks his damn hand in to adjust the coolant hose (which is giving no coolant) while the thing is running :\
Came in to say this. Step one should always be "turn off the machine". Thank you Mr. Overstreet!
Sometimes they run air, it blows the chips away and cools the cutter.
I was a machinist many moons ago. This vid caused me real pain, made jump and exclaim a couple times.