Machining Weld Test Coupons for the Local Technical College - Machining 8 Foot Long Bars of Steel
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- Опубликовано: 27 сен 2024
- Some jobs are just taken to help out others. This job is for the local technical college weld program. We are machining the Weld Coupons for them to do their weld certifications on.
I mill these ever couple months, and it has been easier and cheaper to mill 8 feet at a time. They can cut them to the lengths they want, so it's a win for both of us.
Doing jobs like these are definitely not profitable but are good for the local communities and for furthering people's education. I don't do this for the money, but to help out where needed. My hope is that some skilled welders will come out of this program with the knowledge and desire to make this a lifelong career.
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A lot of people questioned the angle used, no root depth left and some the alignment(grain) of the material. As Josh has indicated he did what the TAFE teachers asked him to do. If anyone wants to question the TAFE instructors who are all fully qualified pressure ticket welders, they should refer their questions to the TAFE and not Josh. All these TAFE teachers have taught this for a year or two and their previous students have met the industry requirements. So leave Josh alone.
Bob, why are you beating me up with your comments ?
Maybe read again my comment on grain direction, yes, I understand Josh preformed the material as directed by the customer, The customer got what they wanted.
Is it the best use of material ? My experience of 25 years in the welding field says it is not....
As far as your comment regarding angle and root depth, the angle is determined by the weld procedure[ also known as [WPS] and the land [not root depth] can also be dictated by WPS and weldor preference and the type of weld being done [SMAW, GMAW,GTAW]......
My comment was not to 'BASH' Josh, but to point out something that in my experience had caused major issues with doing bend tests. Maybe they are only doing X-Ray tests and grain direction will have no effect......
No reason to turn Josh's wonderful channel into a congressional hearing argumentative zone......
Cordially, Paul Brown
@@ypaulbrown You have agreed that Josh did what the customer specified. You and many others have issue with what the customer (TAFE) specified. The qualified instructors , who have been teaching this stuff for many years would have very good reason(s) for specifying what they did. Instead of questioning the messenger (Josh), have you (or any others) sent an email to these same TAFE instructors with your concerns.
Hi Josh. I started machining in back in 1976. I've spent most of my career in screw machine work, but I have also done a huge amount of manual stuff. In 1990, I opened a small screw machine and turret lathe job shop. When people used to talk crap to me about how I set up a machine, I'd tell them to go buy them a machine and set it up their way.
I've never believed that my way is the only way, so I guess that's why I enjoy watching videos like this.
We can't learn effectively if we don't have an open mind to others' ideas. I truly enjoy the content you provide. Keep up the great work. I'm looking forward to your next video.
Thanks. You're right about setups, there are many ways to do it, they might all work, but I do it how I want and get the job done.
Hey Josh, thanks for helping out the tech school. I’m 54 and I signed up to learn welding at my local tech school in January. It seems kids today did not have shop class growing up (both boys and girls). Someone convinced our schools to auction off the shop equipment and send the kids to “college” and now our shipyards and fabrication shops are struggling to fill jobs. Here I thought I was going to school to learn welding and I’m in welding class trying to explain how a tape measure works (fractions of an inch) to a bus full of students who “graduated” during covid. Our country is in trouble as a generation of highly skilled workers gets ready to retire and will not be replaced by the next generation.
I agree 100%. I have trade school student apprenticing in my shop. This person didn’t know how to read fractions on a ruler, could not determine how many feet in a mile, can not convert fractions to decimals (and visa versa), can not find the correct open end wrench for a bolt without trying several at random - AND is getting As and Bs in the trade school.
My last apprentice was the same way. Bitt, after 2 1/2 years with me he is now a lead mechanic at Lockheed Martin building F16s. I am proud of the skills he developed in my shop.
I taught Aviation Mechanics in a local school and the students were definitely not prepared for it. Ten percent were good and forty percent were not interested in learning. It’s a different world from when I was in school but 😢
Sure better than hand grinding all that material off ! Surprised the instructor makes it so easy on the students. Back when I was in school they gladly would have let us spend 3 days prepping a weld before ever striking an arc.
I agree with you on this Josh, machines are tools. My dad always told me "take care of your tools and they will take care of you." However, he also taught me that tools are also a consumable and you aren't going to make any money by saving them for the next guy. Sometimes that means modifying or using them in creative ways to get the job done.
If extending the quill was so bad, why does a Bridgeport have a quill at all? Oh yeah, to do things you couldn't if you didn't have a quill!
Thank you for inviting us into your shop for a bit. Even those of us who offer our two cents, when it was not asked for. It is always enjoyable to watch your thought process. 😊
That's right!😂😂😂
I'm absolutely amazed at the longevity of the end mill. The air gun is working very VERY well! I'm so sick of tending the sump on the flood coolant tank that I pretty much gave up, and machine dry these days. Tramp oil, and the presence of bacteria, is a killer with flood coolant.........not to mention the mess.
I don't see a problem with extending the quill. If the machine is rigid enough, it's not an issue.
I’ve never seen a machine like that. I gather from the comments that the Bridgeport head is a modification - if so, congrats on your ingenuity. Great to see you getting work for it after your trouble building it.
Great old school machine shop videos are getting harder to find. I enjoy your stuff sir.
It's always interesting how the folks not writing the checks have all the advice.
In our local school you cut your coupons off the bar stock with a hacksaw and angle the ends on a grinder. What you’ve done given the application is beyond good enough. Also lol I saw great humor in that tune!! I appreciate you sharing your way of doing things.
What an amazing machine, great job
I wouldn’t worry about what other people think, you do what you do. Extending the quill, why have it if you don’t use it. The swarf on the floor, I agree with that sweeping up is the easiest, the only thing I might do different is try to put a bin under where the tool is working to catch as much as possible, only because I don’t like sweeping anymore then I need to.
Well that’s fancy. I had to grind my own weld prep when I was learning to weld. Remember we had to take turns on who’s going in an hour early in mornings to cut enough flatbar on saw so there is enough for that days lessons.
Now days, students are soft. I remember grinding them too. We can't have that now days, it would make them have to actually work.
If I recall correctly, we were graded on our grinding job before we even struck an arc on our test pieces.
Not having them grind their own work is not doing them any favors.
Josh I think you're getting close to 100,000 subscribers I think that means a bonus in revenue I think you'll get it you deserve it you always have great content
That would be nice. I'm not sure how that works though.
Nice to see you helping out the local tech school. Good job Josh !
that machine works great!! now if you had a brand new free 20' long Flex cnc machine.... looks good nice job!!!
those students are going to be spoiled with that super smooth bevel......nice job Josh....
Josh that is really cool that you get to help pass it on to the next-generation. And I love your machine that's a cool set up. If people don't like how you do it thay can move on. God bless brother...
About 5 ways to do this and they all work. Good job.
Thanks for sharing your knowledge and experience keep on making chips
I took the welding academy thru northwoods at new richmond high school. Mr. Leque the teacher made us hand bevel or track torch a bevel. Makes sense tho for just burning out plates practicing.
Firstly, good morning and warm greetings from Germany. I enjoyed this video as always, especially the setup and clearance issues. Putting the vertical mill head on that planer was genius. I appreciate that every time you use it. However, you really could use an 8 foot long magnetic vise! LOL Good job, helping out the tech college. Thanks, Josh!
I had a 24" long mag chuck long ago. 8 feet would really be heavy.
@@TopperMachineLLC 😅
Hello Josh! Good day to you sir. I like your videos, i was really involved with the video about your area being so behind the times. Its really good you helping the school with its materials, hopefully the job pays good. The school itself probably suffers like your shop because economic reasons. And i agree with you about machines are tools, not collector items. Your a shop, not a museum.
The school is really hurting, the district is shrinking. It is a sad ordeal all around, created by the local people in power. So much potential here, and they don't care.
I just imagine doing this with a good old grinder. Seems like if these are being welded you already did half the work for the welder.
Isaac of IC Welds would just have cut that 30 degree bevel free hand with his torch. LOL Not in any way meant as disrespect towards Mr Topper, it's just that Isaac's steady hands are unreal
I appreciate a video of the converted planer. That machine is awesome. Thanks! KOKO!
Hello . And I watch with delight
I remember using a similar device to your cold air device when I was working as a mechanic. It was used to cool down automatic choke systems on carburetors. You plug the air hose in one way and it would blow cold air and the other way would blow warm.
Don't see that it matters the quill is out a bit, its a substantial quill and will take the load easily, it's working really well.
Could that have gone any better. That machine is just brilliant nice one josh 👍👍👍👍
Thanks, I am happy to have it.
Great setup, thanks for sharing.
If you aren’t making chips, you aren’t making money. Keep up the good work.
I can tell you that I use my tools to their capacity. The manufacturer said it does that then it must meet that. If your buy crap tools then maybe buy the good ones and spend the money. For some items, I buy the cheap stuff and it lasts longer than the expensive item. You never know if the tool you purchased is the correct one until you need it the most.
Fascinating. I'm surprised to hear you get criticism for doing things your way. In my business we might have respectful conversations among colleagues to compare notes about how we do things, and I personally learn a lot from those conversations. But then, this is the internet...
The hold music was killing me! 😂😂 I was waiting for your voice to break in and say “Thank you for still watching, your video will resume shortly”! 😂
I also expected a pair of dancers to make their way across the lower bit of the screen.
🤣🤣🤣
More like la 90’ porn movie
hay Josh bin watching a lot of your videos in fact all just like the way set up show this and different ways of doing so i have not commented a hole lot till i Heard that if we comment on the video then it's better for you no matter how short the comment so from now on i'll drop a couple of lines to help out if it does not help then lets know but either way i hope you win BIG CHEERS mate
I heard it helps too. Thanks.
Great to see you giving a break to the local tech college, even in better off areas they're struggling. I'm just a little confuzzled, every weld test I've ever taken had a 22.5deg bevel per AWS standards, even in welding school.
Totally agreed - sweep it in a pile and shovel it later, just don't sweep it under the machine for the maintenance guy to deal with. I had a router operator that loved doing that, and any time I'd have to work on the vacuum bed there'd be an hour of cleanout waiting for me.
I just cut to what they asked.
@@TopperMachineLLC Yeah no I'm not questioning you, I'm questioning them. Who knows, maybe they're using it for an intro course and wanted easier root access. It just confused me a little.
@@skwerlzpractice pieces were 30° (60° included angle) when I was taught to weld.
I did some test coupons mailing job on some Hastaloy X... 3/8x3x6 plate ,
Siemens has a big plant here for steam boiler production....
man, that stuff was hard as Chinese Algebra......thanks for sharing the video
Josh....cheers from florida
that reminds me of having to grind edges on scraper blades for coating machines for canning coating main cylinder they could slice your hand open just pressing down on them they were about 6 ft long they had double bevel one side
I've got to chuckle at the people who get triggered by cutting with the quill extended like that. The engineers at Bridgeport were smart cookies - the quill is that large in diameter to make it as stiff as possible! So cutting with the quill extended like that was absolutely intended by the designers. Greatly enjoy your videos! I'd enjoy some comments on climb cutting. When I was in shop class, climb milling was something that my teacher considered "absolutely evil." Maybe our machines, being WWII surplus, were wore out and couldn't take it? Love to hear your thoughts!
Seems like they (students), should make their own coupons. Or have other students in machine shop make them. Very nice of you to do this for them.
The tech schools don't teach machining anymore around here.
Why do you worry about what the nay sayers are going to say, you a very experienced machinist and a good worker, these nay sayers if they haven't worked in a machine shop, first they don't know the safety aspect, they don't know nothing about feed rates, yes it urks me when someone can tell a experience journeymen how to do a job in a insulting way, keep up with your educational and informative videos, thank you for sharing.
Hi Josh, I have a heavy duty workshop vacuum cleaner in my home workshop and it is fantastic for cleaning up the floor, it will suck up all the metal chips I can point it at. Much quicker and easier than a broom, sucks all the chips out of the machines as well.🇦🇺
I've tried commercials vacs. Sweeping is far better. Dollar store brooms are way better than $20 brooms.
@@TopperMachineLLC Ok Josh, stick with what works best for you, I really enjoy your channel and I an sorry to hear how depressed your area is. Stick with it as long as you can or as long as you enjoy the work. 🇦🇺
That long table on the shaper really saved the day, this would have been a LOT more work on a standard vertical or horizontal mill. Great job, Josh. (A nice 30 degree cutter would have been handy, but ya gotta do what ya gotta do.
Everything is fine, you just milled in the wrong direction. You should have milled in the opposite direction, so the vibrations and processing would have been much more favorable
You mentioned people crying about the way you do stuff. Im glad we didnt have people watching back in the day when i was in my uncles machine shop ,They would have been triggered so hard lol we didnt clean machines on production runs until the end of the day. You clear your area for your material work holding and thats it. Some machines wouldnt get cleaned until the weekend if the swarf wasnt in the way of the job . Just keep on doing what makes Josh money .
Exactly.
Next job: making a mounting bracket for the cold air gun.
Morning Josh,
Loved the set ups and the camera work. TOP NOTCH. Have never seen that cold air gun thingie before...pretty neat.....It just occurred to me that you can advertise that you have the WORLDS LARGEST MOWER BLADE SHARPENER.....LOL....Nice seeing you helping out the local tech college like this.....all snow n banks here finally gone, yaaaaaaaaay !
Your vids are improving more and more each and every one. Keep up the great work !!
Don
Sharpening mower blades would be the least profitable job in the world. LOL
@@TopperMachineLLC Was joking of course, LOVE your planer mill....
just wondering? do you have a shaper? never seen you using one...a small Atlas 7B is for sale on Marketplace sorta close to me....might go look at it....
@@donteeple6124 I have one, but would like to get rid of it. 26" Worchester. You interested? Give you a good deal.
@@TopperMachineLLC Yes Im interested...will call you....
Don
That is a heck of a nice shaper. I was just watching the vid on it.
It all costs money, but..... have you looked for a more rigid, higher HP head to replace the B'port head with? Something that would complement the rigidity of the planer frame and speed-up cycle times?
If I had a need, I would consider it
hi josh as always a gr8 video! have you ever thought about making table stop blocks to fit closely in the t slots of your various machines? i made some our summit HBM they really work well for set ups of parts and fixtures have to do some tweeking if close tolerances are required. but they work good, got some for the hbm and our various knee mills. hope you and the missus can hang tough there in wisconsin!! good luck and stay strong
I have made several different ones. Look at my older videos. I think I have a video of making some.
Hi Josh, I never heared of this air cooling thing before, How does it sepatate hot and cold air?
I find it nice to see your enthousiasm about the job and results, thanks for filming editing and posting.
It's a Venturi effect. Hot air out the back. Works great.
Can’t you bring out the head and angle in the other direction. 30degrees the other way. What do you think. Coming in at the front of the bar instead of the back.
Good stuff
Let the chips fall where they may 😂
I'd rather hear tools clanking around then music
Josh, could you have tilted the head opposite direction and cut with the end of the cutter instead of the side? I'm still learning and setup seems like 99% of every job. Thanks for the videos! Jim
This has worked out best for me on these long cuts. More meat on the cutter, less breakage. Corners chip.
Probably not enough travel to tilt it the other way. Even if possible a right hand spiral cutter would tend to lift the part off the table. Not good practice.
Like the idea of cold air cooling, but am intrigued as to where the air comes from ?
The air compressor
@@TopperMachineLLC I realise its from an air compressor, I was thinking more of the cold part of it, just wondered if it passed through a cooling down section, thats all.
@@neilward9932 Venturi effect. It separates the cold and hot. Hot air out the back, cold to the tool.
I was wondering what new apprentices are using to practice. Gas, stick or is that all passed over these days? Thanks for the video.
I have no idea.
I'm wondering about the planer mill, was it originally a planer that got modified to use a Bridgeport head or designed and built that way from its inception. Whichever it's a cool machine.
Thanks for sharing.
Planer that was converted by the previous owner.
My thinking is, if you have a quill and you can't run it out like that...why have the quill at all?
My buddy's ole lady must have been wore out....she got replaced!
sir you are a great machinist .but i have a set up question. why not put two plates up on the table.. one where you had it and one behind the t slot then your clamp would be that much lower. some 1/2 by1/2 by 1/4 angle iron as the stretchers. again i will never be the machinist you are and only can dream to run some of the machine you use every day...
I considered this. The problem is that it may have been too much for side milling.
If you weren't supposed to use it at that angle, it wouldn't let you set it at that angle
Im a guy with a Bridgeport in my garage shop. What is the issue with milling with the quil extended some? Are they not made to be able to do this? I do try and keep the extension to a minimum. It makes sense to me to keep stick outs to a minimum in general for stability with lots of thungs but how is this hurting the mill?
It's not like you are going to be going through two inches of material that looks like it maybe a piece of 3/8 thick stock and a 30 degree angle isn't that much. You don't have to do this full thickness of it for the welding students to pass the course.
Muzak elevator music now?
I am surprised they did not have you leave a 1/8" land on the bevel...
pretty much standard for groove welds [either open or with backer AWS D1:1
structural code]
I questioned a lot of the method. Angle being the biggest question. What do I know?
@@TopperMachineLLC sometimes there is a 37.5 angle beside a 30 degree....man, that finish was marvelous......I am jealous.....cheers, Paul
Hi Josh, I do not see the comment I made about the grain of the metal being parallel
to the long side of the coupon....when the coupon is welded and cut, the grain will be
running at 90 degrees to the bend, and the base will most likely fail instead of the weld....
very hard to pass a weld qualification with that type material....in the local community tech school
I attended, they ordered coupons, and instead of 8" wide material cut in 4" lengths, the supplier
or the dept. head ordered 4" cut in 8" lengths.....[2] 55 gallon barrels worth,,,,,and then second semester ,
the same thing,,,,,it was very difficult to pass a test due to the base cracking or breaking.....and a break is a break is a failure, no matter where it happens........
we did our own bevels with a plasma and Bug-O track....
Unfortunately, you would not be able to bevel 8 foot lengths like you are doing.....
I hope the students can handle the failure rates and understand why the material is failing....
Just this old guys experience.....thanks for listening....Paul
Just doing what they asked.
@@TopperMachineLLC Josh, I figured that......poor students get to suffer, one of those open root/backer groove butt welds takes about 2 hours to do.....and then to have the bend test fail....it is disheartening.....you do great work, I am still jealous of the finish you get......cheers, Paul
Hey Josh, help me out...
I am working the math along with you and we are coming up with wildly different numbers.
3/8" Thick plate, cut at 30* should require a Y movement of .217" (.375 X Tan(30)). But you seemed to cut the entire coupon in .125"??? I am lost, where did I go wrong in my math?
Thanks
I was off on my math too.
I don't like to complain, but the high pitch in the music was not pleasant on my hearing. The low pitch was fine. I have a type of industrial deafness where loud or high pitch sound is very unpleasant and if too intense can actually cause pain. Great video otherwise.
Hi Josh. After watching you use the cold air gun I went straight to eBay to buy one. The least expensive Chinesium cold air gun was right at $200.00 and some as high as $600.00. Did you luck out on the price you paid for yours (you quoted $40.00) or are they normally available at that price and I just couldn’t find them? Thanks. Tom
On the video I linked to one for around $60-80. It's in the shopping section of the video. Don't ask me how to find it there, I have no idea, but it's there. I added it to the list of products. I hope this helps.
Hi Josh. Thanks for the reply. I couldn’t find them there either, so I went to my friend Mr. Google and found that Amazon had cold air guns at about $38.00 As much as I hate doing anything that helps Jeff Bezos, I went ahead and ordered one. Thank you again for showing me how these cold air guns work. Tom
OMG! You're so mean and abusive to that machine. Don't you know that machines have feelings. I'm so upset that I have to go to my safe space and get into the fetal position and fondle my therapy ball of Play-Doh. Just like those plates, you did such a bad job they'll give the job to you again. On a serious note, thanks for helping out the tech school and the future tradesmen and women.
Here’s the best way to deal with what people think about what your doing and how your doing it……………FUCK’em!!
Great job
✌💖&💡
Why listen to the armchair machinist. Do what you do.
Great video thanks for sharing
I can't believe that a school of this trade, has no way to take care these exercises. The schools I've seen are set up to do all aspects of weldind procedures.
Track torches bevel machines.
Or is the teachers and aid just to lazy.
Will be a go payin jobfor you though.
They don't have much equipment left. No focus on the trades
Sad that there is not enough emphasis on the trades, in our old welding shop we set up a shaper with 30 degree jaws, it worked well to prepare the test plates. Takes do rely on good will, so good on you. Ray.
please no muzak
Cool job Josh. I am a retired welding instructor from a local technical college. If those plates are to be use for AWS/ASME welder qualification tests, the bevel angle called for by the test is 37 1/2 degs. + or - 2 degs. A 30 deg angle is ok for practice but the full 37 1/2 allows them more welding passes. I'm sure you are doing what your Tech College called for. Great to be a machinist you can always take more off. As a welder you can put MORON lol!
I thought the 30 degs was a little off. I even asked them to verify it. Do what the customer wants. But I will remember that for future reference.
Retired toolmaker from the Alcoa forge plant in Cleveland ohio. I made pipe coupons for the millwrights taking pipe certification tests. We also cut the J angles at 37 1/2 degrees with 1/32 flat at the root.
@@TopperMachineLLC Glad to help... your channel is a good one I enjoy it very much!
There's absolutely no reason to explain your machine usage. People that bitch about how you use your machines are idiots. You've proven that you know exactly WTF you are doing.
Excellent stuff. The quill doesn’t seem over extended to me - do people really get bent out of shape on that? No obvious chatter from the tool on a decent size cut says all is well. But what the hell do I know about it? 😊
People have a delusional view on how to run these machines, and get upset if you do something differently.
@@TopperMachineLLC they’ve likely never even turned one on.
@@StuartsShed because they live in Mommy's basement and watch RUclips. 😂
Thanks for the video keep on keeping on.
It was interesting to see how you did this as we did something similar on a smaller length a few week ago. I am looking forward to see how you tackle the crankshaft
Why would anyone give a hoot about extending the quill? That's what it is made to do.
Josh, please explain the terms you use in your videos. You mentioned 'climb milling', is that the term you use?
A light pass at 90 degrees on the edge of the stack to clean up the edges first would have given a perfect root thickness and had no mill scale , not that is really necessary , but then when you start the cut and set the depth to get the root size it will be the same end to end and no going back to re-cut a final pass .
Still was a faster way than some one grinding a angle on all that metal .
That planer/mill is so good for some big work .
That crank shaft job will be a interesting setup to see.
Maybe a boring mill job ?
Keep up the great work and keep the chips flying .
While cleaning up the stack would help, you need to remember this is basically charity work. Cutting costs on my end is important. Funny how all this work is just for a throw away item.
How would that work when the plates aren't perfectly straight? If they were perfectly straight there would be no variance on the root thickness from the angled cut either...
@@kennethney4260 That is why I said that taking a light pass on the stack to make all the edges straight first would make a even root size and no need for a second pass on the angle to get to size on the length of the parts .
Not that it has to be that perfect anyway , it's just for welding .
I like your philisophy; you are a professional , not a hobby machinist, so you know what works and makes money for you. Never mind the detractors.
Your DRO doesn't compute and display the feed rate ?
You know I taught welding and my students always had to prepare their own test cupons
Nice job. But why didn't they do both sides?
Only weld 2 PCs together for the bend test.
I don't understand why you are making these, the tech college should have a machine shop class, let the students make them, win-win everyone learns.
They no longer have a machine tool course.
Thats a nice flexible milling machine Josh !! Just the right size too.
I get welding coupons pretty often at work. We have 8 welder/fitters where i work so they are being tested regularly.
I've done the bevelling but mostly the milling of the sacrificial strip after they are welded. Its a break up of my usual routine and i enjoy it too. Cheers from Canada.
I wouldn't worry about those that hate you. They need to get a life.
Good for you, Josh...giving back. Hang in there. Thanks for the video and see you next week. Cheers.
I've been fascinated with those venturi coolers...
Can you tell us what the exit temps are on the hot exhaust and cold primary supply is?
Great vid!
I really don't know, but it's cold. My guess is 40-50⁰F output. It's got to be over 100⁰F
G’day Josh. Nice work on the welding coupons mate. No worries at all climb milling on the big girl. I’m actually teaching at a polytechnic these day’s training apprentices. We’ve been doing batch runs on the Haas CNC lathes weld prepping pipes for the fabricators. Cheers from downunder. Aaron 👍🍻
I'm not familiar with this type of machine and its operation, so could you explain why you have the bed travelling in that direction for cutting the material and not in the opposite direction.
Direction it's designed for.
Back in the day, we used torch and a track cutting attachment
investing in the future of the trades :)
Hi Josh, that's a job well done as always buddy, theres absolutely nothing wrong with extending the quill, thats what its there for, keep on doing you. thanks for sharing and best wishes to you and yours
You think this machine could use some height added as well to save bending over as much?
Maybe, but I'm not overly concerned at this point.