Machining A New Spindle - Saving My Customer A Pile Of Money - Manual Machining
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- Опубликовано: 27 сен 2024
- A few months back, I did a job on a similar assembly where I replaced the bad shaft. Now the customer wants me to make a whole new shaft out of solid. Nothing too difficult.
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This reminds me of a Bugs Bunny episode where they put a whole giant Redwood tree in one side of a mill and comes out the other side as a toothpick. 😂
Been there, done that. lol
Back in the 70's, I was at work and saw a shaving grab a guy like you said. It stripped him naked from the waist down in a matter of seconds before someone was able to hit the emergency stop. He was OK, but; damn lucky it wasn't a whole lot worse.
Yep, you can't Dick around in a machine shop, that stuff will mess with your junk, or just turn you into junk.
Came here for undisclosed Anchor Lube ™ product placement, and was not disappointed.
It was touch and go there for a while, especially during the thread tapping. I thought he was gonna leave me hanging.
But bro brought it back around for the keyway milling. Bravo.
Who else jumped (if just a bit) when the camera went flying! Nice work Mr. Topper sir.
Lol, I sure did. 🤣
I always tell the new guys that everything in the building will try to kill them at some point, they always think I'm exaggerating.
You couldn't be more right!!!
Excellent work - the science of cutting technology is fascinating and that's why I really enjoy seeing machinists make big chips with good material removal. I'm so glad you left the bit in where the stringy shit wrapped the camera and threw it - showing just what can happen with that stuff and what to watch for. Great content, thank you. As always, blown away by the surface finish straight from the cut. That's the way it's done!
Thanks Stuart.
Good save for your customer, your upgrade is a good one I believe.
You betcha. 👍✌️
One of those jobs where you have 25 pounds of chips and 5 pound part. Fantastic work. That lathe is awesome.
Thanks 👍
It is much better to have 25 pounds of chips and a great part instead of a pound of chips and a part that needs to pound sand.
I like your videos and I'm glad you don't talk like we are beginners.
There is a balance, this channel is more directed at those that have some experience and are for the most part in the business. Then there are some very good channels that do talk to the people at the beginner level, those ones are aimed at the hobby shop folks.
Nice video Josh. I hope you're proud of the work you do - people like you make the world go round.
I appreciate it!
It amazes me how worn out a shaft can get and still do its job. Ive repaired dozens of shafts. All sizes. All purposes. Retired now though. That is a good demonstration shaft to show folks. Sixes and nines. Looking good.
Whew, your right Josh, thanks for leaving that footage showing how quick accidents can happen. There's many cases where the operator was not as fortunate and are missing from fingers to entire limbs from the accident. Another cause is long sleeves and loose clothing, they can get caught as well and that machine, even a small drill press will always have more power and be quicker than the human body! I cringe every time I see stringy chips start to wind up. That shaft was a great project and your video was a great repair job of it. They could not buy a better replacement. Good work.
Thanks for sharing.
I can agree on all points, except for the long sleeves. I often wear long sleeves in the winter. Just being cautious and aware of your surroundings are your most important safety appliances. Every safety apparatus designed can and will kill you just as fast as what they were designed to prevent if you are unaware of your surroundings and careless.
@@TopperMachineLLC
Yes, the primary safety device is between your ears, applying a process called situational awareness. Many a fool who is thinking about Betty's bouncy birds, you know the little bird in the Paridae family, those lovely flocks of Tits, had ended up mangled by distraction.
NGL my butt was puckering up when you were filming that gigantic 15+ foot long murder noodle early on in the video. 😂
@@TheUncleRuckus murder noodle. Lol.
Good morning, thank you for the video.
Not only less expensive, but much better quality. Good job!!
Great job Josh! I like that you're able to save your customers money!
Excellent vid josh......the customer saved a bunch of money by switching to topper.😊
Is that wheel for Vegetable and packing plant equipment?
A couple of passes and the rust is all off and as good as new!. It's just not good for cleanliness and friendliness of the machine's sliding bearing surfaces.
Nice finish! Sorry to see the insert break.
EVERY time I have to hit an exact dimension, I overshoot the size and ruined the fit. HA!
Our skin starts to get thin at my new senior citizen age. My tuff hands were strong and calloused but not as a almost 63-year-old, the skin is SOOO thin that a hard bump can skin the backs of my hands. The chips draw blood once in a while.
I got to go and and turn out a bushing for a project I started yesterday now! Thanks, for the great videos!
I really hate that. The least abrasion or scrape means a week of wearing a bandage. I end up wearing long sleeve shirts so as not to scare people.
It's for a power plant. I hate rusty material, but without ample indoor storage, I am kind of stuck.
Very positive comment for the algorithms
That couldn’t of turned out better good warning about them stringy turnings absolutely lethal can be very hard to prevent on finishing cuts 👍👍👍
Thank you Josh!
Enjoyed the machining, some good tips. Finished job looks great.
Bedankt
Thank you very much!
1) Don't use heat on rubber wheels like that, you run the risk of separating the glue from the rubber 2) use DISH SOAP AND WATER as a lubricant when pressing these, not grease. The soap will dry and be sticky and will help hold it on, grease won't and will let it work loose.
We press pallet jack tires on several times a month and have no issues just using the soapy water for a lube.
Nice machining work... good job
Hi Josh - I reached a milestone today - watched the last of your videos after finding your site a couple of months aga - now have to wait for the next to come out and no more binge sessions - all good watches. from AU
Another happy customer with the cost saving over buying a new part. Some of these parts have ridiculously high prices and can be made for way less.
Great video and a terrific service for your customer! I wonder if DJI would sponsor you; I'd never heard of them before but a camera that can survive being chip-whipped into a tool post is robust enough for my humble needs.
Thanks Josh for the video, and yes them stringy chips are bad news for sure they can get you before you know it, that was alot of turning down but great job 👍
It wasn't bad. I like jobs like this.
That killer spaghetti will cut your fingers off in no time. Always have to be alert around machinery like this.
I've been bit once or twice by it. You learn real quick where not to be when doing these cuts.
Thanks for the video, I wish I would have watched my uncle more, and learned from him.
Another awesome job, Thanks for taking me for a little weee ride, That was fun can we do it again please Mr Lion Lathe😂
From kiwi land.
Shows how quickly things can go wrong with powerful spinning machinery, like those pto demonstrations for farmers where they fill overalls with hay and it makes contact with the pto, industrial equipment is no joke, even with emergency stops or foot breaks things happen so quickly you wouldn't be able to respond in time if you place yourself in dangerous positions.
Yup, that's why I don't stand next to the chuck. Pay close attention to where I place myself in all my videos.
Or even foot BRAKES to keep from BREAKING things.
Just me maybe, but there is something mesmerizing about watching blued chips breaking off. You got super lucky with that long spiral! It never tangled around the work piece. I was cringing the entire time it was forming.
***
LOL...yup...made a string of metal that ate your camera!
***
Probably people that don't machine stuff would never notice the flash of light on the facing operation on the second end. They have to see the work piece stopped to know if they got it faced off yet or not.
Lovely cleaning cut
Beautiful work!!!
you should cut that camera grab into a short and do a voice over of what happened and why chips like that are so dangerous. that feels like a viral short opportunity.
Good video Josh, I really enjoy them.😀 Oh yeah, I love all the measurement numbers.
That turned out very nice 😊😊😊
I have seen stringy chips clean an entire chip pan out of other stringy chips in less than 2 seconds
Me too. You never forget that sound.
@@TopperMachineLLC nope, whoosh thack, thack, thack... foot brake, check to see if I'm bleeding, ask a coworker to look at the areas I can't see. Go back to work, clean the floor later, and the chip pan, then check my pants. good to go!
Edited for for clarity.
@CothranMike unfortunately I work alone most of the time. I have to wait to feel wetness in my boots. Either from the blood I couldn't see or poop. 🤣🤣🤣
Good looking chips. Stringy chips can be dangerous.
Very interesting to hear that you have ditched the GoPro cameras. These newer manufacturers like DJI and Insta360 are certainly showing the older brands such as GoPro and Drift the way to go.
The DJI is far superior to the GoAmateur. I have had zero freeze ups or lost footage since using DJI.
Saving the customer money
23:23 Dude! Ouch! 😂😂. But, it sure gave a tactile demonstration of shop risks.
Fun fact - that 3.937" diameter is 100mm. I only know this because my Hemi block cylinders are by default 3.917", which is 99.5mm and I had it over bored by 0.020" which made it 100mm.
Wow you’re right. I never would have guessed that a metric dimension would be that close to Imperial. 1 15/16 is 1.9375 so 100mm is 0005 shy.
@@ellieprice363 yeah it just bugged me one day why they used such an odd diameter for the cylinder bore and for kicks I converted it to metric and that is how I found out.
I’ve never had much luck using a CNMG for finishing, the string I make always jams between the tool and workpiece causing a skid mark on it, you seem to have no issue with it however. I’ve seen you finish with a C lots of times now.
The temp issue with tapers, I recall I believe I’ve had heat in the live center causing tapers to. Until the center warmed up it would taper quite a bit. First cut would be straight (cold), then tapered, then straight again. All I could think was the bearings heating the live center causing it to distort one way more then the other until it all equalised.
I've had great luck with cnmg inserts on finishing. Biggest thing is taking enough DOC to make a more solid chip. Too light and it will get in behind and score the work.
Thermal expansion is a major player in machining. Once you learn how to plan for it, it isn't really an issue. It takes a lot of time and practice to get there.
@@TopperMachineLLC I tried to keep a load cell in the circuit and monitor the increase of force, easy to do, that was one of the items we made back then. Noticed a sharp increase initially, adjusted and continued to monitor. Overnight jobs always started all over again since the system chilled and lost the expansion. WW2 machinery, overworked with poor maintenance, holding too tight a tolerance to ignore these little things.
@@TopperMachineLLCcouldn't agree more Josh minimum DOC no smaller than TNR get on that chip breaker and get a good chip......the first time.
Great video! I am guessing that the saw cut may have work hardened the material at the edges of the cut. Seems like there was of lot of sparks generated when you were cleaning that are up.
Not work hardened, interrupted cut. Carbide doesn't like interrupted cuts.
I was a little nervous when I'd seen that saw cut partway through. Been burned by broken teeth before. Glad it worked out. Great looking part.
I had to learn early how to deal with saw marks. Sometimes you don't have to do anything, sometimes it kicks your butt. This one just cost an insert, no big deal in the grand scheme of business. I always plan a full insert per job, usually never even use up one corner. I'm still doing good.
Nice bit of heavy turning, chips make a good sound in the chip pan at 20 thou feed.
They sure sound heavy when they hit.
well done 💥
Good job
Great work..!!
Thanks a lot!
If you haven’t already seen it done, I thought I would pass along a tip on how to remove bulk material innovatively that's different from what you do in this video. I’ve watched videos of people overseas doing machine work, and one of the videos I watched had an interesting way of removing large amounts of material on the lathe. The machinist would use a cutoff tool instead of a normal insert to hog out the material.
The machinist would have a part in his lathe similar to this video and plunge the tool like he was cutting the part off, only stopping at a depth a few millimeters larger than the needed diameter. Then, he would move the cutting tool and repeat the plunge. Using the cutoff tool greatly reduced the time to remove the bulk of the material. Next, the machinist would use the normal insert to bring the part to its proper dimension. I’m interested in hearing your thoughts about it.
Slower, by far. Total time to turn this shaft down to size was 20 minutes max.
It would be nice to have an ammeter on the lathe motor to see how hard you are pushing it in those heavy cuts.
Hardly using all 15 HP. Maybe 5-6 HP.
A nice way to get repeat business by saving the client big money, also aa good way to produce videos for us to learn and enjoy
It's funny, but as the production numbers go up on a part, the bean counters want to shave every last penny. This is why for the longest time the GM companies glued the doors on their cars. It saved about 2 or 3 cents a car, and over millions of cars that adds up. But the right method is what is being used here, for the billet is the best.
.100 at 20.. dam I need to try this at work
Very cool
good day Josh...best wishes from Florida......PB
Thanks 👍
Great video Josh, that's the kind of work I do, I never know what's coming next,lol 😂. Keeps it interesting, excellent job..
I could never do a factory chop job. I love the variety. Never a dull moment.
Great video, as always! Josh, I noticed Kyle Vanover gave you a nice shout out in the video he released today.
Good
Need to make a CAD cover (Cardboard Aided Design) to keep the splatter of coolant down. At least will get most of it back in the tray to reuse.
I have done that, but it's just better to do it without coolant and cool before finishing. Carbide can take the heat.
I just stole that term from you. Thanks!
NICE
I have a small bench top lathe and one of my major concerns was that you have to cross the arc of the chuck to switch it off in the case of stringy chips whipping around with the chuck. I made a foot stop switch for this very reason and use it every time to stop my lathe so that in the case of an emergency, it’s a natural reaction. Small hobby lathes should come with foot switches like the larger professional lathes do.
Only mid grade lathes come with foot brakes. Big industrial lathes have built in braking with the clutches.
@@TopperMachineLLC keep up the great work and videos Josh. Enjoy watching them from New Zealand.
Lucky that stringy chip didn't take your head off. Better to wreck some recording gear which can be replaced, than to seriously injure you. Thank God that you were well clear of it. But being forewarned means you were prepared for what might happen.
Might the wheel turn with it being greased????? Good video.
The Action Pro 4 is so last week. You should have a promo Email for the Pro 5 by now 🤣It still does make sense to keep with the 4 if you are happy 😉
Haven't heard of it. Muat not be important enough to be told about it.
@@TopperMachineLLC You might score a deal on the 4 maybe if you keep an eye out 😃
Hi Josh, as always impressed with your work and I made a small donation to help replacing your camera gear :)
Come on viewers, Josh can use a little help from us to make great videos about machining.
Thank you very much. It is greatly appreciated.
Did I just witness the biggest blooperS😅 in TOPPER 😂history?
Lol, no. The biggest was when i lost the camera in the sawmill sawdust auger. All I could do was stand there an watch.
@@TopperMachineLLCI thought you found it?
make it out of 2 1/2" stock ,and a donut to weld on at the 2 1/2" dim to move the heat zone away from the 1 1/2' dim
This took less time.
When that insert broke, you said the lathe autofeed kicked out "which is what it's supposed to do." This is very very curious! I've never heard of such a thing and would really love to know how this process works.
Low end machines do not have this feature. Basically it senses excess torque and disengaged the feed.
🤠🤠🤠🤠🤠🤠Thanks for the great video. I wish I knew what you have forgotten................it would make me a lot smarter. I am glad that you were able to get the job done and save the customer money. It is incredible the cost of the new part. You did a nice job filming as always. I am going to a car show. Good to see you!!!!!!!!
Sadly, I wish I knew what I have forgotten also. Where did I leave that caliper????
I'm always shocked at the price of some of these assemblies.
I used to be too, but nothing surprises me anymore.
Josh i hear you talk often about the area you live. If you knew then what you know now would you have settled in a different area !
@@michaelhaiden6718 probably. But I sure wouldn't have started a business.
The coolant you're using looks like soluble oil?
What grade of file are you using for finishing the chamfers? Something like a flat smooth?
Q? One out of 10, if you gave your micrometer to 10 other machinists, what would average so everyone gets the same measurement?
@anthonyrivers8395 everyone should get the same measurement, if the micrometer and machinist are any good.
What grade steel did you use here? 1045?
Do you recycle the metal chips? Seems like a lot. I have never been around a machine shop before.
I have a Ford Service, Signs, Like on the wall behind you in this video. FORD # 1
dji osmo action 4
Love my camera.
Very nice work Josh. What coolant do you use? Thanks
TRIM E850
@@TopperMachineLLC Ok Thanks
I enjoyed the vid. What was the rpm when turning the large diameter? Did you increase the rpm when turning to the smaller diameters?
ran it all at 710 rpm
Stringy chips are nasty. I equate it to razor wire.
When you know you need to hog out a lot of material, and end up with a radius in a corner, why not use a circular insert to do all the cutting? Is it too much tool pressure per cut to be efficient?
I never considered that. I don't think I would have problems with tool pressure and rigidity. I think the insert would not handle it as well as the CNMG does.
What steel are you turning the spindle from?
covered in the video.
I didn't catch how much interference you went for.. I'm assuming about 1 thou per inch of diameter?
Covered it in the video.
@@TopperMachineLLC Ahh.. Must pay more attention in class..:)
curious how long did it take start to finish?
I plan for an hour total job, with filming it takes way more. Just the turning would take 20-25 minutes total.
Hi...don't know if you are open to it, but would you be willing to send me the damaged camera gear? I do electronics tear downs and reviews. Damaged gear works fine for this.
Send me an email. RUclips@toppermachine.com
Just an ooooopsies, just par of the course of the job.
RIP Camera and Mic, You gave up your electronic existence so people could actually see how dangerous working around shop equipment is. Lesson well learned.
Only the mic, camera lives on with just a few scratches. LOL
Very positive comment for the algorithms
Not being a smart a$$ I am truly trying to learn. When Abom79 did a lot of manual machining his big thing was he hated stringy chips. If he got stringy chips he would make adjustments to eliminate them. On turning this shaft you had a very stringy chip but carried on. I am just wondering what your thoughts are on those stringy chips. Is it just not worth the extra time to deal with those? Thanks. I love your channel and the variety of manual machining you do.
ONE machinist to another,got a tip for you 3/8- 18 NPT think that was the thread size u were tapping,OK,front the bottom of the tap find last full thread got it count up 3 1/2 threads,put a mark on tap. drive the tap to mark,STOP,u will be so close to tap guage its gonna scare u,3 1/2 on interupted tap and 7 on full thread tap, IT WILL BO SO CLOSE TO GUAGE ITS SCARY,,i had good old school teachers when i was an apprentice, if right or wrong let me know,and to all your trolls ITS TRUE
Isn't that an incredibly big waste of material?
Or, do the shavings get recycled/ melted down?
Like 1 commenter said...Bugs bunny cartoon where a whole tree goes in, and a toothpick comes out as the finished product... I guess if the client pays for the initial material and overall saves 'em $ money- then... doesn't matter? I see more value to customer if all that material can be further utilized if not for the initial client, then at least in other client's specific use case
Another excellent video! Back when I was running a lathe, I used to love watching the long stringy chips. Mesmerizing. Then once, they wound up like they did on you! Nothing got hurt, but I learned to pay attention to what I was doing. 😁
Your customers would have payed that money. You just didn't make that money. They took advantage of you.
Thank you Josh. It was most enjoyable and educating.😀
No taper that is great. I know you are busy but some advice would be great. WHAT I BORE SOME THING OVER A LONG DISTANCE AND I GET TAPER.WHAT THEN SEEING YOU ARE A MASTER AT THIS .PLEASE....
depends on which way it is tapering. Getting smaller as you go deeper, could suggest tool pressure pushing the tool holder out, or bar deflection. It could be bad lathe alignment.
Nice you were helping Kyle with his Lucas. -Doozer
We have talked at lengths about it. He will get that thing ripped into shape v
Yeah hogging material whith a cnmm insert !!!
Nice job, Josh. I think, if you look in the Machining Fundamentals book for "interference fit", you'll find a picture of that spindle 😆. Thanks for showing us how it's done and have a good weekend. Cheers.
Lol, I was sur happy it went together well.