SECRET Process Of MACHINING FLAWLESS Parts
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- Опубликовано: 12 май 2024
- Trevor shows how to achieve a PERFECT FIT. Machining a part to fit seamlessly into another using ONA’s AV35 EDM (Electronic Discharge Machine). A Precision Punch and Die that Fit together Perfectly using wire EDM technology.
0:00 This is Precision
0:41 How it’s made
0:44 ONA EDM
1:08 Tight Tolerances
1:19 Components Solidworks
1:31 Subscribe
1:51 Punch and Die
2:04 Mitutoyo Setup/Fixturing
2:30 Additive Machining
2:42 Slug Removal
3:20 Roughing Pocket
3:40 Offsets and Compensation
4:49 Clearance
5:03 How We Made the Perfect Part
5:22 Titan Tooling Promo
5:37 CNCExpert
5:54 Precise Fit
6:06 Outtakes
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#CNC #Machining #Machinist 
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I spent many years in an EDM shop (wire and sink) and always thought that watching a wire EDM in action is equivalent to watching grass grow or paint dry. You (and your video team) made it exciting and very interesting.
Thanks Karlo, It's definitely not easy to make one of the slowest machining processes exciting 😆 Thanks for watching!
@@trevorgoforth8963 but damn, those cuts are precise. There's a DIY Qire-EDM solution, I was thinking about building one for my hobby shop - but the needed arc generator from BAXEDM is over $3000. That's a solid investment for a hobby project. I've seem some people trying to build them themself out of an old stickwelder - but the precision comes with the timing - and an estimate won't really do.
Hello, colleges. More than 15 years experience fanuc wire EDM in Russia. Extrusion tools .
I mean super accurate tolerance and a disappearing act is cool and all but whoever ground that block to perfection is the real hero here 🤣🤣
Hahaha you ain't wrong! I'm just glad we didn't have Mr. Nogo do it. 🤣
For sure Mr nogo will use bearing ball trick to achieve the perfection 😂
I miss that perfect character Mr jessie 😂😂😂😂
And the key to it all is the guy that drilled the hole lol.
@@mohammedalbattal77 Maybe we can talk Beau into coming and giving Trevor some training lol
@@jdsharp1366 lol Exactly!
I am neither a machinist nor an engineer. I've watched many EDM videos and wondered how it could be done without leaving a kerf. Yours is the first video that explained the process and clearly detailing how it is done. I suppose others merely assumed that their viewers already knew that it required *TWO* different blanks.
hello bud,
its correct. whenever you cut something into two, a gap is created to at least the width of the blade, no matter how small the blade may be! Apparently also including a blade 1/4 the sized of human hair! Crazy!
The first piece I ever made like that was back in 1985 with our first SODICK 1WH Wire machine. First attempt was spot on with some attention paid to the details in the program while taking into account the wire diameter and the ensuing "overburn" as a result of the spark gap. The part was presented to the company President and he was amazed. That sold him on the technology and we over the years had purchased over 10 more wire EDM machines.
Growing up in the USSR, as an aerospace college student I had a summer job in 1990 at a plant in St. Petersburg (then Leningrad) making parts for various missiles. They had a row of basic versions of this same machine (among other cool stuff).
Channel is seriously getting better at making content, and it was already great. Better than any manufacturing show on tv!
I must admit man has done some pretty cool things. The technology in that shop is top notch all of which are huge boat anchors out of water. What’s really cool is the brilliant minds designing the machines and the brilliant minds running them. Beautiful piece of art Trevor and thanks for sharing.
Thanks Tony!
Man, every day you are progressing more and more, you are going towards the top, for sure, in this way, you will reach one million subscribers very quickly BOOM 💥
For a few years, pieces like this puzzled me, but now I know the secret of this craft, thanks to you Mr trevor 🌷
I'm not a machinist, just took some high school classes a while back. Zero tolerance is insane, especially with metal heating and cooling - great job!
no such thing as Zero tolerance. Absolutely everything has to have a tolerance.
Zero tolerance has little to no application in real life as far as moving parts are involved. You need tolerance to offset shrinkage and expanding of materials. That's the very basics of material science.
It's not zero tolerance, just very very precise. Tolerances on wire EDM are as low as 2 micron but that's not zero. Things like gauge blocks have even tighter tolerances and you can clearly tell because they "stick" together due to Van Der Walls forces as if there was glue holding them together, yet there is nothing, just blocks of steel.
They are using an iron alloy know as an Invar. "Invar, alloy of iron that expands very little when heated; it contains 64 percent iron and 36 percent nickel." "Lohaus says it had been long suspected that this behavior was somehow related to magnetism because only certain alloys that are ferromagnetic (capable of being magnetized) behave as invars."
"As the temperature of an Invar rises, the spin state of some of those electrons increasingly flips. As a result, the electrons become more comfortable cozying up to their neighboring electrons. Typically, this would cause the Invar to contract as it warmed up. But here, the Invar's atoms also vibrating more, taking up more room. The contraction due to changing spin states and the atomic vibration expansion counteract each other, and the Invar stays the same size."
This is a brilliant fit, very impressive, kudos to you. I was a prototype machinist in 1984 and learned to use a Charmilles wire EDM. We made some basic parts, but there was no skim cutting available. I made a “punch & dye” of my first name, but they did not fit together, close but no cigar. We then got a 4 axis Mitsubishi with skim cutting. Made a couple of name plates for senior managers. The die from steel and punch from brass, the fit was not as good as Titan, but it impressed the bosses. Can’t imagine what it cost, all the programming was manual, but then again, we were an expense department!
Awesome video Trevor! I always had an appreciation for EDM. It was a nice break from CNC machining.
Done EXACTLY the way i was expecting
I love you guys and anything Titans of CNC!
Great audio/sound fx while sliding the punch into the die.
Absolutely amazing machining. Thank you for sharing this.
Unbelievable! Congratulations!
Thank you for the education and inspiration
Metric units would be nice as a pop up. Love Trevors presentation
This is the most iconic video on the subject of machining i've seen so far
Do you sell the punch and die itself? It so satisfying to have on my desk 😬
I remember when I was in machinist class and the instructor demonstrated zero tolerance. He had two pieces of perfectly machined surfaces of steel blocks. When you slide them across each other, they would stick together. Air tight contact.
This gives me like, feel good vibes. Like my anxiety makes me feel so good when this goes back to smoothness, and complete. Beautiful imho.
Awesome Video Trevor! Thats a cool looking part! 😎
Thanks Brother
Awesome video Trevor! Super interesting!!!
Barry is going to make pixiedust out of trevor when he watches this! 😆😆
😆 He interrupted our video so I had to talk some smack 😜
For my next video im gonna full slot that block
Super cool. Crazy tolerances to make it disappear! Great job Trevor 😎
Belo vídeo Travor , achei o trabalho muito bom , conheço muito bem esse tipo de usinagem e sei o quanto é complexo ,gosto muito das postagens que vocês compartilham , parabéns 👋👋
Muito obrigado!
What is the sensor that senses and controls the distance between the work piece and the tool?
Wow! That is amazing.
Incredible! 👍
Top professionnel and fascinating ❤👍🏽
Incredibly exciting, you surprise all the time🙂
I like this guy and his explanation 👌
Mesmerising ❤
such a love for those pieces of metal.. LOL.. I think that if I had one I think I won't be able to put it away as well.. LOL .. thanks for the explanation, it's an amazing piece of "art" to my eyes!
I love it. We had an agie cut classic and the manager at the time wanted me too run it but it hadnt been ran since the early 2000s. I read and read the book checked the de ionized water, Checked my pulse, flush, had the wire auto feed working. Everything. Only had floppy copy programs and we didn't have the right software or something. The world and me will never know.
woooww... that is amazing dude!
That was amazing !!!! How in the hell did they cut stone with that much precision when building the pyramids? No CNC back then .
Whats so cool about yall's channel, I can finally show my wife what I do at work. I mean with out the clean floors and grinding dust everywhere. It's exactly the same.
With this machine, the industry has reached a new level
Sooo satisfying!
Hi Trevor, What an outstanding workpiece is the one that you fabricated,I am really really impressed,Doe,s the machine makes the cut under the water to compensate for temperature differences on the cutting edge ? and so avoid expansion in the material ?.Thank you so much for these kind of superb videos,
iam so glad , you people making wire edm video I too wire edm operator
Amazing.
That was so good I nearly cried
Thanks for the nice content, is there any chance that someone could do such seamless fit using cnc mill? Or completely impossible?
So mesmerizing
At what temperature difference between the parts will they no longer fit together until they equalize?
I loved this video!
Beautiful slip fit
This has got to be one of the most interesting and strangely informative advertisements I’ve ever seen.
Not in a negative way at all!
!!!!Mother of god!!!!!it's amazing work!!! Congratulations!!!!
A true feat of engineering. The name of the channel is well desereved
What cuttin speed can we achieve on stainless steel ? For example 50mm do ee get any speed tables with machine ?
What happens with the finished product when it i a hot room or surrounding, guessing the piece gets stuck
ok ngl first 15 secs BLEW MY MIND. I thought it was CGI, like a Blender model, until I saw the hand.
I heard that super precision machined parts had invisible seams but holy shit man
whoaaah I thought the opening noise it made was a start to a song and just fit the shot really well haha
How did you make finish on a punch after cut off?
Is there wire deflection within the center of cut? Depending how long the cut is, and how many spring pass cuts there are?
That is "AWESOME"!
You guys have the best toys.
as a machinist, all i can say is ZERO TOLERANCE IS HELLA BOLD STATEMENT YOU MAKING
We already know your goal is more subscribers. I don't need reminded before and after the actual content...
A few questions:
Firstly, I run a laser cutter at a sheet metal shop. I run the old pulsar lasers (Amada LC-2415), but we have one of the "newer" Amada fiber lasers (I put "newer" in quotes because we bought it in 2017). The kerf on the pulsar laser is around 0.005" (I think it's thinner in the fiber). I know this is a stretch with the pulsars, but I don't see why you couldn't achieve around the same micron level precision with a fiber laser if you adjusted the offset correctly and controlled the position of the head to micron precision (albeit, on sheets that are much less than an inch).
What makes EDM more precise than laser cutting? Is it more about the precision in that thick of a piece, or is just demonstrably more precise than laser cutting in general? Or could it be that attaining the level of precision you get with EDM requires extremely high mechanical advantage to move in such tiny increments (so much so that the movement becomes glacial) and running a laser at that slow a speed could fry the laser of cause other issues?
Also, what do you use a die set that precise for? Is it for some kind of extrusion? I was under the impression that punch and die sets are used to punch, emboss, form, or generally shape a work piece in some way, and I thought you always need clearance for that. What can you do with a clearance of around a micron???? It's freaking awesome! I'm just very curious.
If you try this at home…. Make certain that your steels are both annealed or the amount of warping after cut will make your fit impossible.
Nice video Trevor!
What’s annealed mean?
Thank you sir!
@GreenEYESfromOHIO annealing is taking the stress out of the material by cooking it, even plastic can be annealed
@@apostolrobert5810 i wish i could be annealed
@@angrydragonslayer - 😂😂
Can you please use imperial and show the metric conversion for your measurements? The old world is hard to compute in the modern era :P
I've long wondered what would happen if someone made a pin-tumbler lock with this kind of precision. Would it be pickable?
What kid of tools or machines require this type of precision?
Very cool.
Can this technology be used to make parts that match helically?
That's so flipping cool
Where can I get one, this would be an awesome conversation piece in my office for a non machinist.....
Ryleigh was in awe watching her daddy the whole time!
How many cycles of going in and out can said machining handle until there’s a visible gap between them?
VERY NICE PIECE!!! Well done. Question: How many hours of the EDM-machine was necessary and how much is one hour on this machine?
I have not ran a WEDM in almost 20 years. Now it is probably $200-$300 an hour. 6 to 8 hours for both parts. I could finish both those in less than a 10 hour day. I do not know how fast they cut today.
how much temperature change is allowed to still function?
I think it might have passed by the surface grinder as well. I might even think it took the same amount of time at the grinder as it has in the EDM machine.
Grinding is way faster than EDM. 40 + years of tool and die making says so.
Is this possible to do to a 1911 slide and frame to make the perfect slide to frame fit ever produced on a firearm?
It's kinda incredible that even with how precise that block is and the punch, air was still able pass, allowing the punch to rest into place at 6:00!
Or did you have an air hole cut into the stand, underneath where you got that shot?
Where can i buy this or something that displays the same level of precision?
A great many people appreciate the tactile and precision art qualities of things like this. You could produce a “punch and die” set like this as an executive desk toy and sell a million of them. I would definitely love to have one.
I always thought zero tolerance would require the parts to be pressed together, like with a hydraulic press. So why does a part like a wheel bearing in a car hub need to be pressed in or out? Is it "less than zero" tolerance on parts like those?
Be nice to have one of those samples sitting on my desk....do you sell the small blocks??
Man you guys should sell those!
This is amazing.... where can I buy something like this?
Where can I buy the finished product. That would truly bless my desk
Customer : How efficient is the cooling system on the ONA?
ONA: Yes
i would like to buy one of the zero clearance blocks. What would one cost?
How did you break the punch off the holding part? i saw you move it back and forth to break it off, but wouldn't that leave a burr or raised end that needs to be filed? And i guess 0 tool pressure, so no chatter or anything happens?
You have to leave a tab on a flat surface and grind it off to perfection
The part is badass.
Are those tolerances provided by the manufactures with the spark distances too? Or do you need to formulate those on your own?
ONA provides it's customers with a tech library that has a wide variety of power settings for tons of different materials and thicknesses. Unless your cutting some crazy material type or trying to get an insanely good surface finish that is uncommon, there will be a technology file provided that you can use!
Nice. Where can one by one of these machined parts?
That was so entertaining
Okay, let me get this straight...
So to make up for the material loss by the wire on each piece instead of cutting it to the exact measure. You basically cut it up a little bit bigger, so that it stays at the exact measurement that you wanted it?
Im curious How heat or cold Temperature change the Material
In a vacuum would these cold weld in place?
Do you guys take orders? I have a DO-A3 project that no-one can make parts for. TI with pretty crazy tolerances.
Ok, dumb question time: when cutting the punch, why does it not fall out of the shell? Do you have to leave some kind of tab that keeps it from shifting in the cavity or dropping to the bottom of the tank?
That is great idea to make Safe Box on the Wall a bit bigger to install inside of the property even in living area and then when you will open it Stick a piece of Magnet and pull it
So, how much time did it take and how expensive was it to do?
Nice we used to do that a lot during my apprenticeship u should cut two different profiles on either sides of the job
Incrível! 👍
How do you calculate the cost of job and how much the cost per mm Squre?