DIY Lost foam casting a large aluminum metal lathe base
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- Опубликовано: 2 апр 2024
- This is the first part of trying to cast and make a large aluminum metal lathe using the lost foam casting method
Music from epidemicsound.com 
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Man, just lifting 70kgs of molten aluminium is nuts. Epic job!
No way man
I used to watch your videos 7yrs ago as an 11yr old and now I was planning on building my own lathe and I come across you again
Dude, results speak for themselves. ANYONE saying ANYTHING negative about this project has NEVER tried to do something this awesome. Keep going.
The project scale is amazing, material selection is questionable. Aluminium gets work fatigued too quickly and becomes brittle. For a lathe, this can be incredibly dangerous.
Wow. I'd be out in the street dancing like a crazy man if I'd pulled that off first try like that! Fantastic job!
Lolololoololololololololol to tedious for me.
So excited for this new chapter! I really wasn't sure such a massive lost foam casting would go well, but, the title didn't say it was an epic failure, so I was somewhat clued in 😅
This was the most awesome large aluminum lathe bed casting I've ever seen. I've seen home made lathes and a lot of Gingery aluminum machine castings but not one like your scaled up version. I just saw took a glimpse at all of your videos, I'm subscribing. I'm gonna binge watch them this weekend.
I'm going to keep my eye on this build, too.
MyFordboy would be proud - epic casting
I have to say it came out so much better than I thought it would. That is a huge project to cast. Thumbs Up!
Been following you for years, it’s been awesome watching your skills and projects progress. Please continue sharing, your hard work is appreciated!
nice to see you doing projects again...
I’m all caught up to recent videos, I’m excited to see your plans and I pray you get the dream workshop you want, most high God bless you
I know it's been said but I'm so glad you're back. Good luck with the new workshop, hope everything goes smooth. Looking forward to it.
You have a very high level of experience nice I'm happy to see someone trying hard to build something special
I find this really impressive and thank you for taking us along on this project, the end result did not disappoint, after flattening this will be a great base. inspiring, I might make some parts for my cnc this way. can't wait for the next video.
Can't wait to follow this project. Looks good and fun.
Dude, f*k the haters. That’s the largest home casting I’ve ever seen, and it came out much better than I expected. Me personally, I would probably weld steel than pour aluminum; but, I’ll definitely follow your journey and see where it takes you.
That casting is huge! Very impressive and exciting.
Okay, an algorithm suggestion that I’m stoked about.
Excited to follow this.
AWESOME JOB!
Really glad to see your content again, man. I missed you.
Amazing casting, you're incredibly talented
Time to start scraping!
Awesome! Such a cool project!
Wow!! You like to do things in a big way. I cant wait to see the rest of this project.
What a job! Well done. That looks tremendous and hopefully a good basis for your new lathe.
whoa, you were the solid aluminum bat channel from years ago! Now I remember. Its been too long... good to see some content going up.
What a gangster! Amazing build dude.
Absolutely genius.
I am like all watching totally chocked and amazed. What a magnificent outcome for first try. It inspires people. 👍🙏
Great awesome job, what a size !! Thanks for sharing
Very cool project and nice video!
The material choice baffles me a bit though. I looked through your channel and looks like you got a lot of aluminium so I guess the primary motivation was "free material" to make it out of, but I don't think it's a good choice as lathe base. You want as much weight as you can in your base and as much similar materials so everything you mount to it stays solid and doesn't warp with temperature changes and different expansion rates, so that's why most lathes are either steel or cast iron. Next to that the aluminium is also a lot softer so the wear surfaces will be worn out more quickly. Even if you mount steel linear rails, it's still going to warp a lot and stuff will be under a lot of tension, contrary to aluminium extruded profiles that can give a bit of way and stuff is usually mounted with locknuts that aren't absolutely fixed in place, as well as those machines being inherently limited in what kind of materials they can handle.
As far as I understand it, you never want to work on materials harder than what the machine is made of, so this lathe would only really be suited to work on other aluminium or things like brass, since the machine itself will flex resulting in worse precision or even tool chattering while working on harder materials.
But the thing I really dislike about using all this aluminium as a lathe base is that it's perfect material to use on the lathe or on a mill. It's kind of a waste to put such nice material on the base of the machine when you could make the base out of iron or steel and use the aluminium to make beautiful stuff!
But I'm not hating on the project, that's a beautiful cast and I'm sure you can make a functioning lathe out of it, it's just something I've never really seen before.
You are not a machinist. You have never even laid hands on a lathe.
@@bami2 You made my point.
@@Katchi_ they are right....
@@Katchi_ He's not wrong though, that's typically why machine bases are cast iron or granite
Eh it can be done, it definitely can be done. I work in a wafer fab producing devices on nm scales, a lot of our machines are aluminum based with steal linears. Some of those have run 24/7/365 for 25 years now without damage to the aluminum base (to address your wear comments).
Very well done!! That’s an impressive feat!
damn bro that's a massive project and you're handlin it like a champ
Welcome back! I missed your videos, bro
This is the content i love!!!!
Wow! That was awesome.
that's a pro job! well done!
Weigh a 1” x 1” x 1” piece of foam and the same of aluminium then next time weigh your foam form before moulding in sand and calculate the weight for aluminium then add 10% for losses that will give you a good starting point
I just found and subscribed. While Aluminum is not my first choice, I think you will get some good use out of this lathe. Looking forward to seeing this lathe come to life.
Subbed! Can't wait to see how this turns out!
Welcome back MP dragon
Really great work!
Beautiful casting
Super cool! Well done!
dude that is a huge cast and overall turned out very well for the size!
i thought i did large casts. lol
Wishing you all the best in your awesome effort ....!
This project got you my sub! Thank you!!!
So cool, I can't wait to see what kind of performance you get from this lathe
Badass. Subscribing for the rest of this 👊🏻
this is amazing !
fantastic job
This is so cool!
Beautiful...like poetry!
for surfacing, you just have to make two more of these and then rub them together according to the three plates method. easy peasy!
(seriously though, this is amazing)
Thats impressive work.
Вот это отливка! Выглядит впечатляюще! Однако, станок будет иметь проблемы с жесткостью - это однозначно!
Wow. You’ve definitely just gained a new sub!
oh this is going to be good, subbed
Dude… sick!
Very nice!
Thanks for sharing
Cheers
add hardened steel to the ways you'll be glad you did the alu is a okay base but will wear quickly
i'm pretty sure that ways are just flat base for linear rails
that's the plan
But there is also problem with two different materials with different thermal expansions joint together. It will warp with changing temperature. And with long piece like this it can be a lot.
there are cnc machines made out of extruded aluminum profiles that have linear rails
@@kigara3906 nah, bimetallic actuation is measurable on enclosed 3d printers because of significant assembly/operation delta, but for reasonable repeatability on “open air” cnc it’s completely fine
10:13
NICE!
Woaw, prieks dzirdēt progresu!
You are lucky to have had it come out good the first time.
nice work!
Impressively done. Make sure the ways are leveled and machined to the best tolerances you can get before using it or you’ll end up with inaccuracies in the spindle bores of the machines you’re making.
i wonder, can you fill a mold like that from both ends? you'd have needed 2 furnaces to heat up two loads of Al in tandem, and i guess 4 people to pour it in unison, but if you filled from both ends at the same time wouldn't it have reduced the cooling issue?
Amazing!
Very impressive. Very few flaws and none that matter.
Can you fill the cavities with epoxy granite to dampen vibrations that will occur when using the lathe? Will you be adding hardened steel rails for the way surfaces?
nice. good job!
Very cool!
Maybe a shop that works on large engines like those used in naval vessels would have a mill large enough? If you can't find one perhaps you can make a 'self-milling' device. Like an angle grinder on a sled.
amazing!
That thing is amazing! Man, fine work. Maybe you could find a huge sheet of glass and use that to smooth it off
Pretty good in fairness considering what you had to work with!
This is how i run the first part after coding. I use foam instead of the material, because it can be measured, and it gives way if there is a bad line of code without breaking the expensive tooling. Also you can run feeds at like 600% in foam so checking the very 1st part after coding the part is far less time consuming.
Ps Hope that lathe bed doesnt warp all over when you load it, I have a bad feeling you made a chatter box lathe under load. But I have a bit of faith and a whole lot of hope it works anyway! -- Machinist/Tool and die, fabricator of HP.
Olá amigo trabalho fantástico !!!Esse projeto me interessa e muito, e vou acompanhar!!!
Abraço e boa sorte sempre!!!
I was fully prepared for something janky as hell. This was the opposite of that. Surprisingly clean casting, really curious about how you plan to finish it.
Ayyyyyy there he is!!!!
I was surprised to see a new video from you and then equally surprised to find I was no longer subbed. I think YT automatically dropped my sub during your break from uploading 😕
Heck yeah!
incredible :O
nice job
perfect job for a mateur
amazing
Send it to Steve Watkins, he owns a 1943 planner that is just the thing for getting things flat
Awesome job, man. I wonder if you could have preheated the entire thing to assist in the travel problem. Doesn't matter, it's out of sight and of minimal structural significance. Impressive home setup, Impressive furnace, subscribed liked and will be reviewing the back catalogue.
Wow…just…wow😮
Nice size !
You might be able to find stainless steel linear rails which would expand slightly more with heat then standard Steel.
Nice bed, however, I'd be concerned about building a lathe out of aluminium due to the high thermal expansion, and wear issues when compared to cast iron. Facing the slides with cast iron or steel you would end up with thermal expansion differences with the materials. You have piqued my interest so I subbed and will enjoy the journey with you 👍
That's a cool part.
And absolutely amazing to do that as a DIYer.
But aren't these normally cast iron? Cheaper, heavier, all that
very nice
SUBSCRIBED!
Wow! 👍👍
I would recommend making the ways from ground steel or cast iron if possible for longevity.
Very cool .. will you be buying harden ways? I’m curious to see this process
Nice job. Huge respect for such casting. At the same time there are questions with hull stiffness of future lathe. Why didn't you reinforce it with steel rods or something like that? Plus, upper surface will be grinded by moving parts of lathe. You will need to put there steel too. Best regards. ^^
That looks amazing! Wouldn't it be a good option to use a big sheet of a sandpaper on a flat surface to make the lathe casting straight?
When you think about it, you dont need to grind and level the aluminium, its only the steel ways that matter.
Once they are scraped flat, bolting them in place, even using Babbitt levelling compound, should do thevtrick