Glad to be a mechanical engineer to understand where they DID show the machining part. Infact here's a few of the machining processes that they're shown: 0:34 Surface Grinding of Blank 0:53 Wire EDM to cut the profile (you really do get a machined gear out of that single process) They've also shown a lot of the measurement processes used nowadays, optical inspection etc.
This is formula student. In the lifetime of the car these gears are unlikely to break down, but it would have been nice to see it at the end of the season :D
Wow this just blows my mind. Who wouldve understood how many smart and dedicated people it takes to get everyday machinery we use to work correctly time and time again. I think the definition of hero's is wrong. If the lights ever go out you'll wish you knew one of these guys.
i believe the end dimensions were accurate when the vibration grinding was finished. of course they measure it afterwards too, but you also have to measure the part size BEFORE it is vibration grinded because when it is finished, it has to be the perfect size. this is done by testing the abrasives and setting the time and vibrational parameters on the machines. the first few gears made were obviously bad in size, but they adjusted the technology afterwards. this is called indirect measurement!
This vibratory process is likely Accelerated Surface Finishing or (ASF). This method of vibratory finishing uses high density, non-abrasive media with the addition of a chemical accelerant to convert the surface of the part to a state that the asperities can be slowly honed down. This non-directional finish significantly reduces frictional coefficients, thus increasing wear resistance, decreasing crack propagation points and ultimately gaining operational life. Material removal can be negligible at millionths of an inch.
Buy a WRX, or a used Mustang Gt/ Camaro SS if you want quick, this car is a blast. I have fun revving it to the moon, taking corners like a fool, and just drove JDLs show car, I am excited about turbocharging my own. The show car was limited to 280whp, but trust me when I say that thing was a rocket.
The most crucial part: tooth surface preparation by either polishing ( @Roessler) , grinding or the arc wire machining is missing. Also the eventual coating with wcc or dlc ....would be nice. If regtulations allow.
I enjoyed the video however it seemed like a lot of processes were missing from the video although I'm no gear expert. At 0:54 you see what looks like a milling machine with a fine bit that seems to drill a hole less than a mm deep and makes sparks while doing so. If this is the pre-EDM stage I would have thought the hole would need to go right through the product in order to feed the wire of the EDM machine through it and yet it didn't. Next at 0:58 you see a magic machine that you just put in a blank and out comes a finished gear. I thought it was the EDM machine and yet not only has it done the vertical shaping (by EDM) but also the scalloping (don't know the correct term, rotary profiling??) as though it's been turned in a lathe. Are there machines that can do the rotary profile as well as the vertical profile? Lastly they show a completed planetary gear assembly that seems to be the drive unit that connects the electric motor of the kart looking thing (electric formula student??) to the wheel and hub, etc. As I say, I'm no expert so would appreciate someone explaining the processes and machines. Thanks in advance.
EDM is a thermal process for removing unwanted material by applying cycled discharging sparks in the gap between an electrode and a conductive workpiece. This method is typically used for machining refractory metals and hard materials, which are difficult to machine with conventional machining techniques.
Planetary gear in Wheel, nice. But a shame you didn't show the tempering and grinding after.... and the Surfacemassurments not on the Flanks..... well..
As a mechanical engineer this video made me laugh. 50% of the video were the people looking at the gear and the whole process was just wasteful. And what about hardening/surface treatments? Wven if the steel was already hardened they should apply a surface hardening treatment
Right, first off I would like to ask yet again! How the hell I got here? Second, I would like to know where to get one of those little F1 cars. They look AMAZING
PastorOfMuppets now you know better. I even work with mechanical engineers who work with human tissues and membranes. This field is called soft tissue mechanics. The mechanical engineering field is incredibly wide and diverse.
It don't seem like a precision gear at all, I mean yeah little bit of surface grinding involved but apart from that EDM machined gear and spline, no gear/bore/O/D grinding involved nothing?
00:54 I think we're missing a lot of this process. It looked like a laser cutting device but then it goes under water or some other liquid and gets effectively machined? They are hiding the proprietary technology I'm just curious how that works I thought it was gonna cut the basic blank but apparently it didn't have to Cut through the metal. it cut 2 specific depths like a milling process. Anyone know the name? I'll look it up whatever this equipment is.
EDM is a thermal process for removing unwanted material by applying cycled discharging sparks in the gap between an electrode and a conductive workpiece. This method is typically used for machining refractory metals and hard materials, which are difficult to machine with conventional machining techniques.
Thomas Ramsden thanks. I want to learn 3d modeling. I have some experience with pro engineer. Which software would you recommend for production quality 3d models?
If licenses are not an issue, NX is the best (used by Apple, Boeing, Redbull, SpaceX) and its still pretty easy to use. If licenses are an issue, than Fusion360 is pretty powerful and free for a year. Fusion also does CAM and FEA.
Our formula student had an old metal flask welded in place for an oil catch ... no wonder these guys do so well.
Glad to be a mechanical engineer to understand where they DID show the machining part. Infact here's a few of the machining processes that they're shown:
0:34 Surface Grinding of Blank
0:53 Wire EDM to cut the profile (you really do get a machined gear out of that single process)
They've also shown a lot of the measurement processes used nowadays, optical inspection etc.
1:47 also shows vibratory tumbling of the gears to improve surface finish and remove burrs.
This is half life, you didn't show how does the gear dies.
#GearsLiveMatter
Half process...
This is formula student. In the lifetime of the car these gears are unlikely to break down, but it would have been nice to see it at the end of the season :D
@@FirstLast-yh5vc This is Formula Student. The gear is probably designed to last 1000 km to save another 2 g of weight.
somehow let me remind the life of a bolt video from red bull racing.
yeah, they go a lot of inspiration from that video, and it was very well made
Love this. I believe Red Bull did a similar one for a bolt a while ago
im pretty sure this was inspired by it.
This video should be named the life of mechanical engineer
This is so satisfying to watch ..
A raw piece of still being changed por something mechanical :D
Mechanical engineering it's best engineering
Wow this just blows my mind. Who wouldve understood how many smart and dedicated people it takes to get everyday machinery we use to work correctly time and time again. I think the definition of hero's is wrong. If the lights ever go out you'll wish you knew one of these guys.
Amazing video. Deserves more likes and views
Xade Red Bull's better
Xade nope, it kinda passes from blank to toothed gear in 3secs. Can't understand how they cut it and why the placed it underwater
That was EDM, (Electrical discharge machining)
brettlinton why wasn't laser cut? And what's the machine that submerged the part?
yes
The grind never stops
We must transit motion boys..
and this is where the series takes off
All that precision work then they throw it in a vibration grinding set and don't test the dimensions after...
Yeah I was a little confused at that part.
i believe the end dimensions were accurate when the vibration grinding was finished. of course they measure it afterwards too, but you also have to measure the part size BEFORE it is vibration grinded because when it is finished, it has to be the perfect size. this is done by testing the abrasives and setting the time and vibrational parameters on the machines. the first few gears made were obviously bad in size, but they adjusted the technology afterwards. this is called indirect measurement!
That wasnt a grider, it was a tumbler, it simply breaks edges, doesnt really change dimensions.
depends on how long you let it tumble :)
This vibratory process is likely Accelerated Surface Finishing or (ASF). This method of vibratory finishing uses high density, non-abrasive media with the addition of a chemical accelerant to convert the surface of the part to a state that the asperities can be slowly honed down. This non-directional finish significantly reduces frictional coefficients, thus increasing wear resistance, decreasing crack propagation points and ultimately gaining operational life. Material removal can be negligible at millionths of an inch.
It's amazing how far technology has come.
2:17 $11 usb microscope from ebay? :D
You'd be surprised how common these things are in manufacturing. Easy to give a quick visual inspection and the quality is good enough just for that.
Yeah, thats awesome. I use them daily :P
or maybe a $2000 Dino-lite ;)
gear chennai
Totally copied/inspired *Life of a bolt*
I think inspired ) itsnot so easy to make video like video by RedBull.
yep inspired, and who the fuck cares just enjoy the vid
Usain Bolt retired
Jelle Giesen this one was nicer
LAZERKONG thats true , but the idea has been copied . Wich is not a problem. With all the respect its a good video
This gear actually has a funnier life than me
I can probably buy a 2017 BRZ with that money.
A Brz? Might as well buy a civic
jerardo rosales I own a brz and it's a phenomenal vehicle, drive one for yourself.
alex moore it looks great and it's cheap but it sure as hell isn't quick
Buy a WRX, or a used Mustang Gt/ Camaro SS if you want quick, this car is a blast. I have fun revving it to the moon, taking corners like a fool, and just drove JDLs show car, I am excited about turbocharging my own. The show car was limited to 280whp, but trust me when I say that thing was a rocket.
The most crucial part: tooth surface preparation by either polishing ( @Roessler) , grinding or the arc wire machining is missing.
Also the eventual coating with wcc or dlc ....would be nice. If regtulations allow.
It's by watching videos like this one that I realize that Mechanical Engineering was not a bad choice for me.
That end cars awesome. i want it now.
tarksable well just think about how much work went into making that one gear, and from that get a rough idea of how high the price would be.
How familiar are you with the gears wars?
man, without those we are dead already
Thanks
So they sent the part off to be tumbled and heat treated? I work for a company that can do everything shown in the video without sending off the part.
Looks like I've ended up on my weird recommendations again
never in my life have I seen a machinist wearing a lab coat
These videos are incredible
Missing a bit the important part of hardening.
Unfortunately not all processes could be included in the video.
I enjoyed the video however it seemed like a lot of processes were missing from the video although I'm no gear expert. At 0:54 you see what looks like a milling machine with a fine bit that seems to drill a hole less than a mm deep and makes sparks while doing so. If this is the pre-EDM stage I would have thought the hole would need to go right through the product in order to feed the wire of the EDM machine through it and yet it didn't. Next at 0:58 you see a magic machine that you just put in a blank and out comes a finished gear. I thought it was the EDM machine and yet not only has it done the vertical shaping (by EDM) but also the scalloping (don't know the correct term, rotary profiling??) as though it's been turned in a lathe. Are there machines that can do the rotary profile as well as the vertical profile? Lastly they show a completed planetary gear assembly that seems to be the drive unit that connects the electric motor of the kart looking thing (electric formula student??) to the wheel and hub, etc. As I say, I'm no expert so would appreciate someone explaining the processes and machines. Thanks in advance.
What is the ”cutting”-procedure called? When the gear is formed out of the raw-material?
Did you find out? Here I am a year later wondering the same thing.
EDM is a thermal process for removing unwanted material by applying cycled discharging sparks in the gap between an electrode and a conductive workpiece. This method is typically used for machining refractory metals and hard materials, which are difficult to machine with conventional machining techniques.
It's more precious than a diamond
Before this was a bolt, now a gear, im going places
Planetary gear in Wheel, nice.
But a shame you didn't show the tempering and grinding after.... and the Surfacemassurments not on the Flanks..... well..
I love technology so much....
Incredible...
Cool Video guys, very nice👍
The attention to the detail given to f1 car parts is insane
It’s not F1 ^^
As a mechanical engineer this video made me laugh. 50% of the video were the people looking at the gear and the whole process was just wasteful. And what about hardening/surface treatments? Wven if the steel was already hardened they should apply a surface hardening treatment
not everything could be shown so they could only include certain parts
Wanna know what grinds my gears? Perfection.
Right, first off I would like to ask yet again! How the hell I got here? Second, I would like to know where to get one of those little F1 cars. They look AMAZING
1:12 that part really grinds my gears
cease
Awesome vidéo!!! Bravo !
i like the part where the gear is shown.
wait till they find out about home-depot
a weapon to surpass a metal gear
Could somebody list the processes that are shown in this video in making the gear? For the benefit of noobs
Anyone know what controller the man was using with his left hand in the beginning?
So each wheel has an electric motor, with a planetary gear box that the actual wheel bolts to? Is this for torque multiplication or something?
No tempering?
The gears were tempered, but not all processes could be in the video.
it's disappointing me;/ Carburization and heat treatment is very important stage and maybe the most sophisticated comparing to that was shown.
So, how much exactly do you know about the gear wars?
Super quality product!!
Amazing video :)
1:51 1:55 What are the names of the processes ?
Deburring/Vibration polishing ?
Vibratory finishing. It removes burrs and sharp corners
This changed my perception of Mechanical Engineers
Really? What did you think they would do?
I didn't know their work involved such extensive use of computer software.
PastorOfMuppets now you know better. I even work with mechanical engineers who work with human tissues and membranes. This field is called soft tissue mechanics. The mechanical engineering field is incredibly wide and diverse.
Interesting!
What's the music used in this video? I like it, thanks!
You know what really grinds my gea... Sorry couldn't resist...
Was that a plasma torch that operated under water?!
that was a wire edm machine, it's removing material by creating tiny sparks between a running wire and the work piece.
Gearhead would be proud
A motor at each wheel would make ground clearance a lot more practical on a truck.
When the life of a gear is more epic than your life as a human
Do they use CMM for all the gears they make?
No checks for gear profile, lead, runout and pitching?
Cool video! But hey, a straight cut cylindrical gear? Come back when you have made the perfect conical gear 😉
Have you heard of the gear wars
It don't seem like a precision gear at all, I mean yeah little bit of surface grinding involved but apart from that EDM machined gear and spline, no gear/bore/O/D grinding involved nothing?
You can imagine how much in such meticulously way producted gear will cost.
this almost madee cry
What is the device the engineer operates by left hand @ 0:18 ? Is it a HW part of that CAD program?
What is the medium in 1:50 and 1:54 that Rosler use for polishing the gear?
Which designing software do they use
And how much does that gear cost at the end?
do they use planetary system?
Yes, it is an in-wheel compoundend planetary gears set.
Why does the into look like the same formatting to AutoVlog?
Powertrain Engineer: *drops it*
which software you use for cad designing purpose
That was smaller than I thought
Only wire EDM?? That's incredible if their process is so good it doesn't require hobbing or broaching!
This is making of the gear , it life starts when it assabled on a wehicle.
there will be a time where subatomic distance of precision are possible
On which software you design?
That's called quality
00:54 I think we're missing a lot of this process.
It looked like a laser cutting device but then it goes under water or some other liquid and gets effectively machined? They are hiding the proprietary technology I'm just curious how that works I thought it was gonna cut the basic blank but apparently it didn't have to Cut through the metal. it cut 2 specific depths like a milling process.
Anyone know the name? I'll look it up whatever this equipment is.
EDM is a thermal process for removing unwanted material by applying cycled discharging sparks in the gap between an electrode and a conductive workpiece. This method is typically used for machining refractory metals and hard materials, which are difficult to machine with conventional machining techniques.
I guess it means that only one tire performs better than the others because it was equipped with a "perfect gear"
Bruh this video made me think about life
how about how you made the steel for the gear？
The steel for the gear was bought.
Looks similar to the "Life of a Bolt" video the Red Bull F1 team made.
Well, the final gear was way smaller than the blank in the beginning...
What is the device that designer is using with the left hand??
It's a HP SpacePilot pro. These 3d mouses are used alot in AutoCad applications to increase productivity.
Thank you for the answer..
Difference between quality engineering and "made in China"
really , gear story started with desgin, from hand to with report, many participate to give us one gear
i dont know...but that second guy in the blue polo is pretty darn cute
just amazing!!!
First half a minute is a massive advert for Microsoft tbh.
what about hardening, maybe one of the most important things..
Is this Kerbal Space Program?
can someone explain what the part with all the small pill looking things is 1:50
vibratory tumbling, used to polish surfaces and remove burrs.
woah i forgot about this comment, thanks for the answer. a lot has happened since then huh @@IkarimTheCreature
I finally realized that it is a bearing?
Does Not tempt much. Kudos to video makers n editers especially.
which 3d modeling software he is using?
Muhammad Saad Siemens NX 10
Thomas Ramsden thanks. I want to learn 3d modeling. I have some experience with pro engineer. Which software would you recommend for production quality 3d models?
If licenses are not an issue, NX is the best (used by Apple, Boeing, Redbull, SpaceX) and its still pretty easy to use.
If licenses are an issue, than Fusion360 is pretty powerful and free for a year. Fusion also does CAM and FEA.
kzinty Thanks for your guidance :)
Why did the gears not get hardened!?! :0
Planetary gears in the hub? Why?
Parker electric drive
Why? In place of a transmission they use planetary gears? Is it for packaging?
Packaging is the main reason. The compounded planetary gears set allow us the create an in-wheel assembly containing the motor and the final drive.
is this for kers
and you also "created" a lot of unsprung mass, which rarely is a good thing
Imagine one of these falling out of ur hands during production