I just watched because this is what I did for 35 years in Canada ... the size of the castings is truly impressive. The AI narrator makes me feel like I am at work again ... for no pay
I was at Cooper Bessimer in Stratford Ontario, Where were you ? Lots of heavy industry around there. Hendrican Springs, Timberjack Logging skidders, 3D and many, many more.
The sand mold process is definitely one of the coolest parts! It’s fascinating how intricate and precise it has to be. What do you find most interesting about making sand molds?
Do you think ai cares? ;/ I dont like what i see, still more people lets ai work, meanwhile they do... what? getting supid themselves? where this world goes... sory for my englisz :)
Requiring carefully preparation and coordination. Effing AI or text to speech. When I heard that sentence, I clicked away, left this comment and gave the video a 👎
Don't forget, that back in the day, everything you see being done by automated machines here, was done by men with lathes, milling machines, radial drills, hobbers, calipers and steel rules to create the dynamos of the Hoover Dam and Niagara Falls power plants, the huge single cylinder steam engines of the NYC subway system electrical power plants, steam locomotive frames cast as one piece with cylinders, and that were hollow to hold lubricating oil, and all the engines in planes and ships of 20th Century wars.
Sad to think our government allowed so much of this type of work to freely leave our country over the last century and be replaced with a banking/information/data/tech/consumer type of economy. Those type of facilities created so many highly skilled jobs that really boosted a local economy. Massive facilities that had to be maintained built operated and supplied. How they thought it was a good idea to lose manufacturing capacity shows how inept and greedy our politicians are and have been imo.
Here I am- 80 yrs old retired machinist worked in western Canada to old east Pakistan after watching this I feel like a nobody or nothing! Wow! I truly would not know where to start!
This takes me back to my younger days machining big castings for Cooper Bessimer in Stratford Ontario Canada. We made ships engines and pipeline compressors. I loved every moment.
@@haroldneal2365 They were cast in Japan and Korea and shipped here for machining. All the patterns would have stayed there I am afraid. Cameras were not allowed in the shop. Pretty high end things going on back then.
Indefinitely. The need for such forgings outweighs any monetary consideration. I wouldn't be surprised if Germany goes back to nuclear, at least for mini nuclear plants that are much easier to manage. Waste becomes self absorbed and not buried. In the mid future fusion may become practicle 50-75 years from now. Small fusion reactors are already being made.
Half the land could be covered with windmills, the other half with panels. On days when the clouds and wind cooperate, the plant could be operational. Production will be low and costly, but at least the CCP will be pleased.
Hello brother. +1 and a whole lot more. I found the latter half of the film absolutely frightening. All I could think whist watching it was: God, I would hate to have been the setter!
The segment on the generator shaft if full of factual errors. The first is that this alloy is an industrial secret. No manufacturer of a generator would ever accept such an alloy, nor would a power generating company., These shafts _must_ be made using a openly specified alloy. Further, any metallurgist can determine the composition from a tiny shaving, in less than a day. I have seen it done. Any one of these four instruments can do this in minutes: x-ray fluorescence spectrometer, optical emission spectrometer, inductively coupled plasma, and energy dispersive x-ray spectroscopyut. At 11:15 there are two errors: (1) if that is a "seven ton" press, then I am the Easter Bunny. For four years I ran a _twenty_ ton press, and it was _tiny_ compared to the size of this press. And (2) the flaking material is rust, iron oxide, not slag, which is a by-product of _smelting_ ores and recycled metals. Slags can be classified by their precursor and processing conditions; e.g., blast furnace slags, air-cooled blast furnace slag, granulated blast furnace slag, basic oxygen furnace slag, and electric arc furnace slag. The major components of slag include the oxides of calcium, magnesium, silicon, iron, and aluminium, with lesser amounts of manganese, phosphorus, and others. None of these are present in a workpiece such as this.
You sound like you know what you are talking about. I have no idea but i am fascinated with this sort of stuff. I watched a video on 'The Mester Press' .....WOW! I was hooked from there.
Unless, the final user an the maker is the same company, also "secret material" can be secret between 2 or more companies. I am not saying this is the case but could be. Also yes you can see the chemical composition of a metal with a spectrometer, but you can not figure out how it was made, what heat treatments has be done to it, forging etc.
If you want to get an idea of how hot the core of the earth is, work in a place like this. Yes those people get hot even in the heat proof suits. That steel, iron, aluminum, lead, copper, tin, or any other molten metal is extremely HOT. One tiny mistake or tiny safety hazard can end your life in places like this
Faurarii, aceștia care lucrează în otelarii, turnătorii, forje, laminoare, ies la pensie!!! La munca grea pe care o fac, nu cred!!! Multă sănătate le doresc și să aibă grijă de ei!!! De la un român și țăran liber.
I work at a steel mill I’m the crane operator when I first started man I thought I was in over my head running that crane but now it’s like like driving a car just feels normal
On the job training can't get any better then that. No book or school will ever beat it imo. Learn from your mistakes and also learn from the mistakes of others all people that got to a highly skilled level of any job or hobby started out as a novice at one time.
What's amazing about all that is practically everything they use was made in same way they are working basically you need a foundry to make a foundry equipment.
I was lucky enough to see smell touch all this stuff as a kid. I miss it. "When I smoked" I could lite up on cooling parts, spit on everything before you touched it. I even worked for a Castings Binders co. Got me a titanium digging bar I watched a smith pull out of his oven and hammer out for me as a kid, while I worked on his cool oven's gas and air.
I think they dropped a few zeros. More like 700 to 7000 tons of newton force. Hot forging uses much less than cold forging. Probably under 100 ton. The scale of this is throwing me off. I can't find a good source for something this big.
@@TodayMachine Keep workshop audio. If you are going to have narration, have it done by someone who knows something about casting and machining. The narration was at least in part created by AI. Some was just taken from brochures from the company that made the machines. There doesn't have to be a moral to every statement. "This is done to ensure the quality and usability of the part" type of statement is used way to much in most AI narration. Basically, the narration was very low effort. I only made it less than 1/4 of the way through before coming in here and downvoting and then leaving this comment.
@@TodayMachine 4:47 I would rather hear about those massive milling machines, tool sizes, cutting rates, accuracy and look at the size of that tool changer at 5:08
The technology behind CNC boring and heavy machining is truly remarkable. It’s amazing how advanced equipment meets the demands of such large-scale operations
My older brother who's no longer with us used to be responsible for multi ton casting back in the 1970's at a foundry that no longer exists in Willenhall, West Midlands
Very impressive! At times like what follows after 8:20, you can see the chips get hot enough to turn color. I am surprised that coolants (liquid, mist or air) do not appear to be used for much (but not all) of the machining shown in this video. The segment on machining a crankshaft, starting at 25:58, and running until the end, is especially impressive.
Coolant isn't used on some tools. Carbide is hard, but it's also brittle. It likes it's temperature to stay even, doesn't mind it being hot. Shock cooling will cause cracks to form and lead to edge failure. Many of the tools that weren't running coolant were big face mills which often run without coolant. One of the primary uses for the coolant is actually for chip evacuation. Recutting already cut chips is hard on tooling and screws up the surface finish. Coolant flushes the chips out quickly to prevent them from getting recut and packed tightly in the hole. It's essential for running the long gun drills with straight flutes, no spiral to help clear chips. The coolant running thru them is usually high pressure, 600 - 1500 PSI and if it fails, the drill will weld itself inside the hole. There are usually small passages that pass from the end of the tool that's in the spindle all the way to the tip to pass the coolant to the very end. Because it's a constant feed of coolant, the carbide temp stays stable and happy at higher cutting loads. Also, they may have just turned the coolant off to make it easier to see what's happening. I've assisted in setting up machines to make certain shots for a film crew making a promotional video for the company a few times. Often we'd just run the tools dry, usually on a scrap part, just so the audience could see the action easily. Always had to include the slow-motion shot of the automatic tool changer changing tools in the spindle. And if you had a 'robot' doing something, that automatically became the focus of the 'artsy' folks making these video's.
@@marcseclecticstuff9497 Thank you for the reply. I understand what you said, and it makes sense. I've also heard that carbide tools are very tolerant to running hot, and may actually prefer that to an extent. Since making a mistake as a teenager LONG ago, I've been mindful about clearing chips when doing hobby work with a drill press, especially on aluminum. I once dismissed chip removal until I noticed no chips coming out of a thick aluminum piece and no progress in drilling depth. A ball of aluminum had wadded around the bit, making it impossible to either continue drilling or removing the drill bit. I felt like Homer Simpson (DOH!)
I worked at a foundry that made rolls of sheet steel and they set them outside to cool, for days you couldn't come within 100 feet of them without having to escape the heat.
A beautifully shot video with an infuriating artificial narrator. What it leaves out is very important information. The very first part of this video shows the workers skimming off the 'slag', the molten impurities off the top of the boiling hot metal. This is extremely important for the strength and combined matrix of the pour. Then the video shows the person getting a small sample of the pour to confirm the material inside of the molten mix meets the desired combination of metals in the pour. This work is extremely dangerous and extraordinarily hot. Humans die often if there is any malfunction. So safety procedures ,in the United States are well followed. In other nations, seeing this kid of work done is pretty terrifying.Massive respect to the men and women who do this kind of work, no matter the scale of the pour and processing involved.
I don't see how it can be. The holes for the pins can be easily drilled out, but how can they separate the two parts? I suspect the machining of this job was programmed up as a demonstration of what the machine can do, and some guy with a sense of humour put a fake universal joint in to make us watch to the end.
@@keithammleter3824 Haha, a u-joint cliff hanger... could be... :)) Seem very expensive to cast, forge and machine this just for show though. So, that's what I'd like to see; how they would separate them. I think it can be done - you know, until you've seen a crankaxle having its crank pins turned, or how a cube is made on a lathe, that is kind of hard to imagine as well. It would make sense to save the u-joint for last to support the rest of the machining while the axle is one rigid piece.
@@Trottelheimer Well, the machine shown probably cost $500,000 or more. 5-axis machines sell for up to $1,000,000. If you make machines, you have to show potential customers what they can do. There is no evidence the billet was specially cast. They probably just went to a local steel supplier and bought an off cut from some heavy rod to demonstrate the machine with. When the demo was done, they threw it away. My local steel supplier has a cutting service and can supply such a large diameter round bar for less than $200. What weird 4-cylinder engine has a universal joint right on the crankshaft? Universal joints are standard range parts like bolts, nuts, and bearings. Made by the million on special machines for a unit cost well below the cost of using a CNC machining centre.
Its crazy when you look at all these giant blocks of steel and that all the iron came from a star that went super nova about 5 billion ish years ago, and that all the iron we use was once a dilute solution as the planets oceans, only the addition of oxygen in the oceans turned all the iron to rust which then settled on the seabed to be discovered billions of years later by man as iron oxide. There is so much of the stuff!
Did that guy said exerts of pressure of 7 tons? Holy crap try to get your facts straight there guys. I have a 12 ton hand jack in my shed and it's not 70 tons because that wouldn't get the job done so now I'm just confused.
Interesting, but not seeing the mold created and not getting info on what the end-state objective is, really takes away from the ability to show a before/after transition… Watching similar videos depicting the foundry work associated w/ forging large maritime vessel engine blocks, having those more detailed steps included makes the video less drab and monotonous, IMHO
It's pieces like this that are left over from what ever happened in antiquity and people think their big carved stones. When in reality they are big humngus pieces of metal. Not carved stones.
11:24 "... at the highest operational level, the press can apply 7 Tons of pressure ..." That tells me how much force the press applies not its pressure. Pressure = force ÷ area
Amazing video. Is it reasonable to assuming that the giant cast blocks are used in nuclear plants? It seems that the multiple cylinders on one axis is where nuclear fuel is loaded and chain reaction controlled while on the other axis, water flows and converts to steam? If the Audio could be paced slower, (some of the commentators say it's AI), I think it's ok; but could be better; given the hi-quality video. On Content, I think the video could have been in 2 parts; 1st Part: 'Casting to Forging' of Heavy block, plate and shaft and their machining. Part 2: CNC operations w/ High Precision Robotic arms. If you don't mind, some observations on Part 1 - ( 10 minutes ) for transcript (?) Foundry section: On the first cast block, the amount of molten metal poured in is 160 tons while the casting retrieved after cooling; is 136 tons. So where did 24 tons disappear? Also if the ladle capacity was mentioned; and duration to pour, etc. it would've helped. You state, 'Time required for cooling, is ‘weeks’ as the cooling has to be gradual to reduce internal stresses' (localized ‘shrinkage cracks’?). The dimensions and thickness of the cast block could have been included? The robotic arm to clean the casting - I suspect - is to avoid accidents in case there’s some ‘hot spots’ (due to mould failure) and molten metal may sputter out from such ‘wells’? At 5:00, video shows several cast blocks with ‘machined and bored cylinders’. Obviously, for a casting of this size, not to have even finer levels of microscopic shrinkage cracks - is unbelievable. At 7:00 - Milling Plate 2000 x 1000 x 200 thick plate Material: HT steel with 118 Newtons / mm square (High alloy, high tensile steel is generally correlated with higher hardness - difficult to weld, for example). Amazing that Milling operation is carried out both on the wider surface and on the sides - simultaneously. At 10:00 - Forging the generator shaft: The work piece weighing 80 tons, is around 1.5 mt x 1.5 mt x 13 mt long? Stages, forge to square, then to octagon, then to hardening by water quenching and finally to machining. Tensile strength achieved:800 N/mm2 ! Anyway, a great job! Thanks.
Sad to think our government allowed so much of this type of work to freely leave our country over the last century and be replaced with a banking/information/data/tech/consumer type of economy. Those type of facilities created so many highly skilled jobs that really boosted a local economy. Massive facilities that had to be maintained built operated and supplied. How they thought it was a good idea to lose manufacturing capacity shows how inept and greedy our politicians are and have been imo. Covid was a wake up call for the better that we need to get back to our roots of building things in this country at a high level.
It's insane to this day people are getting that close to the process. I've heard of people falling into those and they have to bury the entire thing since there's no way of _getting them out_
I just watched because this is what I did for 35 years in Canada ... the size of the castings is truly impressive.
The AI narrator makes me feel like I am at work again ... for no pay
"I pretend to work. They pretend to pay". This video was pretty incredible though...I agree.
It must feel nostalgic watching this video! What advice would you give to someone just starting in this line of work today?
I was at Cooper Bessimer in Stratford Ontario, Where were you ? Lots of heavy industry around there. Hendrican Springs, Timberjack Logging skidders, 3D and many, many more.
I worked 32 years in a Steel Foundry. We are the unsung heroes of all industries. Only the bravest people can do this kind of work
@@Jaydog555 CAN I SEE THE PATTERN FOR THIS CASTING
@@haroldneal2365 ermm.. I don't think bro means he was like, a character in this video
Especially you folks whose shoulders they stand on today!
One of the easiest jobs honestly
Awesome images. Sadly the commentary is only vaguely inspired by what is happening, without any detailed knowledge.
Commentary audio is also broken, it crackles. All other noises from the video seem fine.
it's a robot...
Pretty hard to inspire speech generating software
It seems to be reading word for word the bullet points off a sales brochure !
It's AI
You didn't show the cool part...making the sand mold. I find that part amazing.
That part can get pretty hot too 🤪
The sand mold process is definitely one of the coolest parts! It’s fascinating how intricate and precise it has to be. What do you find most interesting about making sand molds?
Making the crankshaft with what looks like a solid universal joint was strange... I'd have liked to see the joint "emerge" from the billet... 🤔
I was looking forward to that, as well.
me too!
im no friend of ai
Do you think ai cares? ;/
I dont like what i see, still more people lets ai work, meanwhile they do... what? getting supid themselves?
where this world goes...
sory for my englisz :)
Someone used text to speech because the original isn't in English. Why pay an English narrator? I don't think you know what a.i even is lol.
Requiring carefully preparation and coordination. Effing AI or text to speech. When I heard that sentence, I clicked away, left this comment and gave the video a 👎
Agree. Hate it and the hordes of sheeple ready to lay down and obey their robot master.
Nor am i
Don't forget, that back in the day, everything you see being done by automated machines here, was done by men with lathes, milling machines, radial drills, hobbers, calipers and steel rules to create the dynamos of the Hoover Dam and Niagara Falls power plants, the huge single cylinder steam engines of the NYC subway system electrical power plants, steam locomotive frames cast as one piece with cylinders, and that were hollow to hold lubricating oil, and all the engines in planes and ships of 20th Century wars.
Battleship guns
Sad to think our government allowed so much of this type of work to freely leave our country over the last century and be replaced with a banking/information/data/tech/consumer type of economy. Those type of facilities created so many highly skilled jobs that really boosted a local economy. Massive facilities that had to be maintained built operated and supplied. How they thought it was a good idea to lose manufacturing capacity shows how inept and greedy our politicians are and have been imo.
These giant CNC machines and forging machines not only create products with high precision but also open up a new world for modern industry.
No forging at all in the video
Here I am- 80 yrs old retired machinist worked in western Canada to old east Pakistan after watching this I feel like a nobody or nothing! Wow! I truly would not know where to start!
It really is impressive eh.
This takes me back to my younger days machining big castings for Cooper Bessimer in Stratford Ontario Canada. We made ships engines and pipeline compressors. I loved every moment.
b. Could I see the wood pattern, please?
@@haroldneal2365 They were cast in Japan and Korea and shipped here for machining. All the patterns would have stayed there I am afraid. Cameras were not allowed in the shop. Pretty high end things going on back then.
Napisz ilu niewinnych Indian właścicieli tych ziem wymordowaleś ?
Our foundry in Sheffield has cast big components as much as 600+ tons !
Irigylem azokat a szakembereket, akik ilyen nagy elkatrészeket, nagy pontossággal el tudnak készíteni! Ez is művészet mint a hegesztés!!
I couldn’t work out if this was an informative video or an advert for the machinery.
both , pride and show , they are brothers of the smiths forging samurai sword
They're one and the same thing
Proud to be a HMC and hbm operator for heavy engineering ❤
They build those big battleship guns a long time ago without all this modern technology. Show that
why?
@@ecki74 🙄
Just amazing what the human mind can conceive. I celebrate the genius of these inventors and engineers. Just, think, we're just getting started.
Buck Rogers Jet Packs.
It is interesting that these inventors and builders all come from a very small part of the world…
One wonders how long such companies will stay functional in the energy environment of Germany, but it does seem to have a unique niche.
Depends on "leadership"
Fuck NATO
Indefinitely. The need for such forgings outweighs any monetary consideration. I wouldn't be surprised if Germany goes back to nuclear, at least for mini nuclear plants that are much easier to manage. Waste becomes self absorbed and not buried. In the mid future fusion may become practicle 50-75 years from now. Small fusion reactors are already being made.
my company closes its doors soon. we did the same stuff.
Half the land could be covered with windmills, the other half with panels. On days when the clouds and wind
cooperate, the plant could be operational. Production will be low and costly, but at least the CCP will be pleased.
Retired machinist here this blows my mind. Never run any machine that has cnc. Old school and glad of it .
Hello brother. +1 and a whole lot more. I found the latter half of the film absolutely frightening. All I could think whist watching it was: God, I would hate to have been the setter!
The segment on the generator shaft if full of factual errors. The first is that this alloy is an industrial secret. No manufacturer of a generator would ever accept such an alloy, nor would a power generating company., These shafts _must_ be made using a openly specified alloy. Further, any metallurgist can determine the composition from a tiny shaving, in less than a day. I have seen it done. Any one of these four instruments can do this in minutes: x-ray fluorescence spectrometer, optical emission spectrometer, inductively coupled plasma, and energy dispersive x-ray spectroscopyut. At 11:15 there are two errors: (1) if that is a "seven ton" press, then I am the Easter Bunny. For four years I ran a _twenty_ ton press, and it was _tiny_ compared to the size of this press. And (2) the flaking material is rust, iron oxide, not slag, which is a by-product of _smelting_ ores and recycled metals. Slags can be classified by their precursor and processing conditions; e.g., blast furnace slags, air-cooled blast furnace slag, granulated blast furnace slag, basic oxygen furnace slag, and electric arc furnace slag. The major components of slag include the oxides of calcium, magnesium, silicon, iron, and aluminium, with lesser amounts of manganese, phosphorus, and others. None of these are present in a workpiece such as this.
Even I picked up on these same errors - and I'm a friggin horticulturalist !
You sound like you know what you are talking about. I have no idea but i am fascinated with this sort of stuff. I watched a video on 'The Mester Press' .....WOW! I was hooked from there.
Unless, the final user an the maker is the same company, also "secret material" can be secret between 2 or more companies. I am not saying this is the case but could be. Also yes you can see the chemical composition of a metal with a spectrometer, but you can not figure out how it was made, what heat treatments has be done to it, forging etc.
you are literally a dog
If you want to get an idea of how hot the core of the earth is, work in a place like this. Yes those people get hot even in the heat proof suits. That steel, iron, aluminum, lead, copper, tin, or any other molten metal is extremely HOT. One tiny mistake or tiny safety hazard can end your life in places like this
The workers are braverman like
facing the volcanoic eruptions
everyday.
Faurarii, aceștia care lucrează în otelarii, turnătorii, forje, laminoare, ies la pensie!!! La munca grea pe care o fac, nu cred!!! Multă sănătate le doresc și să aibă grijă de ei!!! De la un român și țăran liber.
I work at a steel mill I’m the crane operator when I first started man I thought I was in over my head running that crane but now it’s like like driving a car just feels normal
On the job training can't get any better then that. No book or school will ever beat it imo. Learn from your mistakes and also learn from the mistakes of others all people that got to a highly skilled level of any job or hobby started out as a novice at one time.
What's amazing about all that is practically everything they use was made in same way they are working basically you need a foundry to make a foundry equipment.
So satisfying to watch that big boring mill making chips! I ran a big Hercules boring mill for a number of years in Arkansas. Good times!
Do you know why they need lube for some jobs and not for others?
I was lucky enough to see smell touch all this stuff as a kid. I miss it. "When I smoked" I could lite up on cooling parts, spit on everything before you touched it. I even worked for a Castings Binders co.
Got me a titanium digging bar I watched a smith pull out of his oven and hammer out for me as a kid, while I worked on his cool oven's gas and air.
A ilu niewinnych Indian właścicieli tych ziem tam wymordowaleś ?
Công nghệ Hiện đại quá...Các bạn là bậc thầy trong ngành chế tạo.
Si la fundición de piezas enormes es difícil, su mecanizado es todo un arte.
Less talking and less flamboyant language is better.
Amazing what humans can achieve..
I luv watching metal being worked, forged etc. No thermo cycling prior to quenching? Amazing video
11:27 more than 7 tons. Maybe a couple of orders of magnitude more.
14,000 pounds per square inch?
I think they dropped a few zeros. More like 700 to 7000 tons of newton force. Hot forging uses much less than cold forging. Probably under 100 ton. The scale of this is throwing me off. I can't find a good source for something this big.
No thumbs up for bad audio it was very annoying I could only get halfway through the video
Thank for you comment, should we keep the video silent, keep it without workshop audio?
@@TodayMachine Keep workshop audio. If you are going to have narration, have it done by someone who knows something about casting and machining. The narration was at least in part created by AI. Some was just taken from brochures from the company that made the machines. There doesn't have to be a moral to every statement. "This is done to ensure the quality and usability of the part" type of statement is used way to much in most AI narration. Basically, the narration was very low effort.
I only made it less than 1/4 of the way through before coming in here and downvoting and then leaving this comment.
@@TodayMachine 4:47 I would rather hear about those massive milling machines, tool sizes, cutting rates, accuracy and look at the size of that tool changer at 5:08
AI voice over by the sounds of it.
You did well, I only made 8.5 mins.
These machines and the people who designed and made them are amazing! How far we've come with the CNC.
They forgot to show how the molds are made.
And the melt process.
@@ImListeningToReason and the smoko room
Moole...
The technology behind CNC boring and heavy machining is truly remarkable. It’s amazing how advanced equipment meets the demands of such large-scale operations
They always leave my part out I was a patternmaker
Ok ok let go The Friend บ๊ายบายบ๊ายบาย
This is actually one of the better heavy steel videos
The drive shafts are 🤌
My older brother who's no longer with us used to be responsible for multi ton casting back in the 1970's at a foundry that no longer exists in Willenhall, West Midlands
This was cool until it turned into an ad foe the cnc equipment.
😮😮😮😮wow
There can't be very many companies in the world able to handle those huge castings.
"T" Totally amazing! I'm amazed! 😃👍
ว้าว Number One
Impressionante, grandioso.
Rubbish ai narration.
It said the giant forging press applies 7tons of pressure.
8 secs. in: "carefully preparation" Couldn't stand any more.
Lava stirrer has to be one of the most badass jobs ever
They are not stirring it they are removing the slag off the top
Это фантастика, которая стала реальностью !!!
Вы Боги !!!🎉🎉🎉
Very impressive! At times like what follows after 8:20, you can see the chips get hot enough to turn color. I am surprised that coolants (liquid, mist or air) do not appear to be used for much (but not all) of the machining shown in this video.
The segment on machining a crankshaft, starting at 25:58, and running until the end, is especially impressive.
Coolant isn't used on some tools. Carbide is hard, but it's also brittle. It likes it's temperature to stay even, doesn't mind it being hot. Shock cooling will cause cracks to form and lead to edge failure. Many of the tools that weren't running coolant were big face mills which often run without coolant. One of the primary uses for the coolant is actually for chip evacuation. Recutting already cut chips is hard on tooling and screws up the surface finish. Coolant flushes the chips out quickly to prevent them from getting recut and packed tightly in the hole. It's essential for running the long gun drills with straight flutes, no spiral to help clear chips. The coolant running thru them is usually high pressure, 600 - 1500 PSI and if it fails, the drill will weld itself inside the hole. There are usually small passages that pass from the end of the tool that's in the spindle all the way to the tip to pass the coolant to the very end. Because it's a constant feed of coolant, the carbide temp stays stable and happy at higher cutting loads.
Also, they may have just turned the coolant off to make it easier to see what's happening. I've assisted in setting up machines to make certain shots for a film crew making a promotional video for the company a few times. Often we'd just run the tools dry, usually on a scrap part, just so the audience could see the action easily. Always had to include the slow-motion shot of the automatic tool changer changing tools in the spindle. And if you had a 'robot' doing something, that automatically became the focus of the 'artsy' folks making these video's.
@@marcseclecticstuff9497 Thank you for the reply. I understand what you said, and it makes sense. I've also heard that carbide tools are very tolerant to running hot, and may actually prefer that to an extent. Since making a mistake as a teenager LONG ago, I've been mindful about clearing chips when doing hobby work with a drill press, especially on aluminum. I once dismissed chip removal until I noticed no chips coming out of a thick aluminum piece and no progress in drilling depth. A ball of aluminum had wadded around the bit, making it impossible to either continue drilling or removing the drill bit. I felt like Homer Simpson (DOH!)
@@marcseclecticstuff9497 Excellent and informative comment.
Oooh heerlijk vet staal !
Can't imagine how much soot the workers have to clear from their chests every morning.
I wish RUclips had a filter button to block text to voice videos.
We in Germany will do all this too, but better and with renewable energy and no CO²! Believe it, or not... 😁
"requiring carefully preparation" nothing kills a video like a major grammar error in the first sentence spoken by an AI... I think I will pass.
Now that’s a niche market
Fascinating 👍👏👏
Looks like a War of the Worlds machine rising from below the ground
6:22 Schiess nicht Scheiss! 🤣
Amazing fabrication. :)
I worked at a foundry that made rolls of sheet steel and they set them outside to cool, for days you couldn't come within 100 feet of them without having to escape the heat.
A beautifully shot video with an infuriating artificial narrator. What it leaves out is very important information. The very first part of this video shows the workers skimming off the 'slag', the molten impurities off the top of the boiling hot metal. This is extremely important for the strength and combined matrix of the pour. Then the video shows the person getting a small sample of the pour to confirm the material inside of the molten mix meets the desired combination of metals in the pour. This work is extremely dangerous and extraordinarily hot. Humans die often if there is any malfunction. So safety procedures ,in the United States are well followed. In other nations, seeing this kid of work done is pretty terrifying.Massive respect to the men and women who do this kind of work, no matter the scale of the pour and processing involved.
really eye catching
Ah, I was hoping to see that universal joint being machined at the end... :D Anyway, this scale of manufacturing is fascinating!
I don't see how it can be. The holes for the pins can be easily drilled out, but how can they separate the two parts? I suspect the machining of this job was programmed up as a demonstration of what the machine can do, and some guy with a sense of humour put a fake universal joint in to make us watch to the end.
@@keithammleter3824 Haha, a u-joint cliff hanger... could be... :)) Seem very expensive to cast, forge and machine this just for show though.
So, that's what I'd like to see; how they would separate them. I think it can be done - you know, until you've seen a crankaxle having its crank pins turned, or how a cube is made on a lathe, that is kind of hard to imagine as well. It would make sense to save the u-joint for last to support the rest of the machining while the axle is one rigid piece.
@@Trottelheimer Well, the machine shown probably cost $500,000 or more. 5-axis machines sell for up to $1,000,000. If you make machines, you have to show potential customers what they can do. There is no evidence the billet was specially cast. They probably just went to a local steel supplier and bought an off cut from some heavy rod to demonstrate the machine with. When the demo was done, they threw it away. My local steel supplier has a cutting service and can supply such a large diameter round bar for less than $200.
What weird 4-cylinder engine has a universal joint right on the crankshaft?
Universal joints are standard range parts like bolts, nuts, and bearings. Made by the million on special machines for a unit cost well below the cost of using a CNC machining centre.
Strong like Bitcoin 🎉
Its crazy when you look at all these giant blocks of steel and that all the iron came from a star that went super nova about 5 billion ish years ago, and that all the iron we use was once a dilute solution as the planets oceans, only the addition of oxygen in the oceans turned all the iron to rust which then settled on the seabed to be discovered billions of years later by man as iron oxide. There is so much of the stuff!
They guy said one million times precision. I got headache listening to this guy. Out of 6 million words he said maybe only 8 was useful.
I love heavy metal!🤘🏻
This is what has to be brought back to the 🇺🇸
I love Lego’s!!!!!!
Did that guy said exerts of pressure of 7 tons? Holy crap try to get your facts straight there guys. I have a 12 ton hand jack in my shed and it's not 70 tons because that wouldn't get the job done so now I'm just confused.
Interesting, but not seeing the mold created and not getting info on what the end-state objective is, really takes away from the ability to show a before/after transition… Watching similar videos depicting the foundry work associated w/ forging large maritime vessel engine blocks, having those more detailed steps included makes the video less drab and monotonous, IMHO
Heavy duty processing
That CNC boring machine gave me a solid virtual dose of mechaniphobia
Worked at BSC River Don Works in the 1970's.
The title Foundries, Forges and Engineering Division explained all.
Memories of times past.
China is drooling at this
I'm thinking of a mining dozer 🤔,,, bout 2500 tons with lots o horsepower 😎🥳
It's pieces like this that are left over from what ever happened in antiquity and people think their big carved stones. When in reality they are big humngus pieces of metal. Not carved stones.
Heard the voice, stayed for 4 seconds, goodbye.
Keep safety
Hard hats are optional with the foundry team apparently 🤔
Excellent!
11:24 "... at the highest operational level, the press can apply 7 Tons of pressure ..."
That tells me how much force the press applies not its pressure. Pressure = force ÷ area
It looks like they use crews to remove the slag and get samples.
I closed the biggest castiron pour in Canada...30 years ago....they sold it down the river...we poured it all...ductile iron and diamond .
Amazing video. Is it reasonable to assuming that the giant cast blocks are used in nuclear plants? It seems that the multiple cylinders on one axis is where nuclear fuel is loaded and chain reaction controlled while on the other axis, water flows and converts to steam?
If the Audio could be paced slower, (some of the commentators say it's AI), I think it's ok; but could be better; given the hi-quality video. On Content, I think the video could have been in 2 parts; 1st Part: 'Casting to Forging' of Heavy block, plate and shaft and their machining. Part 2: CNC operations w/ High Precision Robotic arms. If you don't mind, some observations on Part 1 - ( 10 minutes ) for transcript (?)
Foundry section: On the first cast block, the amount of molten metal poured in is 160 tons while the casting retrieved after cooling; is 136 tons. So where did 24 tons disappear? Also if the ladle capacity was mentioned; and duration to pour, etc. it would've helped.
You state, 'Time required for cooling, is ‘weeks’ as the cooling has to be gradual to reduce internal stresses' (localized ‘shrinkage cracks’?). The dimensions and thickness of the cast block could have been included?
The robotic arm to clean the casting - I suspect - is to avoid accidents in case there’s some ‘hot spots’ (due to mould failure) and molten metal may sputter out from such ‘wells’?
At 5:00, video shows several cast blocks with ‘machined and bored cylinders’. Obviously, for a casting of this size, not to have even finer levels of microscopic shrinkage cracks - is unbelievable.
At 7:00 - Milling Plate 2000 x 1000 x 200 thick plate
Material: HT steel with 118 Newtons / mm square (High alloy, high tensile steel is generally correlated with higher hardness - difficult to weld, for example). Amazing that Milling operation is carried out both on the wider surface and on the sides - simultaneously.
At 10:00 - Forging the generator shaft: The work piece weighing 80 tons, is around 1.5 mt x 1.5 mt x 13 mt long? Stages, forge to square, then to octagon, then to hardening by water quenching and finally to machining. Tensile strength achieved:800 N/mm2 !
Anyway, a great job! Thanks.
You want to show how huge anchors are cast an made.👍👍🙏🙏🇬🇧🇬🇧
Are they making Lizzo’s bathtub?!
Great n amazing job.🤔❤❤❤
Does the footage have anything zo do with the voice over? 😂
I like to think of casting as the original additive manufacturing method.
Script both written and read by someone with no clue what they were saying.
Sad to think our government allowed so much of this type of work to freely leave our country over the last century and be replaced with a banking/information/data/tech/consumer type of economy. Those type of facilities created so many highly skilled jobs that really boosted a local economy. Massive facilities that had to be maintained built operated and supplied. How they thought it was a good idea to lose manufacturing capacity shows how inept and greedy our politicians are and have been imo. Covid was a wake up call for the better that we need to get back to our roots of building things in this country at a high level.
Abbreviations are fine when done in printed media. When the information is narrated or done with AI, not so much.
Maquinas similares y otras usaban los egipcios.
Ya no se pregunten mas, de como construyeron las piramides.
El misterio ya está resuelto.
😊
The text to speech voice is annoying .
The video wouls be much more enjoyable if you do subtitles and put nice music instead.
🤯‼️
so much better with the sound off
Not a problem.
9:00 That has to be the prettiest swarf I've ever seen
and then some person will say "we dont have today's tools to create pyraminds"
Welcome Home Ghana Accra Kotoka International Airport and Nigeria Abuja to meet Father and mother steve and Cynthia Baidoo Crown, Thanks
Are these commercials for large machinery? The manufacturer and model info is crazy...
It's insane to this day people are getting that close to the process.
I've heard of people falling into those and they have to bury the entire thing since there's no way of _getting them out_
I wounder how we are going to make things like this when we are powered solely by wind mills and solar panels.