These are relatively harmless crashes... the frustration as an operator that invested time setting it up makes it funny. It's funny because it's so vicariously frustrating that you have to laugh or cry, or scream obscenities. It's catharsis. If you're an owner/manager that can't laugh at these, I don't know what to tell you. Operators aren't laughing because they don't give a shit and want to throw away your money, they feel how expensive their mistakes are laughing as a way to deal with extreme pressure and anxiety in many cases.
Hmm... No, not really. Had some problems with X, Y, Z "indicators" that caused the machine to move where it was not before in that program. Usually, the machine stops, but it happened that it didn't stop. Luckily there was not any damage, but failures are happening. Electronic parts can and are going bad. F.
This, and I've personally seen z-axis motors completely fail out during runs. It's rare, but more importantly, it's almost always the fault of the motor and not the user. So yeah, just like any machine. It's only as good as its parts.
@@Maisonierhappened on Hurco, something similar. The machine went to do a program, but the spindle was not spinning. New story, the table went to the final X position and program went on and on. The tools were changing. F.
The tool shop I used to work in, my desk was right by the programmer's. I'm designing some tool or something and EJ (toolmaker on the big mill) opens the door and tells the programmer, "David, there's a hell of a lot of difference between Z-.9 and Z-9.!" and lays a snapped and burned 1.5" ball nose on his desk.
It's been about 3 years since I stopped machining and I still feel nervousness/ sickness in my stomach watching these videos. Not the break, but the moment before when you know it's coming. Similar to that feeling you get when you're proving out a program and spinning parts get close to other parts. That last one had me on edge because I had a good idea of what was coming. I actually lent away from my screen and held my hand in front of my face to block my view. Like I was watching a horror movie waiting for the jump scare.
The worst by far is proving out a program on a CNC lathe. Because not only are you nervous about what the tool itself is doing you’re also watching all of the tools around the tool it’s using. When I was in tech school a guy wasn’t watching a drill and feed that into the Chuck the whole drill Chuck blew up into 1000 pieces. It was so loud people could hear it in the classrooms outside of the shop
@@esavage8855 When I started as an apprentice, there was another guy that started with me. He thought he knew everything. He once just let a program run without checking it and sent a tool straight into the chuck at full speed. The machine never worked the same again. I spent years on it, teaching myself how to compensate for all the inaccuracies it made.
@@FlipAndLand damn that’s crazy. this guy was just an idiot he tried for years to get through tech school and never did and eventually gave up on tech. Plus I work with him and he’s an idiot there too which is why the boss only puts him on production work. There was one time at work he was doing production work on hardened stainless steel and this roughing tool was getting loud and two guys approached him telling him to stop the program and change the tool he ignored both of them and the tool blew up and scraped the part and broke the tool holder. It was a 5/8” 5flt end mill. Somehow he still works there. Now they just put him on production work with aluminum where the tools last pretty much forever. I have story after story about this guy he also managed to crash a manual mill when we were in tech
It really doesnt matter how long you have been machining, its always terrifying. Ive only been machining for 8 weeks as of now, i always check everything before starting up like 3 times.
I was a machinist for 40 years making injection molds. Grossly underpaid trade. I’m so glad to be out of it. This video reminds of the stress of the job.
@@chains6558 Haha, why? I was eager to delve into everything related to CNC, lathes, machining, and so on, all in pursuit of making a profit. I live in Argentina, where there's quite a limited market due to the high cost of the machinery, a shortage of skilled labor for repairs, and various import restrictions. Interestingly, it's more cost-effective to import the finished products than to produce them locally.
Could you please expand on this a bit? Do you mean in general, or specifically injection moldmakers? And if specifically injection moldmakers, do you mean across the board or rather only the ones that make the more "simple" molds? I put "simple" in quotes because I know it's never simple designing molds and holding such tolerances, I rather mean to say "simple" when compared to some other much more complicated molds. Reason I ask is that I was always told that moldmakers are very well-paid, because they enable companies to mass-produce, it's such a specialized craft and some molds can cost hundreds of thousands or even millions of dollars in some cases. Is this not true then? Or is this only true in some areas of the moldmaking sector? You have made me curious, as to me it seems moldmakers are worth their weight in gold and I was always told they are. Your comment comes as a surprise and if they truly are severely underpaid, that is a disgrace, almost criminally so. Without you guys, 3/4 of mass-production lines would cease to exist
FFS people, turn your rapids down when running the program for the first time! I don't care if it's a repeat job either. I still turn most everything down at first, even when I did the programming and all of the setup. And to the programmers- run the simulation in your CAM program too!
There was a lot of poor setups done in these videos too. And yes run the simulations first, look real close where the rapids are, and measure where your W axis is for clamp clearance. And I would always give some extra clearance on rapid moves for the first time running. Distance equals time, and that extra second might be all you need to punch the E-Stop before the crash.
I'm learning the trade from my old man who is a master. He taught me 5% rapid, and single block when you're running a fresh program. There sure is a lot to learn..
Also, if the simulation is good, be careful when you first run your program. Even better if you read it after the compiler did its job. Sometimes it can mess G code.
Bullshit! I've worked CNC lathes since 2006 and never crashed once. And 95% self taught. Hard to believe I know but having OCD helps not crashing but it slows down my set up times.
@@SirRootes never crashed once? Ya ok man. Not sure what your definition of crash is but simply breaking a tool is a crash. Every machinist has broken a tool. You must be one of those guys that comments on how big your schlong is on RU-vid as well.
well that kid that just was let go must have been a master well was getting a grand a week.wish i was..hmm maybe ill use that logic run scrap make more.$$/
@@sgtstedanko7186 Breaking a tool is a mistake. Breaking a $800 mill because you didn't look and see that you're trying to mill 0.3" past your inserts is being a fucking idiot.
I used to have a machine shop with some CNCs for about 7 years. I stopped because of the customers and the liability I had to always assume for the work. The customers always wanted it cheap, and they wanted at least NET 30. The process of making things that are real and not something like a computer program where you can press CTRL-Z to get out of a problem cannot be understated. I worked 15-hour days all the time to pay the bills. Then I found out that I could just be a delivery driver and make better money. I never looked back.
That gives me goosebumps. A programmer forgot to put a max on a program at my work....it was on an open lathe too. Part flew off and hit the wall.....could have killed someone.
I had a 500lb fixture come out at almost 900rpm one time. Christ, that was scary. The thing was perfectly balanced, but it still came out. We put a taper on the jaws and fixture after that.
I had one time one of my coworkers forgot to turn on the fixture vacuum and the part started twirling on the end mill and launched through 2 machine doors. He was lucky he walked away from his machine and that nobody was standing at the other machine
They call them crashing? Call up the wrong program on the pallet of an 800mm machine. Or change the offset what the guy thought was the wear screen but was on too offset to 2 thousands of an inch. Boom game over. New spindle and fixture.
That`s the reason why I was always holding my hand over the emergency button and only let it run on a very low speed every time I ran a new program for the first piece of a series. If you write a multi page long program and a single wrong digit can completely crash the machine, you better be careful. The second piece is a chill run because you know the program works, but the first time you run the program is always stressful. Thankfully I never crashed a machine because of it. Only had 2 or 3 near crashes which I immediately stopped from happening by hitting the emergency button and correcting the error in the program.
I’ve had 2 crashes one was because I forgot a negative sign and the other was because I started the tool at the center of the part before a stock removal cycle on a lathe so it went through the stock removal cycle fine but crashed right at the end. For the second one it was my first ever stock removal cycle I’d ever done when I was in tech school
Right! I think they just didn't know what they were doing, those are funky to hang on to but a little set up time that shouldn't happen haha. For fucks sake use a parallel for the 3/8 hole and some shims for the milling.
I knew what was going to happen but it still kept me in this horrible feeling of suspense. I remember feeling like this everytime I turned on my machine when I started working.
after i crashed a tool holder into a 4th axis jaw that feeling came back every time i started a new setup on that machine for a month. the nut on the holder looked fine too! the jaw looked much less fine, but hey it still works so i didnt fuck up *that* bad, right?
@@justinpatterson7700 I remember when I smashed a brand new beautifull 3 fluted carbide cutter into a clamp we used. It was my second month I think. I still keep it in my cabinet to remind myself of how quitly stuff turns to shit :D
So many were due to poor workholding. If you are running close to tool capacity, a tiny slip will break the tool. The “gunsmith” had the part slip because of poor clamping and perhaps because they were too cheap to buy carbide for the hard material.
This makes me feel better about being a database designer. I do recall the time when my tinnitus was driving me nuts and I hit the button three times to charge the daily credit cards of 300 customers... That was the first time the script ran bug free.
People buy a gopro and think they’re titans of cnc 🤦♂️ use your coolant, don’t use your entire flute length and them feed 10x faster than the manufacturer says
Well nothing wrong with using the whole flute. That's why you pay for it but yes lighten up the step over. You can run 350 ipm in aluminum with a 1/2 em all day long but don't step over so much.
At least these were minor crashes, not butt puckering "oh shit I'm fired" crashes. These are pretty common mistakes, not enough workholding torque, and tool/work coordinate clearances. No one's getting fired. Good learning moment
@@jannickharambe8550 I've seen a dude working on a mill turn lathe, crash his turret into his spindle. 500k machine, 80k in repairs. Had to call a guy across the nation to fix it
I wish we could have go-pros in every machine where I work to make a compilation roast video for the Christmas party. Of course we would screen out the ones that did actual damage to the machines and cost the company serious money... Keep it lighthearted. I think the operator over-reactions to unexpected crunches would be priceless.
Sempre coloque tudo que terá na mesa também no CAD, nunca aperte o botão de iniciar sem ter simulado no Cam de forma mais real possível, confira todas as rotações depois de já ter gerado o programa, faça o setup vc mesmo, só assim terá certeza de que sairá dentro do previsto. Dica de um programador com 22 anos de experiência.
i know that feeling... i work at a precast plant and we just flame straightend all of our moving production pallets (13m long)... in the evening i had to operate the huge transporting and moving crane alone the first time to reinsert the pallets into the drying chamber of the system and hope nothing fails.... if anything had failed the pallet would have hung in the air by 3m and be completely tangled up and sideways/ off of the rolls... every single noise and movement is nerve wrecking.... :O
Ya know, compared to the usual CNC crash videos (catastrophic crashes, lots of sparks and money to repair), this is pretty tame and I found myself expecting the worst and being pleasantly surprised that I didn't have my heart in my throat the entire time haha Edit: and then the last one happened haha
God, the amount of anxiety this video induced is crazy, even after not having worked on a CNC for almost 5 years now. The trust you have to put into your programmers knowing what they're doing...
Software just give you simulation and demonstration how it work. In real life, there are lots of thing can't be avoid of and only experience people can run CNC fluently.
Szerintem meg programozói. Ha azt vesszük, hogy "csak" operátorokat alkalmaznak sok helyen. A székben ülve, számítőgépet nyomogatva, egyetemen tanulva semmi rutint nem szereznek az okosok
As a student machinist this video makes me feel a lot better. I’ll have a minor lathe crash and kick myself for at least the rest of the day. I was parting off some caps for a project using the G54 offset so I didn’t have to touch off each time. I moved the stock out and didn’t reset offsets to -.01 and crashed into the chuck. Luckily I was only running 25% rapid with my hand on feed hold and close to E-stop also. No bad damage thank God
We were all there once. When I was in school we had a guy crash a lathe on the clean up day. He was hand jogging the machine to bore out the chuck jaws and he went to zero out the machine and accidentally hit the tool change button so the turret rotated inside the spinning Chuck and it completely wrecked the machine and cost the school $10,000. Then the same guy had a long program to run so he left to go to work well he didn’t have enough tool stick out so the tool holder crashed into the part. Long story short the teachers no longer let us walk away from our machines at all which sucked when I was in my last semester because sometimes we would have long programs and would have to make multiple parts. He was a smart guy but he was very complacent and made dumb mistakes
my dad got a cnc drill head broke away and ricochet into his head. fortunately it lost all momentum when it got to him. this video got all my anxiety levels up back when i had to stay in the same room as the machine 🤕
Had to follow a person who would override the speeds & feeds so they could get more parts, then they wouldn't change the tooling at the end of shift. Also worked with someone who would change all the tooling at the beginning of their shift even if it needed it or not, so they would get more parts. Better have a strong will in this business or people will walk all over you.
Every machinist has crashed the machine. It is part of learning process. Many of these are technical skills that will be learned and improved with practice over time.
My coworker was running a part today. I walked up and said “you sure are pushing that endmill pretty hard.” He replied “nah. That what they like. I have a paper in my office that tells me so” End mill explodes. I said “did your paper tell you that too?”
It’s even worse when you are a machinist especially since you’ve been the person behind the control crashing a machine. The worst for me are the CNC lathe videos. Those things are so scary when I was in tech school I had a guy feed a drill chuck into the lathe chuck because he was focused on what the tool was doing and not on what the tools around it we’re doing. It blew up it was so loud people heard it in the classrooms outside of the shop. Another time a guy had a part come out of the chuck spinning at 4000rpm and launched the part at the door of the machine. I was on the machine next to him it was so loud it sounded like a gun just went off
Sometimes I wonder how they manage 🤔. Number one with a new program, any machine.. Dry run the program in steps on low speed to see what the machine does. Step 2. Put in the material and run the program Step by step on low run speed but the correct cutting speed. If all went well, the program is ready for full run full speed.
One of our lathes was long overdue for a turret re-alignment. I gave my bosses the motivation to get it done by accidentally slamming a U-drill against a stationary work piece a few weeks ago heh
@@JustDoinItForTheLulz I was working with someone who basically done the same. He asked me what he should do. I told him the turret needs aligning. He said OK and walked off. I left him to it for a bit then went over to see how he's getting on. I found him winding the turret in X- on top of the chuck to force the turret back 🤦♂️
0:40 For some reason, I knew that mill cutter will break before it happened, I just feel it, I have even dreams about breaking spiral cutters. 😀 But this looks like a solid 18 or maybe evein 20 mm diameter, that's pretty hard to break. 😀
Single block and rapid and feed control turned down and stepped through the 1st part with distance to go on the screen could have saved alot of these crashes, and touching the machine with a part of your body to feel the vibration helps to.
Could have been prevented if you used Mastercam to do your cad work. You will physically see a wreck before any tooling is put in your machine. Plus it helps to measure before hand.
