How Giant Workpieces Are Cast & Machined With Heavy Equipment - CNC Machine - Forging Machine Please LIKE, your LIKE will ENCOURAGE me very much. Thank you! SUBSCRIBE to watch more great video: bit.ly/3aDXZlr In this video:
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?
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
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.
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.
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 👎
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 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.
@@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
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.
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.
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
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 was expecting those casts to be for iron. Though the milling is showing a different type of material than iron. Those chips look a lot like steel to me! I didn't know that "Cast Steel" was made. I didn't think it could be made by casting. Steel typically requires iron to be forged to make. From my understanding.
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.
13:47 dude is standing close enough to the hot metal. all he has to do now is say "Flame ON!" If these videos will ever become professionally narrated, I'll Actually add a SUBSCRIPTION to my list.
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.
Thankfully, they don't use those ancient and nonsensical units of inches, feet, degrees Fahrenheit, gallons, and horsepower! That would be a REAL shame.
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.
Man!! The quality of the sound!!? AI channels are truly getting worse and worse. I won't even bother watching more than the 5 seconds I've already seen. Good Bye!
Was this voiceover generated my AI? Clearly the script was written by someone who knows _nothing_ about what is being shown. This is a compliation of separate videos, and the speaker seems to be written by the sales departments. I have seen the generator shaft video as a standalone.
@@darrendel-fante6674 And I don't give a shit about your rip off channels who steal other people's hard work and whore themselves out for the views you say you don't care about.
Why do these videos always show viewers a phony photo-shopped thumbnail CAPTION PICTURE NEXT TO THEIR VIDEO LISTING, IF NOT TO DECIEVE AND TRICK THE VIEWER INTO CLICKING ON THEIR VIDEO? so deceitful.
predictably, reliably awful, out-of-sync narration-- at 1:50 we're seeing two massive pouring vessels dumping white hot liquid metal into a chamber below and the narration is saying : "As the molten iron cools, it solidifies into the desired shape" ... I mean does ANYBODY check the product out before it's posted?
