In this video, I machine a new gearbox shaft using some 4140 shafting material. I show you the process from start to finish, from setting up in the lathe, to milling the final keyway. Adam
Nothing in life is more beautiful to watch than a true craftsman at work. I've been a Machinist 35 years, and I can count on one hand the number of men I've seen with this level of workmanship, and just plain caring. Well done sir.
+Abom79 You're quite welcome. I'm just telling it as I see it. It is refreshing to see someone with not just haphazard luck, but actual Machining Methods. Machining, be it repair, new builds, R&D, is all about methods. When you take the time to learn the right Methods, and never waver (except when you're backed into a corner, or just plain walk on water lmao) then the process becomes muscle memory, which is where speed and total confidence comes from. if you're that guy that's always in a hurry, you'll never be good, or fast. You will have a huge resume, albeit 99% bullshit. lol Your demeanor, and steady pace, even with distraction of commentary and conscious effort to explain in detail the Method to your Madness, clearly screams of a man that took the time to become a true craftsman, always following those methods burned into your soul, which like the Rubiks cube, if you go thru the correct motions, success is never a question. at the level you're at, there is nothing I could drop in your lap that you couldn't, or wouldn't find a way to repair or duplicate. I'm also quite sure you'd also gravitate toward the simplest, most efficient way to reach your goal. I've wanted to do online Upper level process and program "classes" but don't currently have the resources. things like how to relieve endmills, or how to chuck one up in a tool holder. which end goes into the tube first when putting a tool back. the depth of perfecting our trade is bottomless. everyday is a strive for perfection. We're a dying breed, very close to extinction. I have a daughter, no sons, no one to pass it on to. Kids wanna play effin video games, and when they get their HS diploma they want $30 an hour with zero skills. one more generation could be the end of craftsmen with skills like ours. That's why what you're doing here is so important. It's very selfless, and can only benefit the world we live in for the better. I don't like to call it praise, more just recognition for what you represent. Thank You for being the gracious gentleman that you are, and sharing your beautifully honed skills with the world. I have great respect for what you do, and represent here. ok enough emotional crap, fuck off and get back to work!!! lmao. Be Well my Friend, and God Bless. Peace to All.
***** I believe you can be anything you want. The only requirement is honesty. The more honest you are with yourself, the better you will be at anything you choose. Lying to yourself, making excuses for your mistakes, all lead to a big head and no real talent. Always be true to yourself, no matter what goes on around you. It's also very important to see the truth, the real truth in everything you look at, and analyze. Only then can you choose the correct path to built or repair something. Never base your path on others opinions or evaluations, yours is the only one that matters.
You use a dial indicator to zero the work piece in the four jaw chuck. You slowly tighten down the jaws until you get the same number as you turn the piece, usually a machinist will use ZERO, but any number works as long it's the same all the way around.
When you only loosen 2 of the 4 jaws when taking the part out the 2 that you didn't touch are pretty close. That's only when you are chucking up on a diameter that's pretty close to what was in there at first
Enjoyed it immensely Adam, watching you doing your Abom Magic turning a rusty blank into a perfect replacement shaft how can you not enjoy that. Thanks for the video. I watch and enjoy "How Do They Do It" on the TV this is kind of "How Do Adam Do It" great entertainment for anyone who gets a kick of seeing shiny metal appear as if by magic out of a rusty hunk of metal.
When I see such machining, I do not only appreciate the profuct itself but the courage of the man doing the operations, There is accuracy and art and so many more issues that the average schools do not appreciate, I have the most admiration for these silent people I admire their courage and lack of clumsiness and all I can say that any surgeon would learn a lot seeing such a man working to such accuracy. I repeat, I feel that even surgeons should go through this training of guaranteeing such accuracies and such lack of clumsiness. Congratulations.
Sir, as someone who is the end user of work like this, I would like to shake your hand and buy you a beer for going +.002 on the keyway depths! I don't know how many times I have had to sand, or even grind, on keys to get them to fit!!!
I just stumbled onto this video, Abom79 you are an artist. In the world of digital machines to find a true artist is a pleasure. Keep the trade alive :-)
Hi Adam My first comment. I'm just an old retired guy taking up home machining as something to stay busy at until the Lord calls me home. I enjoy watching how you do good work and bring it down to precision. Gives me something better to shoot for. I love to watch people that are good at what they do. Your great, keep inspiring me to do better. May God Bless Donald
Not trying to sound pompous or arrogant, but i honestly thought that was pretty standard. Maybe i just had an incredible teacher (my old boss was a phenomenal teacher). I can usually true up anything from 3-18 inches in diameter in about a minute on a 4 jaw (two years experience). Don't get me wrong though, when it comes to running manual machines, he's on a whole other level, i mostly do CNC work, and he's much faster and more proficient on a manual than i'll probably ever be. His skills remind me of my old boss.
you had a phenomenal teacher.. working a 4 jaw is a pretty nasty thing if you dont know what to turn, let alone how much... so be proud at your craftsmanship.... XD
The way i learned was to kinda eye where the jaws need to be with a steel ruler, snug them down a bit (not very tight, just enough to hold). Stick an indicator on it by the chuck and spin it, lightly loosening and tightening the jaws a little bit until it's within a thousandth or so, and check the end of your part away from the chuck (tap it true with a deadblow). Then apply equal pressure to each jaw gradually tightening each of them. The trick is to have a feel for it and know how much pressure to apply each time until the part is tight enough to run, but not so tight that you make the part into an oval or mar the finish (if it's already at nominal diameter). If you tighten all the jaws down until they don't want to move from the start, you're going to be fighting yourself trying to true it up, and have hell doing so. The first part i tried to true up on a 4 jaw was a piece of 6 in diameter pipe with a finished OD. I tightened all the jaws from the start and it took me 30 minutes to get it true, until my boss came by and just trued it up, teaching me in the process.
I enjoy very much you showing us this type of heavy machining work that you do and it must be most satisfying using good materials, tools and equipment to achieve this sort of outstanding result.
actually its worse than that, in most cases its just a straight up hater that subs just to dislike vids. no doubt the dislikes happen pretty quick, no coincidences
Hi Adam. I appreciate you post this video. My father worked on this job and I've always be curious about. I watched and enjoyed the whole video, and now I better understand why he was always very meticulous about all that he did in his life. And how this job fitted with his behavior. Thank again. Tony.
The Metal Butcher didnt Toms video feature a purposely out of spec chuck to represent a worst case scenario? it was also instructional so he wasnt exactly flying through it. I imagine in this setting starting with a machine thats always maintained and ready to go from job to job makes the task simpler.
This brings back memories of when I was younger going to work with my dad. He worked in a Caterpillar Dealership as a welder. The next bay over was the machine shop where they they rebuilt hydraulic cylinders. Archie was the first Machinist that the dealership had hired.(Retired with 65 years of service) He was a bit overweight always always had a cigar in his mouth and a paperboy hat on. When he would finish a job he would always yell.. "Damn that's beautiful work!" You Sir are doing some beautiful work!
Incredible work, watching that thing take shape and be turned into an identical part was great. You make it look so easy, but I know it takes years of experience to become this proficient. This was a two cups of coffee to watch this morning. Thanks for another great video. Ah well, back to turning wooden pens....Ken
As always good to hear from you Tom. I finally got three tool holders for those cnmg inserts and they are great. The one I used in the video works great for undercutting, and chamfering. It's like getting a ton of inserts for free. Thanks buddy. Adam
I wish are engineers had the machining experience like you do. Instead we hire college kids with master degrees with no machining background. It sad that colleges don't require students to take a three to four years in a vocational machine shop to add on their degree.
Mr18Toolmaker I know exactly what you mean. Had a young guy with a degree come in to work as an engineer (imagineer) and talk about a moron! He couldn't even read blueprints, had no idea what kind of parts needed what kind of attention, etc etc.. I have no respect for those kind of people. They half-ass a college education by believing they need nothing else and that common sense is beneath them. I might do alright with an engineering degree to go with my 7-8 years of machining, programming, fabrication, and all that machine shop stuff you don't hear about, but all that would do is have me working in an office on top of running machines.
I definately understand where yall are comin from. I am currently goin for a BSME at a high tier uni where I can take machining and get certified on CNC. I am probably going to pass on the opportunity for now, but I am going to go to trade school for gunsmithing after I graduate where machining is a core part of the curriculum.
I am currently enrolled in a marine engineering program that requires at least 1 semester of ANSI approved welding and 1 year in basic machine shop classes. I think many of the engineering programs should require such training and be held to high standards for understanding of the basis of what they are designing. I go to Texas A&M in Galveston Texas and see a lot of general engineering kids that are going to the main campus who are either A) disinterested in the engineering program and are just there for money or B) have a genuine interest in the processes that I have to master but don't require the training and therefore miss out.
Mr18Toolmaker four more years of tech school on top of the six it takes to get a masters would put them forever in debt. Ten years of higher education is what it takes to become a doctor, but they can earn back the money in a few years. Whereas a mechanical engineer with three years of in depth machine shop experience would literally never be able to pay off their school debt at about a quarter of what a doc fresh out of school can earn. Very sad but very true. This fact is the reason CNC machining is going to take over master machinist such as abom.
I went to trade school before I went to college and got my engineering degree. The experience gained doing this type of work has been invaluable as I advance. It’s nice to have a working knowledge of what you ask someone to do. Sadly, these trade programs are disappearing, and guidance counselors put a stigma on kids who want to take advantage of these great programs.
I wish I'd watched this before I started making my replacement lathe spindle. Why didn't you drill 2 centers and hold the work between 2 centers? I believe Keith Fenner did a similar project that way. The advantage he says is you don't have to center the work again after taking it out of the lathe for fitting, so I did mine that way. What is the advantage of the 4 jaw? Thanks for the lesson. Jon Soons
Running it between centers is the best way to keep the shaft true on each end. I didn't have a large enough lathe dog when starting the job, so I decided to just use the 4 jaw and indicate after getting started. Not a big deal for me, but I do like turning between centers, and do that often. I'll show it in a future video.
Jonathan Soons you can take deeper cuts at higher feed rate in a 3/4 jaw Chuck . And still get it running true. I only usually turn between centre on smaller shafts .
Nice job on the shaft. I read the comments below and I am struck by how many think thats art or magic. Thats a simple shaft with key ways in it. Don't get me wrong, its not simple for new machinists that get nervous when they need to hold .0005 on a bearing race. I have 38 years on stuff like this, so doing this is just another day at the shop without even thinking about it. You young fellows keep at it because this is an awesome trade. I don't fart around with stuff like that any more because I have 8 machinists working for me now that do it. And most of the time they do it on the cnc equipment. I still push them to go to the manual and do stuff like this when there is only one or two. Man I have never seen a collect holder that old. I am 57 years old and nothing in our shop looks like that but we do have a paint brush that looks the same.
Nice videos! I watch them instead of TV ^^ A small question about 4 jaw chucks: I've been taught to mark my jaws on my 3 jaw chucks, so I put them in the same slot if I turn them around. If I buy a 4 jaw with independent adjustment, do I need to mark them (or is it best practice) It might sound silly to some, sorry!
There will ALWAYS be need for SKILLED machinists ,fitters and turners I,VE run my own business,s for 58 years and went to college at 60 yo just for fun still doing business and fitting at 73 yo every day just great fun YOU are a long time DEAD. IVE DONE THE WORLD TRIPS etc now for the fun.
Here I was spending 30 minutes messing with a 4 jaw trying to get my part centered perfectly, but then you just go and cut two true spots and flip it. Mind blown.
Well damn, this one took over an our to finish watching cause I had to revisit some stuff. Sounds like your real tired Adam, thank you for taking the time to share a great build. Wow!
Adam, I'm a machinist student over here in California, I recently landed an internship at Shell Oil refinery working in the shop. Want to let you know your videos offer a great deal of information and help me immensely. Keep the videos coming.
I want to be a machinist too this video gives me a lot of idea on how to become a good machinist thanks a lot for sharing this video.. i cant wait to go to training school.
Hey Adam... what did you do with the old shaft? Good stock to make a big flycutter! Used 4140 on my flycutter body, but boy do I need to have a chip breaker! Fly Cutter -- Adjustable 3" to 10" swing Just don't tease me about my "radius cutter" to get that 1/4" radius. It worked! So next challenge... who can build the biggest fly cutter. Thank You for your video's!
I just got done watching your video of the pump impeller trim down...did the customer use a more efficient motor...and a smaller pump housing...or change it all together..?
Awesome job Adam! I do have questions. What would you do if you didn't hit your target size on any given section? Could it be fixed or would it have to be scraped? What would the consequences be? How much would a chunk of iron cost? As always, I enjoyed watching, and learned how to pick up the edges on a round in a vice!! This is why I watch, and am truly grateful for what you guy's do and share!!! Razor!
If I cut a journal too small I would have to start over with a new piece of material. The customer is paying for a new shaft, not one thats been welded up or sleeved. I've been down that road, and any machinist has done it. You loose money in the material cost and the labor you waisted, so it's important to hit your marks the first time.
Abom79 As I was watching, those questions came to mind. Thank you for your reply. I guess for you guy's with all your experience it becomes 2nd nature. I can relate as I am that way when it comes to construction and welding for me. Thanks again for sharing your skills, and taking the time for us newb's.
Adam, thanks much for this video. I machine only to compliment my hobbies and this video as others you produce have taught me practical techniques I will use to further my skills. Keep up the great work. Jon
Watch your temp! I'd shower it here and there as I approach my target diam. - Nice vid - Thanks!! Like the old days no need for blue prints or damn computer models! - You measure, you cut and you measure some more - Loved it man!!
Hey Adam: Appreciate you taking the time to shoot and post these videos!! I always learn something new by watching your craftsmanship!! I liked the way you found the center of the shaft when you had it in the milling machine vise....very clever!!
4 jaw chuck magician! Just amazing how quickly he can fail it in. Although done 5 years ago, would love to know an order of magnitude cost the finished job .
Great Video Adam, and a great looking part... Showing all the set-up steps, was an excellent teaching technique... It's also nice that you can make these videos at work... I'm sure there will be one happy customer receiving this nicely finished product of your skill! O,
Adam, Very many thanks for your work. We can get no tuition at all in metal turning in England, and we really appreciate what you guys are doing with these videos. Best wishes, from Chris, London, England.
Hi Adam. What's the brand name and model of the milling machine you're using to cut the keyways in this video? It doesn't look like a regular Bridgeport mill. Thanks for your channel!!!!!
Watching you turn that shaft reminds me of the shaft in the gear box of our Ghel Grinder mixer! the shaft came in and split I think 3 or 4 ways, there was a up auger, a mineral input auger, and out put angled auger and a long delivery auger from the angled out put to the feed bunk and they all were running through that 1 shaft! and it would get twisted about 3/4 of a turn and then things wouldn't stay engaged anymore! I know I put 1 in and I know they had to change it I think 2 more times over the years! then all the pto shafts on our hay mowers, Etc.... great video and great work!
I went to aircraft mechanics school back in the early sixties and graduated. Aircraft tech jobs were easy to get back then. But you needed your A&E license, which I had. Today, unfortunately, mechanics of all kinds are looked down on as less than a 20 year old college grad, who still doesn't know what he wants to do. I came from a large family of trained mechanics (I had 6 uncles) al mechanics by trade. They lived a fine life and all but one is gone now. I am 76 so I speak from first hand experience.
GOD bless you. I am learning Precision Machining Technology. After I watch this video that were helped me get more knowledge about my job in the future. Thanks
Hi Adam ...thats really nice machining video...keep uploading your projects..its a pleasure when i sit back and watch them carefully...nice tip with copper soft jaws...and very nice finish with those insert...real perfect....Greeting again from Shiny Greece.Thanks
I wanted to know why you didn't complete all the turns on one side of the shaft in one go, instead of swapping the position of the shaft that many times. Doesn't it help maintain concentricity?
Aaand I just noticed I wrote the exact same compliment as many did before :D I guess that's why one becomes a machinist - rusty chuck to gleaming shaft. I am currently building a steam engine out of the tons of rusty bolts and chunks of metal I found on our streets - also a very satisfying job :D
I don't cut many keyways and I don't trust running an on size cutter full depth in one shot. I'm always concerned about tool deflection or vibration causing an oversize keway or horrible finish, particularly with 4 flute cutters. Do you ever run into problems cutting keys like that or am I just paranoid? I chicken out and use a smaller cutter climb milling in and out and use gauge blocks to get the fit I want but it takes more time. My background is mainly tool and mold making so I often have a different approach than a pure machinist and don't know all the time saving tricks. I was once making some 4140 fitted shoulder bolts on a lathe with damaged gears and could not get my cutting speed high enough to stop tearing. To get the last thou I took a coarse bench stone I had lapped dead flat with valve grinding paste (silicon carbide lapping compound) and used it like a file. It worked well and I had no low or high spots.
Sweet video! That 4140 turned like budda! Two quick questions? When you single pass cut a key way, are you using a brand new end mill for each job? Also from start to finish, how log did it take to complete this shaft? Video makes everything look like its done in 45 min :) Keep up the beautiful work my friend!
Eddie, I don't always use a brand new cutter, but I like to when I can. I keep the fresh endmills stocked for jobs like this, and it's easy since we sell them. I also mic them before I start to ensure it will cut the keyways to size. The total jobs took a little less than 6 hours from start to finish, but some of that time was cool down, and set-ups.
20- 30 min? is that include programming and proofing time? And unless you got a CNC lathe thats capable of slamin a keyway in, I believe that would add to your 20-30 min cycle time you speak of. But what do I know...
I'm not using one because the company I work for doesn't own any cnc machines. If we were producing shafts all day everyday maybe that would be a different story.
