Machining Cable Sheaves Part 1

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I have two 5" cable sheaves to machine for a customer. He wanted to try running some that were a little tougher and maybe more wear resistant then the cast iron versions he's been using. This will be a two video series. In part one we get the sheaves rough machined to size and machine a fixture to hold them in the lathe. Part 2 will show the heat treating, hardness checking, and finishing to final dimensions.
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Abom Adventures / @abomadventures

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13 апр 2020

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Комментарии : 605

@Abom79 4 года назад

This is one of those videos were there's a lot of people leaving opinionated and misleading comments instead of sharing facts. Here's A little info regarding Hardness of sheaves. Check out the second page. www.seilbahnen.org/de/index.php?section=downloads&download=10460

@MrSuperchargeron 4 года назад

Abom, what kind of arbor press is that? That thing is nice!

@mumblbeebee6546 4 года назад

Bless you for staying cool! Thanks for the videos!

@thomastallman5024 4 года назад

Dont even study the non holders of many amazing machines and skills. There will always be the nay sayers. You rock. Thanks. Ive learned loads

@jtkilroy 4 года назад

Great paper, thanks for posting that.

@Abom79 4 года назад

@@MrSuperchargeron Dake

@Phoeff99 4 года назад

“For all my non-smokers” hahaha Might the be the first time I’ve heard Adam crack a joke. I love how comfortable you’ve become on camera and you should be! Keep up the good work man.

@danielmcnerthney 4 года назад

Likes on Likes! Now I'm ads for taboo free cigarettes.

@metoonunyabidness1391 4 года назад

My father was a machinist I didn’t even know what that meant until after he died. I think about him a lot while I watch these Truly an honorable craft! Thank you for keeping the trade alive

@Smidge204 4 года назад

"I don't have a wrench big enough..." - Words I never thought I'd hear Adam say.

@JimWhitaker 4 года назад

But he did prove himself wrong!

@kevincosgrove4147 4 года назад

I feel like he did so much more shop work when he had his day job I feel like now that he’s on his own not that much shop work but I do have to say amazing craftsmanship in everything he does

@dougankrum3328 4 года назад

working for someone else...they want to see you making chips all the time...like 100% of the time...

@kevincosgrove4147 4 года назад

Doug Ankrum no I mean when he had his day job he was doing more work out of his own shop

@forrestaddy9644 4 года назад

Watch it there Adam. I've machined a lot of wire rope pulleys and they all had a throat angle to funnel the wire rope into the groove from off-axis pull. IIRC, it was about 40 degree or so included (20 degree on the flank to a radial plane) and a radius that blends the flank angle into the OD. Without the flank angle the rope can chafe on the pully corner and in a hardened pulley that could be very bad for the component wires. There are de-facto standards somewhere. I'll look for them later.

@TheJohndeere466 4 года назад

Ive machined many sheaves for over head cranes and they are usually flame hardened and they also have an angle in the throat. These were for a Morgan overhead crane.

@660stihl 4 года назад

Back to where the channel came from. Finally!

@K-Fed 4 года назад

Two things I cannot get enough of: 1. Big freakin' twist drills 2. Watching chips break off silver and slowly turn iridescent blue or purple.

@bigkenny66 4 года назад

Something I never thought i'd hear Adam say: "I don't have a wrench big enough for this nut."

@geoffbackman6347 4 года назад

I just want to say thank you for your content while the world is under this pandemic. I genuinely appreciate it.

@heavymachining7830 4 года назад

After reading too many complaints from whiners and safety suzies allow me to clarify something on cable use and the sheave. A cable has a short life, wear is usually not visible until long after it's no longer safe to use from load and bending fatigue. The sheave no matter how hard or soft will not lengthen the life of the cable by a measurable amount, however DIAMETER will. Less bending = less fatigue. As a operator and maintenance man of over 30 units with winch and cables moving small to 100 tons capacity none of our cables were worn visibly before they got replaced for safety. Many other signs of deterioration of strength show up first. And as for non metal sheaves, delrin etc. Is not legal and certainly would not hold up. A small residential concrete septic tank weight in excess of 7500 lbs. Thanks for the video Adam if you ever need a piece of large diameter steel let me know, we are stocking an assortment at our machine shop.

@dennyray69123 4 года назад

If hardness makes no difference...Why is Adam going to harden them.?

@scottr939 4 года назад

@@dennyray69123 He said hardness of the sheave will not affect the life of the cable, but it will affect the life of the sheave.

@StreuB1 4 года назад

Jacob, as you likely know. Cables and sheaves wear out a lot faster if you cables aren't greased. If the guy is wearing out sheaves, I bet his cables are dry as a bone.

@sr20ser. 4 года назад

Non-metallic sheaves hold up just fine in the heavy industrial sector and aircraft industry. Also, a softer sheave will, in fact, increase life of the wire rope. But, all the same, a sheave and rope are consumables.

@MrCirqueMaudlin 4 года назад

the shot of the chips turning blue is so satisfying!!

@dougankrum3328 4 года назад

Yeah..the way they should be....taking the heat away from the cutter and material....

@jesusisalive3227 4 года назад

Have you seen the latest shaper video he did in slow motion? It shows the chip changing colors while the chip is being formed, very cool!

@johnscott2849 4 года назад

Mr Pete be calling you buba for using the pipe wrench. Lol I learned a lot watching you and Mr Pete . I am close to Mr Pete's age. Still learning

@_f355 4 года назад

I have to be honest Adam, I mostly watch your videos to appreciate the excellent workmanship, as I am not a machinist by any stretch of imagination. That said, there's a great educational aspect to these videos as well that I appreciate a lot - it is nice to understand how machining works - so I think it would be extremely nice if you could explain how you choose tools, feeds and speeds, whether to turn the coolant on or not, etc. That seems to me like the real hard problem in machining - anybody could learn how to operate the controls and use the indicators, but this is something that's completely non-obvious unless you have a lot of experience. Thanks in advance and keep up the great job making videos!

@wdhewson 4 года назад

Thanks Adam. You're the only thing I watch that has no virus content. A welcome relief.

@RinSenna 4 года назад

Few notes from someone in the industry: we typically test hardness on bar stock at the mid radius if possible and take an average of 3 tests. You can pick up calibrated hardness blocks from tool suppliers to verify your tester is accurate. We check calibration monthly at 25 and 62 HRc. And finally, there may be an adjustment on the back of you machine on the hydraulic that will effect how slowly the weight returns. Hope that helps.

@victor.leslieaugustpikingt8848 4 года назад

Nice to see you back at the grassroots of your art many thanks for a great video, please stay safe at this time

@donpetrey8007 4 года назад

Also when you machine a sheave I remember there was a special tool was a machines bar that tested the sheave to make sure it wasn’t worn where the cable wouldn’t get hurt or cause damage to the cable. It was something we had to do when rebuilding some winch boxes on my coast guard cutter from 1942.

@bjre.wa.8681 4 года назад

I tried to send to your facebook page a PDF sheave section drawing to show the proper profile for a wire rope sheave. I don't think the message posted with the attached file though. I think you need to put some taper on the sides of the sheave to get the wire to fall in the groove properly without chaffing against sharp edges. I used to draw sheaves for a living.

@ericreynolds74 4 года назад

Can you do an episode on chips? (No not Poncherelo) why they happen, how and when and why to "break" them. How to read them...as in color, shape...sound? What I've often wondered is, if you make a .010" cut - does the chip measure .010"? Because there's a mixed type of metal in the bottom of the lathe, can you scrap/recycle them? And anything else I don't know to ask about them. You're the best, and I subbed Gypsy lol (she's amazing)

@steveclark5248 4 года назад

8:39 You Slam Dunked that drill through. Unnervingly satisfying. Thanks man.

@richkellow1535 4 года назад

Nice to see you back on what your best at and what has built your viewer platform......machining in it's finest form.

@ZombieHaunter408 4 года назад

Recently discovered your channel. I could watch your videos all day. Excellent explanations, not a lot of filler, great videography, and excellent editing. Thank you for giving your content to the RU-vid community. You're a great teacher.

@dougankrum3328 4 года назад

I've worked on some small-medium cranes...nobody likes to lube the rope properly as it gets real dirty, real quick....but a dry rope is pretty hard on the sheaves...the rope actually has to 'slide' against the sides of that groove. If it's too dry, cuts just about like a file...doesn't do the rope any good either.

@ctrhenry 4 года назад

Cable sheeves in low use mobile equipment are usually softer than the cable so the sheeve wears and not the the cable. If the shelve wears you replace it, if the cable wears it breaks and drops a septic tank. Typically outside of mobile cranes the cables don’t get inspected much.

@billmielke7395 4 года назад

How hard is cable? 40 ish Rockwell, which is what 4140 prehard is, and I assume pretty good for 4140 in general, isn't that hard.

@krald8421 4 года назад

Yep, this is a horrible idea

@samueltaylor4989 4 года назад

Oh well, let him find out for himself.

@Abom79 4 года назад

Well guys, this man is tired of replacing the sheaves. Right or wrong, it’s his choice to build his equipment the way he wants. I’m not here to argue with anyone, just sharing the machine work involved in making a part.

@truckguy6666 4 года назад

@@Abom79 god damned critical bastards are going to get comments turned off.

@tmtan1303 4 года назад

Thanks! I have been working with wire sheaves many time but this is the first time I see a complete making of it.

@yqwgjsg 4 года назад

I always love to see the old Monarch in action. Most everything you’ve done here recently was on the Victor.

@michaelmckay1567 4 года назад

Thanks your kindness is a great and noble character that gets us through difficult times

@jimmurphy6095 4 года назад

Good ol' turning.... Loved it. Thanks for the upload, Adam! Be safe!

@TheObersalzburg 4 года назад

In a shop like yours, every day and job must have something that's a little different to keep things interesting. And it appears that you enjoy things new and challenging, like heat treating. Thank you for sharing the voyage.

@davidharris6581 4 года назад

Fascinating stuff! I always find your videos satisfying and relaxing. Thanks!

@blairguinea1337 4 года назад

Great machine work as ever Adam, love the style and your professionalism, thankyou Sir

@robertwest3093 11 месяцев назад

Yes I just discovered this channel and I am now binge watching it.

@buyamerican3191 2 года назад

I love al of those gargantuan twist drill bits you have! And they always cut perfectly matched chips from both flutes.

@zvonibab 4 года назад

It looks so easy when you do, never the less life is learning circle I will get there somehow! Thank you for sharing Adam!

@jemijona 4 года назад

Hey Adam, thanks for the tip on stopping the chuck from rotating while tightening and loosening the nut. We were loosening the end cap on a pneumatic air ram mounted in the chuck in my lathe the other day and while one of us was hanging off the 36" Stillsons, the other one of us was holding the brake on the lathe to stop the chuck from turning. Your idea means one person can do the same job. Also, using my lathe to loosen the air ram proves that every tool has more than one use. :)

@The_Impulse 4 года назад

So far the last 2 drill bits cutting the center hole, blew my mind in amazement!! I am seriously impressed the size of the shavings those bits took off.

@arthurroberts491 4 года назад

Sharp drill and a big motor.

@ShouldersMoondog549 4 года назад

Nice finish so far! Need to watch Part 2 now!! That was some bit you used to get the base hole in the sheave! Thanks for the video!

@jerrycoleman2610 4 года назад

Adam, Really liked watching the groove being cut in with that radius tool don’t think I had seen you use that before, I enjoyed watching your video, thanks for sharing your video.!.!.!.

@SteveJohnson-SawtoothIS 4 года назад

This may be dumb, but one of the most fascinating parts of these videos is how well the drill bits cut. I evidently have very dull drill bits. :D

@Sicktrickintuner 4 года назад

Steve Johnson Hardness of each bit makes a difference also, there are cheap HSS and better with 8% cobalt, then even better is carbide Don’t buy the cheap chinesium unless you only drill soft things like dead trees

@ChrisBrown-dy8ts 4 года назад

We have a 100mm carbide drill tip which locates on a holder in the tailstock, no centre drill or pilot holes used , just straight in 100mm hole, they are impressive👍

@donaldnaymon3270 4 года назад

Great work Adam. Those radius tools work real well. Good to know. Thank you for sharing.

@maxnex7676 4 года назад

Great to see Adam back to doing the big jobs that were the start of his channel .

@MattysWorkshop 4 года назад

Gday Adam, it’s always nice to watch some good old fashioned manual machining, only way to go,

@arthurmandel6541 4 года назад

New to show, enjoy your work ,wrenched all my life always liked what a machinist can do keep up the good work.

@cschwad559 4 года назад

Good video. Always great to see old school turning when my favorite material (4140) is the item being machined.

@davelister796 4 года назад

I'm interested in your clean-up too. Can you set-up a time lapse of you cleaning up after your next big lathe job? Then you can run it at the end of the video. I don't need a commentary, just interested in seeing what you do. :-)

@gonecoastal4 4 года назад

The sheaves are meant to be sacrificial so as to not wear the wire rope. Ole boy is gonna be replacing his before too long, I hope it doesn't part when under load.

@StreuB1 4 года назад

My thoughts exactly. Wire rope is hardened and tempered and you never want to run a hard load carrying part (wire rope) on another hardened part. Normally if the wire rope is wearing out the pulley, the wire rope isn't greased enough. The rope should be caked in grease.

@Ropetangler 4 года назад

I don't agree. During my working life as a rigger, I replaced many ropes on cranes and face shovels, and only rarely repaired the lagging on a hoist drum on a couple of shovels. I would have replaced hundreds of ropes, and we did repairs on maybe three shovels, and never had to replace a sheave. It is easy to inspect a wire rope for wear, broken strands and broken wires, especially on a rope diameter of 1/2'', and ropes virtually never fail catastrophically if they have no broken wires. More important than the hardening issue would be the angle of the rope groove, it should be between 42º and 52º and should be 1.5 rope diameters deep. Too shallow an angle causes the rope to flatten and too steep an angle causes binding which in turn causes wear on the rope and the sheave. I would agree that the sheave diameter is too small for 1/2" diameter rope, but not by that much if a manual hoist is being used. For manual hoists, light duty a sheave should be 12.5 times the rope diameter, but if it is more of a mobile crane and medium duty, then the sheave ø should be 20 times the rope diameter. Our crane and shovel ropes were always well lubricated.

@kuno460 4 года назад

Great video Adam thanks for taking the time to film them .

@carlwhite8225 4 года назад

I like the radius tool, guessing I will be ordering 1 tomorrow. Thanks Abom.

@debrainwasher 4 года назад

Very realistic camera work! I could even clearly smell the smoke of cutting oil and was seriously tempted to put on my safety goggles.

@olddawgdreaming5715 4 года назад

Thanks for sharing with us Adam.

@metx121 4 года назад

Adam, Enjoy your videos very much. Thanks for taking g the time. You posted a video about heat treating several videos back. I wanted to leave a comment on that one but didn't have a chance. This is how I heat treat 4140. I'm sure there are lots other ways my dad taught me and this is how I do it. Get you some cast iron shavings. I attach some tie wire to the part if you can and its not too heavy. You need a tray that you can put the parts in. I wrap tool in grocery bag paper. This will help burn off the oxygen around the part as it heats up[. Place wrapped part in tray and cover completely with cast iron shavings. No need for tool wrap.When part is ready to quench just pull the tray out of furnace with tongs and with some pliers grab the tie wire, shake it a little for shavings to fall off and quench. Have a good day and I look forward for new videos

@wipsmoke 4 года назад

Great job on the videos, I am not a machinist, I don't recall even seeing a Metal lathe in person, but the seeing the dull grey metal turned to shiny mirror like is mesmerizing

@4341darkorbit 4 года назад

lovee how you can figure out the jobs and make them easy

@Mariano.Bernacki 4 года назад

Please keep this kind of content coming! Most excellent! Thank you!

@strongmaster 4 года назад

Weird watching a few videos from 6 years ago and watching them now. You can physically see a difference in you. 6 years you looked depressed. Today, you look happy.

@davidsaylors 4 года назад

😂”for all you non smokers “... Thanks for taking us along!!!

@johnboyd7158 4 года назад

Takes me back to the day when I was in the Pipefitters Union. Carried a 24 and 36" Rigid pipewrenchs. Pulling them out meant business!

@parlinate7314 4 года назад

Thanks Adam, this is really good content and great editing.....good light and footage too.

@Lesnz2009 4 года назад

This has been a very interesting project, I learnt a couple of things, thanks.

@daveness8236 4 года назад

Great video. Always like watching you work. I feel like such a rookie on my south bend and Logan. Pays to have good tooling and machines.

@lonnywilcox445 4 года назад

25:00 You could put little hangers on those curly cue chips and sell them as Christmas ornaments.

@toad3048 4 года назад

Well, the world might be going to Hell in a handbag but it"s a Tuesday and Adam has released a machining video with brilliant machining and chips!!! I really liked how you re-worked the old mandrel to fit the new application. I'm watching this Abom79 Lottery video on my son's new hand built gaming computer and it is something else. Thanks Adam!

@biggestpanda6477 4 года назад

It's interesting to see how he works different when hes billing by the hour for a job. Heavier cuts with flood coolant, we rarely see that anymore on this channel. Taking less time to get the part done. I like it.

@tater0909 4 года назад

Hey brother. I’m glad to see you also strive to do better and learn more. Like the heat treating. Each day at my job I try to learn something. To be better than the day before. I’m a nuclear plant mechanic. I sure would love to know half of what you do at machining. Keep up the good work man. Also, I’m a fellow Floridian

@poppopscarvinshop 4 года назад

Thank You for the Extra Content Adam!! Y'all Stay Safe & Healthy!!

@FullcontactNerding 3 года назад

I need to get these inserts, the cutting sound while cutting Steel is so much nicer than on my lathe. Could also be the fact that I work on a much smaller lathe but it’s worth a try!

@rafihussain 4 года назад

Masterly done. Thanks for sharing

@johnz8210 4 года назад

That was really cool. Thanks for the video.

@carloscordero4204 4 года назад

thanks Adam another job well done ! NICE TOO SEE GOOD VIDEO!

@HappyHarryHardon 4 года назад

That first cut on the spud, really nice.

@JayKayKay7 4 года назад

Why am I fascinated by the pattern of the chips? The spiral drilling ones remind of the flowers in Avatar. I think the blue discoloration is a perfect illustration of heat effects. I sit and forget to move during these videos. (Cast Iron Gypsy made a nice "Thank You Adam" clip the other day.)

@sudzkng7 4 года назад

I laughed unreasonably loud at that non smokers joke.

@ChrisMaj 4 года назад

I'm making a lot of sheaves / pulleys, but the ones that I make are anywhere from 15" to 70" in diameter and they are always flame hardened to 50/55 Rockwell, but just the grooves.

@gusm5128 4 года назад

Glad I found this channel, awesome work 👍

@glennmoreland6457 4 года назад

This is just a nice channel to watch altogether is this one...🇬🇧☺️

@ggordon4127 4 года назад

Love the big Monarch nice a quite.

@trevorjarvis3050 4 года назад

Something very satisfying about watching a bigass drill with a razor sharp grind going through a thick chunk of steel effortlessly! :-D

@dexhummer1 4 года назад

Great vid Adam!!! Like seeing the Monarch running again!

@georgelequin5070 4 года назад

Another great video!Thanks Adam!👍

@HEADDYNAMICS 4 года назад

Most of the sheaves on the mobile cranes are made of plastic nowadays. Like a Delrin or the like. Very cool project, thank you for sharing.

@Rubbernecker 4 года назад

Good old fashioned chip flyin'. I love it!!

@Twardowsky29 4 года назад

Great job man! Keep it up. Greetings from Poland

@IONredline06 4 года назад

I love working with cromoly, you can get some amazing surface finishes on it.

@sterlingconley3809 4 года назад

"Hey I hit the trash can." Lol that is great. I got a good laugh out of it. Love watching your vids. Tons of good info.

@jemijona 4 года назад

With that many chips flying about, one is sure to hit the trash can. :)

@davideparise 4 года назад

Ahh man can't wait to see part 2!

@iceinkfxc8595 4 года назад

Hello Abby and Adam, stay safe and well. Hope you can get on the rd again

@MrLembnau 4 года назад

nice work, i also use mandrels on these shorts parts. they work well.

@delalima 4 года назад

looking forward for the next step

@nevetslleksah 4 года назад

I have a app on my smart phone, don’t remember if it cost any money, found it in the App Store. Title is “Heat Treat”. It is from the Heat Treating Society of ASM International. Anyway, you can search a specific alloy and it will give you chemical composition, specifications, characteristics and applications, forging practice and temps, recommended heat treating practice, and recommended processing sequence. Says for 4140 steel fully hardened ranges from 54 to 59 HRC depending on exact carbon content. For hardening, austenitize at 1570 degrees F and quench in oil. Tempering: reheat after hardening to obtain the required hardness. Thanks for making these great videos.

@larryschweitzer4904 4 года назад

I think some of the comments about both the shape & the hardness of the sheave are very true. The wire rope needs to be guided into the sheave W/O rubbing on abrupt edges. When a wire rope breaks it's like a huge steel rubber band. I worked around heavy equipment and saw worn WR break. While I was on the carrier a man got a leg cut off by a WR that broke free of its attachment while under strain. Nasty stuff.

@thomastallman5024 4 года назад

Wow. Thats the first time i ever seen wd40 used for its intended purpose. Water displacement formula number 40

@frankrightbrain 4 года назад

Thomas Tallman I used it regularly in the ‘70s when my engine died after running through deep water that wet my distributor. Pop the cap spray it with WD-40 reinstall and continue on.