Precision Machining Techniques Used To Manufacture A Pump Housing

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CNC Machining a Monster Complex Part on the Heller CP 6000 CNC Machine Tool. Roughing Ductile Iron with HUGE Kennametal tools!
0:00 Roughing Ductile Iron on CP 6000
0:28 Using Huge Kennametal 4" Face Mill
2:37 Monster Godzilla Drill!
3:20 Rotoclear Cameras
3:41 Kennametal Harvi 1TE
4:45 2" Dodeka Mini with Tunable Holder
6:30 Mastercam Tool Paths
6:47 Conclusion
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#Machining #Machinist #Engineering

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Опубликовано:

28 июл 2024

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Комментарии : 226

@steve0stang Год назад

30 MINS? Now that's HELLER impressive!!!

@FiglioBastardo Год назад

Good one!

@oleclausing5768 Год назад

30 mins??? I call BS

@burbman60 Год назад

Its insane, 30 min to rough it out is incredibly awesome. Prob take 30 min to prepare a sand mold for something like this with uncertain results ahead, casting imperfections etc.

@s.s.9627 Год назад

Sorry to burst the bubble but 30mins is complete BS. I count 55 step downs with the 4in HFM which takes 8 seconds to do ~1/4 turn of the part (from 0:28-0:36), do the math and its 29mins just for that single tool! the 2 in runs at 50% the feed of the 4in so add another 44mins and you're already over 70mins for just 2 tools. 30mins is a complete lie. Sad to see them say something so egregiously wrong. I thought titans was more honest than that.

@CNCAddictGR Год назад

@@s.s.9627 you're probably right,i dont get why would they lie like that

@blueridge_ogre1714 Год назад

I have been out of school and in the field now for right at 4 years, I honestly wish all American machine shops and manufacturing shared the same level of enthusiasm, and pride in their trade, as you all exhibit on this channel. I can honestly say that my experience in machining has been the complete opposite. Everyone has an "its good enough", or "not my problem" attitude, and they lack the desire to be better at the trade or teach anyone anything. Despite feeling like Ive wasted my time in school and the last 4 years, I guess I will just have to suffer through and hope for the best. Thanks for atleast giving me hope that I'm not alone in having pride in my work. This really is an enjoyable trade, its just too bad that companies no longer embrace and appreciate the good machinist or the green ones still eager to learn, get better, and earn their pay. Keep up the good work, I definitely want to see the finished piece.

@ms.informed Год назад

It's the same elsewhere, even in Germany, the land of engineering. Not every machinist got into the field because they were always enthusiastic about the trade. And not every aspiring machinist/engineer get to do what they love as a job. Additionally not every company provides enough resources and benefits to attract competence, but they stay afloat, just because they're cheap and make parts that are "good enough".

@jthewelshwarlord6331 Год назад

I apprenticed for a company that only kept me around as cheap labour. The only one who actually wanted me to do well was a coworker, who mentored me for most of my time there. Sometimes my manager could be supportive but never there to teach me. He and my boss kept saying I was "going backwards" and the lack of support and help, coupled with the filthy environment and lack of sunlight spiralled me into depression and anxiety. Isolated myself, cut out things that could have helped me long-term, and after Christmas 2019 I had a panic attack over returning to work after the holiday. One phrase my boss burned into my head was "the only thing lower than an apprentice is the ground under their boot" which summarises how I felt most of the time I was there. Eventually I just fell into mediocrity and was only staying for the pay and job experience, not to impress or progress. Just go in, get paid, get out. I was there for a year before I was made redundant by company losses, and 2019-2020 was the worst year of my life. 3 years later and I'm still suffering from depression, anxiety and perpetual burnout. Been trying to take steps to break it but I find myself still falling into the habits. Would I try it again if my current aspirations fail? Maybe. Would I be willing to work in an environment like that again? No. Should I have sued for the damages? Maybe, but it'd probably end any future career opportunity in machining.

@jestonporter5049 Год назад

The fact that shop owners and leaders are still this way is ridiculous. This has to change. There are some shops out there that are embracing the way things should be, but they seem to be few and far between. Hopefully, the right ones will take over and the others will be left in the dust.

@jestonporter5049 Год назад

@@jthewelshwarlord6331 I'm very sorry to hear about your experience. That kind of mentality makes me furious. I hope you can find peace and have better experiences in the future.

@truegret7778 Год назад

It hasn't helped when so much outsourcing started in the late '80s. From manufacturing, to materials (iron/steel/aluminum mills), to software development, and food. The "it's good enough, or not my problem" mentality has permeated throughout America (and from some of the comments, just about everywhere). And in my opinion, unions have hurt more than they have helped. I learned from my father when you are on someone else's nickel, you give them 110% and take pride in you work. I hope the situation turns around this election cycle.

@trevorgoforth8963 Год назад

Awesome video Barry. Love the explanation of the thought process behind the programming strategy. That part is sick too!

@mohammedalbattal77 Год назад

Yesssssss 30 minutes HELLER 🔥🔥🔥🔥 Barry is the jockey and Heller is the great horse BOOM 💥

@JamesWatts-ik8fe Год назад

Killing it Barry - love all the detail on the Rotoclear as well, cool stuff!

@cdmChase1 Год назад

Haha!! "Look at that cut it's BEAUTIFUL"!! I thought it was just me who is mad!! Love machining.

@leanderfaurholt7118 Год назад

I love Barry just waving the part goodbye here 6:47 😂 I swear something is wrong with this man, and i love it.

@barrysetzer Год назад

Hahahaha I was starting to think noone was going to notice that! You're the first LOL

@archie3537 Год назад

Barry Givin it Hell,! On the HELLER

@skozzy1968 Год назад

Ive never seen something like this in real life, and seeing it so close up and clear makes me wanna watch so much more.

@Kardos55 Год назад

Love that sound . . .

@craiger8484 Год назад

Can't wait to see more

@robertkylethomas173 Год назад

I have no idea what's happening but this is awesome

@chudyhun Год назад

we need more videos for this!!!!

@alex_yates Год назад

Nice work Barry

@barrysetzer Год назад

Thanks!

@user-sz6iz9yh8b Год назад

30 MINS? Now that's HELLER impressive!!!. In rough stage, it resembles art deco sculpture. Very cool!.

@ronjlwhite8058 Год назад

We are all happy now, Barry.

@barrysetzer Год назад

Mission: accomplished

@FiglioBastardo Год назад

😂

@jeremymatthies726 Год назад

Barry, that was awesome. I like watching the milling, cant wait for the next vid.

@barrysetzer Год назад

Hey thanks Jerm!

@Sebastian-ed5kt Год назад

@@barrysetzer hey Barry, wouldn't it be faster to rough the big hole in the middle with a smaller (63-85mm) high feed mill? we did it like that in my old company in the horizontal position with 0.3-0.5mm doc, 750 rpm, 7100mm of feed and air a hole like that would take maybe 10 minutes

@lllllMlllll 11 месяцев назад

What a beautiful piece

@raider1628 Год назад

hope you guys actually show the fixture set up for the 2nd op! would be cool and educational if you guys showed how you guys programed the more interesting parts!

@piratiniwood547 Год назад

Nice video Berry, this is some great chip making, cool.... Next video please😊

@swikocki Год назад

Great job! I always like machining ductile iron, its usually kind on the tools. Just got a new horizontal delivered at work, looking forward to the increase of memory and now being able to use modern tool paths.

@jackjumperx4441 Год назад

Depending on the quantity of units being made, you either cut from solid chunk of material or make a rough cast and machine that down on critical areas only

@MarioAPN Год назад

Based on quality also. And its geometry. Sometimes you just have to use molding, it is chepaer, you can cast crazy geometries, but you can lack in terms of porosity, for example. You can compensate that and everything else, it isa beauty of this work. A lot of pain for the average human tho...

@Honzishek Год назад

that is really good strategy to rough that part . ! cool.

@Avodea Год назад

Good job, regards from switzerland!

@I_________I Год назад

DONT FORGET TO DROPP THE REST PLZZZ? IM WONDRING HOW YOU GONNA MAKE IT WITH THE BACK OF THE EXIT TUBE

@danb3122 Год назад

I like the energy!

@williamlind2843 Год назад

I totally respect the big part makers, but I need constant gratification!! Parts under 2" that are 4 axis mill/turn get me pumped. I love showing what a lathe with live tooling can create. But for me it's job specific and I'm in my wheelhouse. Win, win!

@tonyjesuslover 10 месяцев назад

Great job.

@kingofherdaz7860 Год назад

I'm very curious how you will machine out the hollow part of the spiral

@dougthomson5544 Год назад

You guys say you are machinists, but I beg to differ; you are much more. First, you are a special brand of computer programmers. Second, you have exceptional understanding of aerospace metallurgy. Third, you are expert mechanical drafts people. So, you are souls who have embraced new technologies and have run with them very, very fast. Good on you.

@bigcat.3256 Год назад

HECK YES BERRY!! 30mins is insane! That Heller is so BADASS!!!

@bigcat.3256 Год назад

Also I’m totally a lathe man at heart so I better see some damn turning!!

@simsonlaikongleong3785 Год назад

Barry rocks. Spin us more video.

@barrysetzer Год назад

Why thanks Simson! And I sure will!

@MrChevelle83 Год назад

roughing is the worst part for the machine because of major tool load so i think its cool that titan is detailed on hogging the metal off using the machines strengths then speeding it up on the light tool load cuts. excellent work.

@barrysetzer Год назад

Hey thanks bud, just talkin about what ive seen and done! Thanks for the support!!!

@warehouseman6325 Год назад

That's awesome

@aimlessdude9735 Год назад

You should take those monster chips and cast them into epoxy round bars for tool handles

@barrysetzer Год назад

That is actually a cool idea!!

@harryho9097 Год назад

4:51 that tunable holder sounds interesting. Can we get some more details about this holder? Like how it works? 😅Also, it would be helpful to see a comparison between this holder and a regular holder❤

@phunter198142069 Год назад

Can you 5 axis drill in Mastercam like you can in Hypermill? (Use a shell mill tilted to plunge will rotating the part to bang a big hole in)

@misfit3050 Год назад

On the second note about having to pick up from the beginning. Hermle 5 axis machines have this AMAZING feature called block scan. You can pick just about any line in a program. It will scan everything in the program up till that point, figure out which codes were active etc etc and start you again right from that point.

@misfit3050 Год назад

I also freaking love durabar. We use it all the time

@ecogames7165 Год назад

I think this is not directly a feature of hermle but from the control Siemens/Heidenhain

@andrewhorlock7744 Год назад

Even haas have this feature. The bigger issue is knowing where to start and find that easily on a program that might have a million lines of code

@CalvinEdmonson Год назад

At any point did you find it necessary, or just reassuring, to check the clamping pressure on your jaws? Stout set ups, the best tools, excellent programming, all add up to quality parts. Well done.

@CTLanni Год назад

Looks like fun! What I don't understand is why the billet can't be (or isn't) created with a basic shape to reduce the amount of milling necessary. Is the billet cast or forged?

@kevinedwards7079 7 месяцев назад

Viking music sound like you on a conquer binge stay calm and carry on

@brandonrenwick9125 Год назад

how did you get it to favor the rotary instead of the x,y on the 3d optirough? is that a custom post switch or simple toolpath setting?

@mnstrxj3280 Год назад

I enjoy doing all the CNC work,but come my days off or the weekends. You'll find me at my 40's vintage south bend heavy 10L's & Bridgeports, sometimes you just have to go back in time & sling chips.

@joemattes8389 Год назад

Cool video Barry. Curious, why not rough all the ID with the feedmill after drilling?

@MakeItWithCalvin Год назад

Or plunge rough it?

@4DModding Год назад

This would be a casting in production - I would hope :)

@phillhuddleston9445 Год назад

Probably but for a one off part or low production part casting it even more expensive than machining out of solid stock though neither is cheap.

@supremecommander2398 Год назад

how long until the subtitles for metric numbers are ready :D ahh, can't wait for the 5-axis action

@Peter.S96 Год назад

Damn we use oil to cool our tools always. We never work without cooling but u use kennametal carbid ones without any cooling :o really awesome

@rf11423 Год назад

Really cool Vido, but i have a question. Why you dont use the 9 axis Turn Mill for this Part. The od and id roughing goes so much faster. Or you did it just like you said you are a mill guy? :D Anyways i like seeing mills working as a lathe guy :D

@jonbaker3728 Год назад

Does that beast need to be stress relieved, or allowed to spring a little bit, or do you just keep milling in one chucking?

@vadmalski Год назад

Hypnotising

@GrumpyMachinist Год назад

Nice. I've been anxiously waiting for more content on this part. I would have processed this part by machining the I.D. work first. Does it matter?

@benjaminordonez779 Год назад

YAASSSSSSSSS!!!! BERRRYYYYYY MOOOOREEEEE CHIPPPSSSSSSSSSS! BTW, GGRREEAAAAAAATTTTTT VVVIIIIIDDEEEEEOOOOOOOOOOOO

@TITANSofCNC Год назад

YAAASSSSS

@Renegade48445 Год назад

Love machining cast iron, hate the mess it makes of the coolant and the dust on everything. But Barry I have to ask, why not rough the id with the high feed mill?

@barrysetzer Год назад

TBH I didn't think the dampened holder was going to help as much as it did, so I expected it to sound rough. But, it ended up sounding great, so if I could go back I would've skipped the endmills.

@Renegade48445 Год назад

@@barrysetzer Fair enough... ive found the hf mills push up so hard that even extended they don't bark nearly as bad as a standard shoulder mill. Thank you for your reply.

@jerriayzac8711 25 дней назад

Que estrategia usaste para el desbaste, me lo podrías compartir 😮

@theofficerfactory2625 Год назад

Are you guys gonna show you you will aug out the pipe?

@Stylesidetruckguy Год назад

Just a video idea. Try to show up the 3DP-ing community by machining a benchy.

@flyingjeep911 Год назад

Where is the rest of this part being made?

@koenig Год назад

Can you share the mcam program? Thanks!!

@jakebpau2396 Год назад

The Setz!

@ronakzare655 Год назад

افرین کارت خیلی عالیه

@garethbaker5179 Год назад

Why wasnt the part cast beforehand so that there was a lot less material to machine, therefore saving material costs and the time taken to rough and profile?

@89RASMUS Год назад

Probably a one-of part, making it more economical to machine it out of a billet over spending 100-150 hours to make the pattern and casting. Cheers.

@frankensteincreations4740 Год назад

Damn! You know you’re watching some good sh*t when your eyes are dried out, and your chins wet lol. Unreal what these machines, with the proper user can do… unreal! 👍🤘👏

@travisjarrett2355 Год назад

Good video. Better tips. Should of turned some of it 😉

@barrysetzer Год назад

Blasphemy LOL

@pozalujstapodpishus3062 Год назад

how you convert 3axis strategies to rotate axis?

@Hani13ful Год назад

Post processor for that type of machine nothing science

@saumyacow4435 Год назад

Oh dear, this guy is going to be making love to the machine in part 3...

@robertomurillo340 11 месяцев назад

So, where is the finished part...?

@alexbireta4668 Год назад

Though I am curious about why you used polar interpolation rather than the three linear axes…

@barrysetzer Год назад

Because the head can only go a few inches past table center, so it's really the only way to do it in this case

@sobocinski123 Год назад

why not use a high feed mill to open the entire cavity? then come back to finish sides with solid carbide..or am I getting into practical vs. marketing?

@olafmaestro Год назад

If I see it correctly I assume that the part has a tube that goes around, but with what sorcery other than additive or casting could you machine this from raw stock?

@niclasstorm8192 Год назад

Must be a showpiece of sorts

@alexbireta4668 Год назад

If the bottom plane cuts through enough of the tube, you could access part of it through there, and the rest from the opening on the top

@paulmorrey4298 Год назад

Cheers

@thni1703 Год назад

Crazy

@strange_weird Год назад

What do you guys do with all of the chips? I’m really interested

@barrysetzer Год назад

recycle, for the most part

@denalozecon9074 Год назад

That is super impressive to do that much in 30 minutes. I betcha it took two or three full work days to decide what instructions to give that machine. I don't mean only one person working that amount; any number of people working a total of 16 to 24 hours doing lots of math and geometry, deciding which tools for each step, and many more details I cant describe. I really am just guessing on this, but what I describe is worth it to avoid ruining a part; if that part was ruined and they had to do it again it could cost them over $30,000 as a guess.

@ytfan3815 Год назад

Just forget it, not in 30 minutes.

@EvoKey Год назад

Is it really necessary to machine down the steps on the outside? I would think it would often not matter if the part is visually clean outside, as long as the critical measurements are correct. Because then it is just extra time spent on niceness, and is that extra time spent paying off for both the costumer and you?

@wildin13 Год назад

Depends on customer and application. All those steps can be stress points and some customers like parts to look clean others just want it quick and/or cheap

@phillhuddleston9445 Год назад

@@wildin13 With all the time roughing it doesn't take too much more time as a percentage to make a part look ten times better and finish it correctly.

@wildin13 Год назад

@@phillhuddleston9445 well it depends really. As a tool and die maker I find 30min roughing to 2" on this is shifting, considering that inside bore. I also imagine it needs roughing down to a 3/8" tool in places so those steps don't matter 1 bit yet. Just focusing on the outer shape (none of the important features) I'd bet there's another 45-60min of roughing then an hour or 2 of finishing. But thats assuming its finished with 1 tool which I actually doubt highly. Typically when we do the "lightening out" on the back of gravity dies we use high feed roughing tools to "finish" with a smaller Ap than usual to reduce stress risers

@MWL4466 Год назад

Why would that part not be cast ? We machined volutes for years and they all were cast in a foundry.

@virtuosisimo Год назад

I once snapped a high feed endmill just after five parts

@machinetoolswarehouse Год назад

How much did the billet cost? How much would is cost to have that part machined?

@barrysetzer Год назад

The billet was around $800, and machining it will take around 15 hours, so around $2000

@nikolaishriver7922 Год назад

Two thoughts that really aren't relevant here, but I'd love to see Titans dabble in: Rotary table on the Blohm, and an actual HSM milling department.

@MrAarms91205 Год назад

Do you have blueprint for this part?

@amalfi460 Год назад

New sub here, so what is the part you are making…if you said it i missed it, or do you guys just get told to make this with no explanation?

@barrysetzer Год назад

Hey Neil! I actually couldnt tell you what it is. It’s obvious some type of pump, that we were told was “difficult.” Soooooo we wanna make it easy

@tubbytimmy8287 Год назад

Can anyone get this to work on HLE? I assume I just go to "Rotary Axis" and then "Rotate about Z axis" ?

@barrysetzer Год назад

Yeah, assuming your post is set up for it, you would select 3 axis and rotate about z. You can also change your backplot settings to simulate rotary motion.