Reuse Broken End Mills

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If you've ever spent any time milling I am sure you've also broken, crashed and snapped your fair share of end mills. They're expensive little things, so why should you throw them out just because they serve no purpose to make chips any more? Make something new from them instead!
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Photos:
fishes-00614_-_Prussian Carp [2281x1340]@G._1_12_ by ArtsCult.com
www.flickr.com/photos/artscul...
Public Domain
Birds-82-023 - Ostrich, Rhea, Ceram Cassowary, Kiwi by artvintage1800s.etsy.com
www.flickr.com/photos/artvint...
Public Domain
Music:
Josh Woodward - Swansong

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Опубликовано:

10 фев 2016

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Комментарии : 268

@toolify 8 лет назад

hahah, "redo the solder and all the steps again" :) That was pretty cool!

@SwitchAndLever 8 лет назад

Mistakes happen, I believe showing them is better than trying to hide. Makes for a bit more interesting videos too.

@thomas6244 8 лет назад

Nice job ! I love how you include your failures also... makes it more realistic :D

@corvysone2 2 года назад

Please keep posting your views I find them most entertaining. Bravo.

@Mudsuitable 5 лет назад

they make excellent ear plugs! that's what I use when I get yelled at by the grey beard for breaking them in the first place, just make sure to turn down for the perfect fit and give them a mirror polish, they work surprisingly well and will last forever!

@jonjohnson102 4 года назад

Wait really?

@lars-sorensen 8 лет назад

Love your videos! The small nerdy projects and humor is an excellent combination!

@BruceAUlrich 8 лет назад

I cracked up so hard at the "Oh, carp," part! ha ha

@pjhalchemy 8 лет назад

Great fun and re-purposing very satisfying to see. The boring bar was great along and busted up with the Drunken Ostrich...Thanks for all the work and fun you bring! ~PJ

@warsuper4681 8 лет назад

Very nice, engineering materials have a unique look. I have often turned old cutters into lathe tools and boring bars. Either in a custom holder or on its own. Its a shame to waste.

@SwitchAndLever 8 лет назад

+war super That's what I usually do with high speed steel tools as well, but tungsten carbide is a bit too hard for my taste, to do any serious tool grinding to.

@machine2747 7 лет назад

Thanks for the laugh! Nicely done.

@katyfox2749 7 лет назад

My suggestion would be to make nominal sized plug gauges with the broken shanks , as carbide milling cutters are only a few 0.0001's undersize & would be far more useful as gauges !!!

@SwitchAndLever 7 лет назад

Sure thing, or you could make center punches from them (like I've done in previous videos). Though, I never claimed I was making anything useful in this video, it's more philosophical if anything :)

@scottburrous2375 6 лет назад

Switch & Lever: I've done the center punch thingy, they have a tendency to break/crumble. I enjoyed your humor. In an attempt to prolong the life of my grinding wheels I use diamond cutoff wheels and cup grinders.

@anthonydemaio4545 2 года назад

This comment made wasting 5 minutes of my life worth it, thanks!

@MichelKiflen 8 лет назад

Nice bit at the end where you said something poetic about carrying your mistakes Cool video!

@HanstheTraffer 6 лет назад

Dude you are a natural. Great Video. So much in there while pretending to be corny.

@dessiediamond5974 7 лет назад

Great sense of humour. Loved this

@WoodworkingBarcelona 8 лет назад

Good job man! I always enjoy your videos and graphic design as well!

@SwitchAndLever 8 лет назад

Thank you!

@MrFuchew 7 лет назад

i like to flap my hands in the air yelling noooooo then i lose all strength in my legs and flop around on the ground. then i throw the remnants around the shop while telling anyone that will listen the tale of the terrible tragedy that hath befallen me.

@gordonlong1673 7 лет назад

Fun video. If you want the joint to be the best, put a thin sheet of Copper between the steel and the carbide. Look carefully at the side of a commercially brazed carbide lathe tool and you can see the Copper under the carbide. If everything is cleaned and fluxed well, the solder should pull in easy. The best technique is to get everything warm and close to the melting point of the solder which is when the flux starts to look glassy and then apply the solder to one side while heating from the other. The solder flows towards the heat when the temperature is right. Always avoid putting the solder in the torch flame and dropping globs onto the part. It works even better to have fluxed sheet solder between each surface or snips of solder next to the joint so it flows when it gets to temperature.

@SwitchAndLever 7 лет назад

Great tips, thanks a lot!

@user-pr2fy2oi5k 7 лет назад

i think, that is actually not a copper but a brass with too low zinc or just a bronze in a soldered tools

@mikebeacom4883 6 лет назад

Gordon Long I

@MacMiskenn 7 лет назад

Nice! Actually laughed with genuine mirth :)

@mrcpu9999 6 лет назад

That was awesome. Suckered me in. Well done.

@JohnGrimsmo 8 лет назад

Very cool and addictive video!

@SugarcreekForge 8 лет назад

I am reasonably sure that a person would have to also be pretty drunk to try and ride a drunk Ostrich! Haha. Maybe attaching a piece of steel to each end and drilling them would make a nice Ostrich bit... Have a great weekend :-)

@PollyMotion 8 лет назад

Love your videos! And your humour always gives them a great touch. You have a new subscriber :)

@SwitchAndLever 8 лет назад

Cheers!

@jsblacksmith858 4 года назад

You can also use a square piece of steel, drill it and slot it and clamp the reground endmill shank as a lathe form tool, e.g. for radii

@CompEdgeX2013 8 лет назад

Enjoyed the video..love the mid-stream re-do..happens to everyone...LOL

@flaplaya 7 лет назад

It was a trick, but well done with life lessons and goals so it was not a waste. Cheers.

@leesuschrist 8 лет назад

I like your style! Very clever way to reuse junk carbide.

@Cactusworkshopchannel 8 лет назад

Awesome! haha the graphics at the begging are great! and I love the result. I have a couple of them broken that I could try :)

@douro20 6 лет назад

I used to make scribes from broken carbide end mills. I used a die grinder with an angled diamond grinding wheel, doing the rough grinding against the grain and the fine grinding along the grain.

@susanbarbier5053 4 года назад

I really like the insert key ring thing. Great videos!

@joku900 8 лет назад

Just attach a string to it and you have glass breaker?

@leesuschrist 8 лет назад

+Chuck Norris That's a good idea!

@snowdog90210 6 лет назад

Chuck Norris the real chuck Norris doesn't need a glass breaker. He is a glass breaker

@28cruzin 6 лет назад

Been there, done that. I made boring bars out of a few, just soldered carbide to the cabide. Still have them many years later and they are very handy.

@andrewwilson8317 8 лет назад

If you have or have access to a tool cutter and grinder then you can turn the shanks into long lasting counter sink bits. Smaller diameter shanks can be cut into bits for 3D pantograph engraving machine.

@SwitchAndLever 8 лет назад

That's a great idea, unfortunately I don't have anything such, but it's a great and functional way to go about things!

@andrewwilson8317 8 лет назад

+Switch & Lever perhaps making one might be a good future product for you? There are a few models like the quorn that can be made at home and are held in high regard. My first was made from a pillar drill and an X-y table and spindexer. Worked very well and sharpened lots of tooling.

@robert5 6 лет назад

If you have a lathe, buy some 1/4 shank diamond grinding bits from ebay and then find a small router at a pawn shop, for some reason pawn shops always seem to have a lot of small routers. Mount the router on your tool post and the broken endmill in the chuck and you can easily grind any type of point on it. You can also make it into a lathe cutter that will fit into a quick change took post also, but I really like these as spotting drills. Grind a 60 or 90 degree point then rearrange the grinding bit to grind away 1/2 the point like any other spotting drill. Easy to do after you done a few and these work great. BTW, making a key fob outa these is lame, I expected better....

@littlestworkshop 8 лет назад

Hammer a piece of silver solder flat and put it between the two pieces along with some flux, should ensure a strong bond.

@colsoncustoms8994 4 года назад

you can also "Tin" one (or maybe both?) of the pieces. Get the braze melted onto it and then heat them both up together until it flows.

@volunteerjsp 2 года назад

F.O.B = finger operated button. You've made a key chain ornament.

@SwitchAndLever 2 года назад

Except that's a so called backronym, an acronym that has been constructed from a word after the fact. The word fob seems to originate from the 19th century, and can mean anything from just a trinket carried with you, to now as you point out an electric device often used to open doors. So thank you for your comment, but in all the years this video has existed no one has ever brought this up, which probably should've given you pause 🙂

@kravselj 8 лет назад

cut a piece of it, braze it to square bar and you have a new lathe tool

@RoscoRSR2 8 лет назад

Have you tried cutting a piece with a grinder while spinning it in a hand drill or a lathe? It produces an extremely clean and square cut. I've done this with a large broken engine block valve shank.

@SwitchAndLever 8 лет назад

Nope, that I have not. The idea of carbide dust covering the lathe ways bother me a bit though. I could see how it could be useful for other materials though.

@outsidescrewball 8 лет назад

Enjoyed! Now I know what to do with all of those I have been saving!...lol

@MrLaTEchno 7 лет назад

Well it put a smile on myface ;-) thnxs for that mate

@UnorthodoxFabrication 8 лет назад

I really like this! Thanks man

@dumetwatches6451 2 года назад

I don't break them that often anymore, but they do get dull over time.. i just break off the flutes, and grind them into small boring bars. 3, 3.175, 4 and 6 mm are the shank diameters i mostly use, and especially the 4 mm, make excellent mini boring bars. How to grind those?. I use a lathe with a diamond wheel, first grind to half the diameter, then do the relief on the front and side and finally reduce the shank. I use these tools mainly in titanium, don't have to drill anthpything over 4.5 mm, just go in with my mini boring bars

@mikewalton5469 6 лет назад

very cool idea. i like the way you laugh at mistakes!

@SwitchAndLever 6 лет назад

That's the only way to do it. If you wallow in your failures you'll never move forward. Laugh about it, hopefully learn from it, and move on.

@fall22123 8 лет назад

Broken endmills can have actual use, if you have a tool grinder with a diamond wheel. You can make single lip endmills with them. They really come in handy when you want a tapered or corner radius endmill and don't have one. What I make most often are scrapers for deburring. Grind 3 facets at a 5 deg to form a pyramid with a sharp point. You can use the sharp edges on the tool to break sharp edges on your parts. If the endmill is big enough, you can use it alone. You'll want some sort of holder for smaller ones.

@SwitchAndLever 8 лет назад

If I had a tool grinder I'd go to town, no doubt about it!

@not2fast4u2c 8 лет назад

I have had a lot of those "Oh Carp" moments !!!

@noisytim 8 лет назад

Neat idea ! I love it :)

@irish-simon 7 лет назад

fantastic video I love the edit

@iantattersall6462 7 лет назад

Stefano gottenwinter

@rompdude 7 лет назад

5 minutes of my life which I will never get back...

@SwitchAndLever 7 лет назад

Are you a cancer scientist or perhaps on the verge of solving world hunger? Otherwise I don't quite see how it matters. You'd just find something else to waste that time on, I'm sure.

@rompdude 7 лет назад

Yes as if happens, I'm currently studying the effect of terrible videos and their effect on the blastomas in cancer sufferers. But really I was hoping this video was going to be something useful like a dead centre, or a chamfering tool.. Something of use.

@iamtheomega 8 лет назад

armor piercing tip for 12ga. shotgun round (see: Taofledermaus)

@baladar1353 6 лет назад

Except it will destroy your shotgun's barrel, buddy. As you could hear, it is a piece of tungsten carbide, which is often called as industrial diamond. Maybe your whole face will be blown off by the pieces of your shotgun, but just keep on trying, undertakers have to work if they want to live.

@grayfox8554 4 года назад

I tried the carbide armor piercing round. It does not ruin your barrel, though it takes painstaking time to balance and requires several more drams of powder to give the heavy round the push it needs. At 50', the tumble was minute though the round caused horrendous damage to the 1/2" steel plate that a .50 cal has trouble penetrating. With a little more balancing and fine tuning from our armored, we hope to start using them to fight terrorism soon. Thanks for the idea. US Black-ops

@ChucksSEADnDEAD 3 года назад

@@baladar1353 the tip does not touch the shotgun barrel, buddy.

@schlaznger8049 6 лет назад

If you simply flatten off the end and grind two flutes on it you have a bottoming endmill the can chase holes to provide a square shoulder or be used the clean up the inside edge of a 90 degree cut.

@nieltymx 8 лет назад

i made a little burnisher for cabinet scrapers

@SwitchAndLever 8 лет назад

Thats a great use!

@jimscobie6646 7 лет назад

I've never broke an end mill in my entire life!

@rossclements8874 7 лет назад

you're obviously not doing it right!

@wernerherzog8879 7 лет назад

James Scobie me neither, because I don't have a mill

@MrFuchew 7 лет назад

try harder

@jeronimomurruni 6 лет назад

"I've never broke an end mill in my entire life!" Yet.

@Ropuch7 6 лет назад

the czerstwy chlebie

@kevinkillsit 8 лет назад

You got me haha. I actually thought we were going somewhere useful with that for about 3 mins and was like "this will never work..., but just in case lets see what happens lol.". Nonetheless, nice techniques.

@godfreypoon5148 7 лет назад

After grinding off the sharp corners, you can put it in your nose.

@newvultraz 7 лет назад

As you took from the endmill, the endmill shall take from you.

@YourOldDog 6 лет назад

Excellent! Lot of fun!

@1019wc1019 6 лет назад

You should have so many more subs!

@SwitchAndLever 6 лет назад

Spread the word! :)

@danballarin 4 года назад

Well, I made center punches out of some of mine... If the diameter is precise, they can be transfer punches... That is a real use because other than a giggle, I got nothing out of it.

@dimitrijevasiljevic 8 лет назад

i was wondering im other videos,why do you use a conatact wheel on the beltsander,doesn't it leave a hollow survace?You should make a tool rest so you can make precuse verticalsurfaces.Also an idea for a project,a whole knife

@SwitchAndLever 8 лет назад

+Dimitrije Vasiljevic Not my belt sanders, I cannot modify them. I only really grind stuff where it doesn't mind on that belt sander, there is another one which is flat, but doesn't have a rest.

@dimitrijevasiljevic 8 лет назад

+Switch & Lever oh well the disksander will do then!Really cool chanel by the way!

@mpetersen6 3 года назад

My favorite use for end mills that have one flute busted in a crash is as boring tools

@colsoncustoms8994 4 года назад

You had me going for a bit, I was confused when you started shaping the steel and not the carbide though. You could definitely follow essentially the same steps and use a piece of carbide brazed onto a longer HSS shaft, then grind in a cutting head into the carbide and you'd have a new cutter. Might make sense on a big or really expensive end mill. Or if you needed a special shaped cutter that wasn't available elsewhere.

@SwitchAndLever 4 года назад

Doesn’t make sense in a workshop environment that goes through endmills rapidly. Costs too much to regrind endmills that are broken than buy new. This was more of a philosophical video than anything.

@colsoncustoms8994 4 года назад

@@SwitchAndLever For a production shop, no it probably doesn't make sense financially. For a home shop though it might have some utility. The idea of re purposing the carbine shank rather than just tossing it in the bin has some merit. Hell even if you just used the carbide for brazed tooling for the lathe. I think This Old Tony had a video on making custom brazed cutters from carbide stock. Or maybe it was AVE, can't remember for sure.

@MarcSchaefermeyer 8 лет назад

Too funny! Loved it!

@ArJuna22 7 лет назад

LOL! I was not expecting such an inane product.

@stevenbierlink6695 8 лет назад

Laughing....so...hard.... Love this stuff

@tanjiro3285 3 года назад

i had a strong feeling that 1st bit was going to break

@blackswanprepping8827 8 лет назад

Lol! Great video. I always keep broken stuff around, just in case a tool building Idea pops up :)

@SwitchAndLever 8 лет назад

Just be careful, the line between keeping useful things and being a hoarder is thinner than a hair.

@kenibnanak5554 7 лет назад

LoL, I just make really tough dowel pins from mine.

@ridonculous8374 8 лет назад

lol 😄 you got a new subscriber 😎

@pinkponyofprey1965 8 лет назад

Oh, man, if I had enough keys hahaha ...

@notsomexicanufo 6 лет назад

i bet you could make a punch for drilling holes that way but you would have to weld the piece of steel because if you hit tungsten carbite it might break off and hurt you really really bad

@ranjah76 8 лет назад

good video and funny too

@oxalek8220 5 лет назад

Saw it coming, but watched it anyway. Lol.

@CatNolara 7 лет назад

You could also make a center punch out of it, or grind it to special tools.

@SwitchAndLever 7 лет назад

+Klaufmann please tell me about all the times you've ground tungsten carbide.

@CatNolara 7 лет назад

Not really much, that was just an idea. I have just some broken 1/8" carbide bits that I ground a pointy tip with a diamond disc in a dremel, wasn't too hard. But these bigger ones sure could be tougher to grind. For special tools you propably really need some serious grinding machines.

@godfreypoon5148 7 лет назад

I have many diamond abrasive tools.

@heatmahnz4949 8 лет назад

I would be strength training all day with the amount of end mills ive broken

@Castle6064 8 лет назад

Nice one I like it

@GaryTruesdale 8 лет назад

awesome!

@Askjerry 8 лет назад

At first I thought you were making a ball mill for light plastics and stuff... then I was like "whaaat?"... Then... oh... didn't see that coming.

@kungopus 6 лет назад

😂👍🇸🇪 made my day bro👍👍

@robvaughan1732 7 лет назад

Brilliant thanks for the laugh. :P

@SwitchAndLever 7 лет назад

+Rob Vaughan you bet! Thanks for watching!

@battleminion 8 лет назад

Haha this one should be posted in april fools , nice one

@auxchar 2 года назад

All that for a key fob. I feel like I got baited. I thought you were going to make a new cutter out of it!

@alcatrazmiller1364 6 лет назад

Is it possible to make a d bit?

@kensendelofski3761 5 лет назад

loved it.. made me laugh so hard..

@rasmis 8 лет назад

I was wondering; is it not possible to friction weld them together? You have the lathe to try it on :-)

@SwitchAndLever 8 лет назад

+rasmis It may very well be, though I have no experience. Cursory research (literally five minutes on google) leads me to believe that it's possible to do, but requires the surfaces to be welded to be very well ground to begin with, which I don't really have equipment to do.

@rasmis 8 лет назад

+Switch & Lever I learned about it a few weeks ago, when I saw a gif. That's all I know. Give it a go, and let us know ;-) But stay safe.

@SwitchAndLever 8 лет назад

+rasmis Nope, won't give it a go, as I said, don't have the equipment. Staying safe is for those with a desire to grow old.

@glennedward2201 5 лет назад

I cut my broken ends and run it through my end mill cutter and sharpening grinder and wallah I have a repaired end mill a little shorter than original. This is what slow days are for it’s a bitch to be honest cutting 50 down and sharpening them back up and putting the profiles in them. It’s easier to sharpen a dull one that’s for sure but tossing $50 end mills in the trash is a heartbreaker. I even sharpen my inserts a couple times before trashing depending on style and use. Anything to save the life and $$$.

@SwitchAndLever 5 лет назад

In a professional workshop environment that is a waste of money. The manhours are worth more than the cost of a new endmill, so they either get discarded or they get sent out for sharpening if the endmill is especially costly.

@NoTimeForThatNow 7 лет назад

Pointless! Love it!

@TOM-ph7xy 7 лет назад

hm looking nice but you can also recycle those endmills for good money if you have enough of it. for a real purpose you could grind those endmill to a one tooth cutter to remove broken screw taps. i like your movie, great ideas. have fun and hail to the metal workers

@NotTheMan100 5 лет назад

Make a lathe tool out of it, need a custom id radius just grind it to the shape you want.

@tarak0274 5 лет назад

You should use friction welding.

@Cobrass2 7 лет назад

wow i got so disappointed by the end xD But good job

@Nabakumardas-4831 4 года назад

Thanks

@xtianor 8 лет назад

you should make a video for reusing bandsaw blades.I've forbidden myself not to use a bandsaw anymore

@taylor4386 3 года назад

It would be a lot more useful to put an exact point on the keychain. Then you'd always have a scribe with you

@hamsteaks5541 7 лет назад

Just buy a Guhring "diver" end mill. End of story. We've milled 3" long pockets and inch deep in 4340 (I know, it's not titanium), interrupted cuts etc with a BROKEN off flute! I've never seen anything like it.

@cesteres 5 лет назад

Coat with soft metal and you have a great penetrator.

@Paddington60 8 лет назад

I want one! LOL

@rightagain 7 лет назад

Try chamfering the end of the bit to create a weld prep before soldering it.

@SwitchAndLever 7 лет назад

Isn't the point of chamfering more to make sure you get proper heat penetration? For smaller parts like these, where that is not an issue I don't see much how the chamfer would help.

@coleedson5439 5 лет назад

the chamfer helps the solder flow also i belive

@ipadize 7 лет назад

i once broke a 16mm carbide endmill while cutting aluminium... because the part moved a bit out of the jaws :§

@JamesCromwell2047 8 лет назад

So... when do we get to hear how you know how hard it is to ride a drunk ostrich?

@Liazon098 8 лет назад

I was not expecting that..."tip" in the end about end mills.

@WCGwkf 6 лет назад

A nice and heavy ass key fob is going to prematurely wear out your ignition lock.

@SwitchAndLever 6 лет назад

How fortunate I don't have a car then.

@DiscoverRajivVlogs 5 лет назад

You could have just sharpen the carbide mill as a simple straight flute end mill.

@SwitchAndLever 5 лет назад

Without a tool grinder getting it absolutely flat and perpendicular to the shank is not really doable. Otherwise you wouldn't really be able to use it as such.

@jarisipilainen3875 6 лет назад

i thought you make round cutter lol, but why you need use broken end mill to make key ring lol. you save many steps do it just from cold rod lol

@SwitchAndLever 6 лет назад

+Jari Sipilainen you don't need to use it to make a keyfob, but if you have broken endmills you can use them. Tungsten carbide and cold rod have quite a different feel and weight too.