Neat Machining Video

[kwhizz]

Here's a short Video of the Latest and Greatest in Cutting Tool Technology.......These parts are D-2 Toolsteel and are heat treated to 60 Rc......It used to take us about 3 hours to finish Grind the Octogon and transition Radaii between the flats
With the "New" Tools we are able to make the same part in about 2 1/2 minutes........Remember, This material is 60 Rc


http://i13.photobucket.com/albums/a251/kwhizz/Machine/th_MOV07963-1.jpg (http://s13.photobucket.com/albums/a251/kwhizz/Machine/?action=view&current=MOV07963-1.flv)
Ken http://www.yenko.net/ubbthreads/images/graemlins/flag.gif

[YENKO DEUCE REGISTRY]

What does Rc mean, (other than hardness!)?

[kwhizz]

Rc is the Abbreviation for Rockwell Hardness......60-62 Rc is the hardness of cutting Tools......Drills, Etc..Soft material is like 8-10 Rc just as an example

Ken http://www.yenko.net/ubbthreads/images/graemlins/flag.gif

[ORIGLS6]

So using that scale, Belair would be a 120 Rc A$$? http://www.yenko.net/ubbthreads/images/graemlins/hmmm.gif

[Mr70]

Kicka$$ video Ken.

[Keith Tedford]

At 62 RC we had trim sections in dies that would some times chip. We dropped down to 56-60 and the dies still trimmed the parts fine but didn't chip. CNC machining has taken the machine shop out of the hands of the Machinist and put it in the hands of the computer whiz. Sure cuts down on the cost of producing a big number of the same part. Once the programme is written you can go back to it at any time and make some more parts. I can remember when digital readout on the machines was a God send. http://www.yenko.net/ubbthreads/images/graemlins/smile.gif Now it is digital everything.

[kwhizz]

Without getting into Exotic materials.....about the Hardest you can get metal to harden to is about 62-64 Rc

Ken http://www.yenko.net/ubbthreads/images/graemlins/flag.gif

[70 Forest Green Zee]

Very cool Ken....was this done in your shop? http://www.yenko.net/ubbthreads/images/graemlins/worship.gif

[kwhizz]

[ QUOTE ]
Very cool Ken....was this done in your shop? http://www.yenko.net/ubbthreads/images/graemlins/worship.gif

[/ QUOTE ]

Yep!! If there is any Interest.....I can post all kinds of neat stuff.....

Ken http://www.yenko.net/ubbthreads/images/graemlins/flag.gif

[70 Forest Green Zee]

Hell no....I rather come and see it in person! http://www.yenko.net/ubbthreads/images/graemlins/biggthumpup.gif

[ORIGLS6]

[ QUOTE ]
[ QUOTE ]
Very cool Ken....was this done in your shop? http://www.yenko.net/ubbthreads/images/graemlins/worship.gif

[/ QUOTE ]

Yep!! If there is any Interest.....I can post all kinds of neat stuff.....

Ken http://www.yenko.net/ubbthreads/images/graemlins/flag.gif

[/ QUOTE ]

http://www.yenko.net/ubbthreads/images/graemlins/biggthumpup.gif http://www.yenko.net/ubbthreads/images/graemlins/biggthumpup.gif

[nuch_ss396]

Ken,

Now you're talking a language I know, other than SHP Chevy's. http://www.yenko.net/ubbthreads/images/graemlins/worship.gif

Nice finish on the part ( from what I could see ).
What feeds & speeds are you running on the first cutter?
How much stock per pass were you taking off? Were you
running air/oil mist, or just cold air to cool the tools?

You'll probably find this interesting. I just finished a
multi-year development project with a client for ultra
high detail - high speed machining in tool steel. We
just purchased six 3-axis high speed milling machines
for this project at well over $2,000,000.00

We'll be running in the 30,000 - 40,000 rpm range with
cutters down to 0.006 diameter. Yes, that's two times the
diameter of a human hair. Get this - run time for these
cutters is anywhere from 20 - 30 hours. What are we cutting?
All future US coin dies at the US Mint.

I'd love to be able to post an video of that process, but
then I'd be conversing to you guys from behind vertical bars. http://www.yenko.net/ubbthreads/images/graemlins/rolleyes.gif

[Tommy]

Pretty Cool Ken, that is very nice http://www.yenko.net/ubbthreads/images/graemlins/cool.gif. Looks like it's time to paint the cabinet again http://www.yenko.net/ubbthreads/images/graemlins/grin.gif. I worked for Wolverine tube years ago and if you had more than 5 minutes down time someone was handing you a gallon of paint and a brush... Never saw so much green paint in my life... I think some of the machines had 6 inches of paint on them .

Tommy http://www.yenko.net/ubbthreads/images/graemlins/3gears.gif

[Xplantdad]

I'll bet that the router bits are quite expensive...we used to use the same type of machines to route out the circuit boards at the facility that I worked at... http://www.yenko.net/ubbthreads/images/graemlins/beers.gif

[mrtimstik]

The vid looks good. Can't believe those cutters go thru 60Rc like that and throw real chips. Looks good so long as the numbers are there. Had a Bostomatic at my fingertips and did some hard milling in the past but the chips were usually dust. Since I have been working where I've been working, I have been designing a lot of parts that require wire work. The parts lend themselves to that process and they encourage it. You gotta wire dere on da nort side?? http://www.yenko.net/ubbthreads/images/graemlins/wink.gif

[kwhizz]

[ QUOTE ]
The vid looks good. Can't believe those cutters go thru 60Rc like that and throw real chips. Looks good so long as the numbers are there. Had a Bostomatic at my fingertips and did some hard milling in the past but the chips were usually dust. Since I have been working where I've been working, I have been designing a lot of parts that require wire work. The parts lend themselves to that process and they encourage it. You gotta wire dere on da nort side?? http://www.yenko.net/ubbthreads/images/graemlins/wink.gif

[/ QUOTE ]

We got 4 Wire Machines "Up Nort"......just bought the latest Charmilles 440 machine..........Ya Hey Der.....Eh!!

Ken http://www.yenko.net/ubbthreads/images/graemlins/flag.gif

[Mr70]

It really is a nice,clean,cutting edge professional shop up der.
The machinists know their stuff and the boss,Paulette, keeps everyone on their toes.

[GRB]

I love to watch stuff like that. I drive my wife crazy waching "How Things are Made" and "How Did they Do That".

[kwhizz]

Nice finish on the part ( from what I could see ).
What feeds & speeds are you running on the first cutter?
How much stock per pass were you taking off? Were you
running air/oil mist, or just cold air to cool the tools?


Spindle 1650 RPM , Feed 40 Inches per Minute,
Depth of Cut .010 Deep........... Length of cut 1.5"
Modern Technology.....Crazy........It's the Coatings that have been developed that are the Key to this Magic.....these tools have two coatings on them, without the second coating they would fail......Here is how it was explained to me.......The second coating is put on in a thickness relative to the Empire State Building being 1MM (.040) high, the coating thickness would be like a Dime laying on the sidewalk in front of it.......The Crazy thing is that almost all the heat leaves with the chip, after machining the part is just mildly warm to the touch.....The Cutter cost about $175, and we did about 60 pcs with absolutely no change in size.......we had to hold +/- .0002 which was no problem........Can't deviate from the manufacturer's Speeds and Feeds....the first time we ran this part this way , as the Tool comes into the part you just stand back and wait for the crash because it go's against everything we have learned in the Past....Pretty Cool.......We ran with just air blowing on the Cutter to clear the Chips

Ken

[68l30]

Very cool! Thanks for the info...

Oh yeah,I'm in QC... Now I get to watch machines run as I eat my lunch....Thanks! http://www.yenko.net/ubbthreads/images/graemlins/tongue.gif

Steve http://www.yenko.net/ubbthreads/images/graemlins/Charley.gif

[nuch_ss396]

Yes Ken, the coating(s) you are referring to are actually
only a few microns thick. Normally, these coatings embed
partially into the substrate of the tool steel ( carbide ).
The faster you run them, the better they cut.
Sounds contradictory, but it's true.

Steve

[gwawa]

In case you didn't look closely, this is just one of the lug-nuts off Ken's Biscayne he recently completed....

[Xplantdad]

[ QUOTE ]
In case you didn't look closely, this is just one of the lug-nuts off Ken's Biscayne he recently completed....

[/ QUOTE ]


Too funny http://www.yenko.net/ubbthreads/images/graemlins/beers.gif