I love this kind of video a lot - to be honest, more than the actual machining :D There is so much that goes into the planing of a project like this and its great to see your approach and preparation of tooling. Thank you Peter!
@EdgePrecision
Жыл бұрын
Thanks Stefan!
@mg30ebay
Жыл бұрын
I've designed features like that. The cavities are just clearance pockets for electronic components. I can just about guarantee they were done almost by eye against the part envelope, and so were the corner reliefs. This video should be required viewing for designers, so they can understand why it's important to sanity-check your design against standard tooling like end mills. Also, such features should have generous use of MAX and MIN on the dimension where possible. You may have modeled it with a .125 radius but .25 might be just fine.
@EdgePrecision
Жыл бұрын
Yes I agree but in this case I have to machine to the drawings dimensions. The tolerance of the pockets isn’t real close. +-.010 but the corner radiuses could probably larger. But I don’t know. Thanks!
@mg30ebay
Жыл бұрын
@@EdgePrecision I meant, in general, designers should put thought into giving you as much leeway as possible. This video is a great lesson to show why it matters. They may have done what they could on this part, who knows.
@sharg0
Жыл бұрын
As one that have machined stuff like this I couldn't agree more. Good communication between designer/engineer and production is essential. Everyone benefits when the right tolerances and requirements can be set! (Thankfully I've managed to avoid copper, give me inconel any day!)
@user-hf6qn2fc4w
Жыл бұрын
@@sharg0 Привет! Подскажи пожалуйста какими фрезами вы обрабатываете Inconel?
@Ujeb08
Жыл бұрын
required viewing fir the designer - I agree. I also think that the extra cost for the needed tooling modifications should be deducted from the engineer/designer's pay along with an explanation. That would send the message home to the inexperienced designer.
@jimsvideos7201
Жыл бұрын
There's a lot going on here; thank you for the insight particularly for working on copper.
@pamdemonia
Жыл бұрын
Happy New Year! And thanks for letting us in on your thinking. Very interesting.
@brianbures4478
Жыл бұрын
Great setup information Peter!!!
@user-wv4ss5fb6g
Жыл бұрын
Waiting inpatiently for the next part!) Thanks!)
@osirismachining6994
6 ай бұрын
Amazing video!
@Mrgeoffrow
Жыл бұрын
Thanks for this video. I’m starting a red copper job next week with some 55xDia holes, I think they’re some kind of radiators.
@Horus9339
Жыл бұрын
I have really missed your content, here is wishing you and your Wife a Happy and Healthy New Year.
@danielgilbert5312
Жыл бұрын
Thanks Peter!
@timo.M420
Жыл бұрын
Very interesting good job
@danielgilbert5312
Жыл бұрын
great video
@philbert006
Жыл бұрын
I don't know anything about machining per se, but I have a good bit of experience with copper. It is definitely a difficult material (and expensive) to work with, whether it be soft or rigid, solid or tubing. As you mentioned, it's soft but very sticky. It has tons of issues with heat, and it work hardens basically instantly, which I'm sure is why it dulls carbide. It gets really surprisingly hard super fast. It can quickly and easily be annealed, but it will surely deform and that's not even remotely practical. Good luck with this. Sounds like the kind of job that warrants a pass.
@EdgePrecision
Жыл бұрын
We have done job before. So it is possible but you are correct it is difficult. But the money is good, no make that very good. So it will be worth it.
@philbert006
Жыл бұрын
@@EdgePrecision well there you have it. You mentioned it was a familiar job so not so much new engineering. If it pays well enough to satisfy you, that's all that really matters. Thanks for sharing.
@TrPrecisionMachining
Жыл бұрын
good video peter
@Xlaxsauce
Жыл бұрын
All that extra effort you put into that steady rest was worth it I think. Be nice to get it case hardened to give it an extra cool look
@EdgePrecision
Жыл бұрын
Or how about QPQ.
@MC_Motors
Жыл бұрын
Where do you buy your soft jaws? Love the vids, thanks!
@sharg0
Жыл бұрын
Not that I have much experience with machining copper but I think two things are key with the tools (for the soft alloys): a sharp edge and a coating suited for copper (to avoid the build up edges mentioned in the video). However I don't think temperature is the problem since copper easily "cold welds" when under pressure (demo: take two clean copper wires at least a mm in diameter, put them across each other on an anvil and hit them with a hammer - they'll easily fuse). If jobs like this gets common it's probably worth having a chat with suppliers of cutting fluid to find one that minimises build up edges with copper.
@EdgePrecision
Жыл бұрын
As I said in the video. I'm not sure what is going on. But when I have milled pure copper this is what happens to the tool. Lets take a un-coated carbide endmill. It literally dulls the tool. There doesn't appear to be any (or very little) buildup of material on the flutes. Now carbide really isn't a solid material. It's what is known as a sintered material. Its made of compressed powder bound together with a binder then sintered at a high temperature to form the material we know as carbide. I think what is going on with copper and a carbide tool is this. The cut shaving flowing over the cutting edge of the tool is, at a molecular level welding to the binding material and dragging the carbide off the tool. This has the effect of eroding the cutting edge. So keeping everything cool and lubricated helps with this. Now a special coolant may indeed help here. But to change 300 gallons of coolant for one job. Not really feasible for me. Now a special coating again may indeed help here. But I looked into that and so far I could not find one specifically advertised for copper. But in any case this would be a very special, and probably very expensive/hard to obtain option. It is a less expensive and faster option to just replace standard easily available tooling as it wears out.
@sharg0
Жыл бұрын
@@EdgePrecision Yeah choosing the "right" cutting fluid is difficult when the materials change a lot. But what sometimes helps is to adjust the concentration - your supplier should be able to advise on that (or it's time to find another supplier in my opinion). Same with coating, your tool supplier should be able to give good information (I'm spoiled with a supplier here in Sweden that even coats special ground cutters if needed).
@brucejenner4800
Жыл бұрын
I'm fairly sure I used paraffin as a coolant for copper?
@FriedrichWinkler
Жыл бұрын
What do you use ansys 2021 r2 for? Is that Sapceclaim?
@chazmakarowski5429
Жыл бұрын
Would you test your feeds and speeds on a piece of scrap copper for end mills and thread mills of this size? I'd hate to break a tool in the finish part is my thinking
@coyzee1
Жыл бұрын
i reckon he used to.
@danielgrebner8412
Жыл бұрын
Form taps. I make thousands of copper parts. M2 and M3. Hardly ever have any issues.
@danielgrebner8412
Жыл бұрын
really like the tap extensions. very clever. i've never made one like that....yet.
@rickybradby1312
Жыл бұрын
Hi Peter, Could you favour roll threading for copper? I find neat cutting oil works better than water based coolants on C101, C109 and C111, but your Mazak is coolant based only I believe? Do you rotate the part to empty the cavities during the cycle?
@EdgePrecision
Жыл бұрын
Yes in my machines I use water soluble oil for coolant. No I am not going to need to rotate the part. These are small pockets and the coolant should have no trouble in flushing out the shavings. Because of the doors on this machine can’t be opened while it is running. It makes it impossible to apply any oil to a tap. So I prefer to mill threads whenever possible. Otherwise I might have tried to use form taps. But if I was to break a tap in one of these parts it would be a costly mistake. So I feel better milling the threads.
@spazzywhitebelt
Жыл бұрын
We've machined a fair amount of C101 and have had good results using carbide tools meant for aluminum. I kinda like machining it right up until you leave coolant on it and it oxidizes a little making ruining the otherwise beautiful color.
@nickjarman2783
Жыл бұрын
When machining a softer material such as copper is a different coolant required or will generic coolants suffice ?
@EdgePrecision
Жыл бұрын
I use the same coolant.
@adthelad1
Жыл бұрын
Did you consider thread milling the tapped holes at 6:14 ? Thanks for the video!
@EdgePrecision
Жыл бұрын
If you are referring to the holes I made the tap extension for. Not really. To do the circle for the 10-32 STI thread it’s like a 1/4-32 thread size. It would be very difficult. It would have to be a custom tool as well. Probably not impossible but for two holes I think tapping is the way to go.
@adthelad1
Жыл бұрын
@@EdgePrecision Thanks for the reply
@floodo1
Жыл бұрын
Yes thanks for the explanation. I was wondering about this.
@BenJohnsonDotNet
Жыл бұрын
I doubt they make STI form taps, but I've always had good luck with 4-40 and 2-56 form taps in copper.
@stuarthardy4626
Жыл бұрын
Peter I have machined copper at a hobby level ( copper boilers for coal fired loco's) I found that HSS tooling worked better that carbide , the best carbide inserts were the high positive polished ones for aluminium , its a bit like the rules are for brass/bronze do not use the cutters/drills if they have been used on steel they will not cut as well if at all sorry if there are typos as my dyslexia is bad today looking forward to see how you approach the acutual cutting
@EdgePrecision
Жыл бұрын
Yes I would agree with you for your cutting conditions. With the slow speeds and manual type cutting strategies with no aggressive flood coolant. In this case the the small diameter tools I need in the pockets. I will need the rigidity of the carbide for their long projections. Except for some drills and maybe some reamers. I don't really use any HSS tooling anymore. I don't think I have but maybe a dozen (probably less) HSS endmills in my tool cabinet anymore.
@SomeGuyInSandy
Жыл бұрын
Hey!
@presicionturning5672
Жыл бұрын
I ennoy your videos. Kinda relaxing to watch. Question, is there a central dispatch type webcite for machinists to bid on jobs? Thanks
@EdgePrecision
Жыл бұрын
I don’t know of anything. I think Titan made some web page where you could post your capabilities and possibly get work. You would have to do some research on his web page. titansofcnc.com/
@bd12660
Жыл бұрын
Xometry is a company that does that.
@richhuntsd12
Жыл бұрын
Hello Peter. I was just curious how many threads deep did You end up tapping the small sti threads? Then If Your like me You don’t sleep well until the Hand tapping is complete!
@EdgePrecision
Жыл бұрын
This kind of depends on the Heli-Ciol insert going into the hole. Heli-Coil has data on this you can get on the web if you do a search. But on this drawing they specify a thread depth.
@brodyhmachining
Жыл бұрын
I see the parts youre putting on this machine often are smaller than the typical work people would put on it. Does this cause significant headaches? Seems like the versatility of this big intergrex basically makes it a do all machine.
@EdgePrecision
Жыл бұрын
Its usually easier to do small parts on a large machine then large parts on a small (really to large for that machine) machine. Especially so on this machine because the milling spindle has a high max speed of 10,000 rpm with 50 Hp but still has plenty of low end torque. The turning spindle only has a 1600 rpm max speed and 60 Hp. But even that is high enough speed to turn most small parts. Yes for the majority of machine parts this type of machine is one of the most versatile machine.
@brodyhmachining
Жыл бұрын
@Edge Precision thanks.
@AidenFXMotionDesign
Жыл бұрын
I have a question. What kind of insert I use for an interuppted cut. For example to rotate jaws?
@EdgePrecision
Жыл бұрын
I use the same inserts I machine with. Of course these jaws were aluminum. But on steel jaws slow down the speed and feed because the interrupted cut. A smaller depth of cut on the roughing passes would also be good.
@floodo1
Жыл бұрын
nice
@TheFool2cool
Жыл бұрын
Do you send the customer these videos? So they can get an appreciation for what happens on the other side?
@EdgePrecision
Жыл бұрын
No I don’t. But there are sometimes people that work at these places that watch my videos.
@derick3482
Жыл бұрын
do you ever use solid mil free form for 2d machining? say contouring or profiling or pocketing ??
@EdgePrecision
Жыл бұрын
The software I pretty much exclusively use is Esprit TNG for the Mazak.
@derick3482
Жыл бұрын
@@EdgePrecision no I know that but for simple 2d machining which 3axis Milling operation do you usually use? solid mill free form ? or variable Z roughing? or do you use solid mill MOLD even if it's not 4 axis or 5 axis?
@EdgePrecision
Жыл бұрын
I use the same software for everything.
@derick3482
Жыл бұрын
@@EdgePrecision the features ? of the software what do you use for milling let's go INSIDE THE ESPRIT
@EdgePrecision
Жыл бұрын
Maybe I’m not understanding what you are asking. The Mazak Integrex does both turning and milling. In fact I use this software (an older version) to program for my horizontal mill. I would use the same version but I need a proper simulation model and post to do that.
@master8laster49
Жыл бұрын
Many years ago when I was an apprentice we made a lot of EDM electrodes in copper, we used "brain killer" fluid for perfect finish in copper. Probably cant get that anymore. 🤔
@glenndwyer5786
7 ай бұрын
I call it abrasive like aluminium
@LastDaySpecialist
Жыл бұрын
Aluminum
@DJKinney
10 ай бұрын
But what IS it? What is "the part?"
@EdgePrecision
10 ай бұрын
I don't really know. I think because of the material and the milling it is used for a heat sink for electrical parts that are mounted on it.
@bcbloc02
Жыл бұрын
It looks pretty straightforward until you look at all the details.
@brianbob7514
Жыл бұрын
That is a strange part.
@chrisyboy666
Жыл бұрын
I’d rather machine Monel k then copper…can lose money very quickly on copper jobs like machine Glue
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