How To Machine A Complex Part 600% Faster Using Trick Techniques
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- čas přidán 25. 06. 2024
- CNC Machining complex 5-axis part using DN Solution's DVF 8000T using the tabbing method. This part supplies power to Millions of people and we made one. Making a part from start to finish, genius fixturing techniques to save on machine time, money, and material all at the same time.
00:00 Intro to Machining a part using tab method
00:22 5-axis machine fixturing technique
00:49 Machining a part hang out of vise
1:56 Roughing Operation on material
3:17 Programming in Mastercam
3:52 Finishing on 5-axis machine
5:56 Tabbing Method in machining
6:40 Machining a custom fixture
8:22 Final operation on Complex part
9:43 Final part reveal
10:56 CNCExpert.com
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#Machining #Machinist #Engineering - Věda a technologie
Actually getting to see a real part, machined in a practical way, is the best type of video you guys can make. Love this
Top level machinists working together. That's good to see.
Yeah usually its knives out
Being able to make snap tabs is definitely a great advantage in 5 axis mills. As for the way you mounted it for op 2, I would definitely have added two locating pins. Even if the pin clamps worked well enough to maintain tolerance. Having that much more control over the parts' exact location is cheap insurance, especially for the last fixturing.
Actually planning to run a part in this fashion in a couple of weeks once all the tooling has arrived. So the fact this video appears while im still mulling over the strategy to get a good result with tabs is a godsent. Keep up the good work titans!
Stick with it - might take you a few goes to get it right but once you dial it in its a game changer. 90% of what we make in our shop now uses this method 👍
@@Mazrim_TaimCan you explain to me briefly what this tabbing method is?
Ps: I don't understand much of what he says, I'm still learning the English language
@willianbr3101 it means you use the stock to your advantage as break off points or tabs so you have minimal work 2nd op work to do. This video explains it much better than I can!
Jessie is the Mr Miyagi of 5 axis machining. Wax on wax off. 💥❤🙏. Much love and gratitude
9:05 These 5D machines never cease to amaze me.
Some slick toolpaths in this one, I’ve been wanting to learn how to program the tabbing method for a while now
This is such perfect timing!! I’m explaining to the owner why we need a 5 axis!!
Nothing new but it is a good method . I have used it for 25 years. Before YT .Keep up the good work titans!👍👍
I use the method all the time. Love your work, and keep it up. 👌
Awesome part. Really liked that fixture.
Beautifull part and process. Also cool to see the deburing in OP2 that was milled in OP1. Show you also trust your own process. Great job and cool looking part
Very cool dude. I like those Mitee-Bite expansion pins, especially large odd size plates with random holes locations, makes it much easier to fixture.
Amazing video Jessie! You really are incredible at what you do!
Been finishing parts 100% (no second position) with tabs since 1996. Tabs only need to be .015-.010 thick, width of tabs in the center .250 to .375. Best to use small End Mill e.g. 1/2 end mill when finishing tabs and the tab side of the part, reducing the torque on the backside of the part. Break tabs and blend with Dotco or Die Grinder.
You can use a Serrated Vise and avoid prep operation for the Dovetail. Machine the part 100% complete in one position.
Also, I have used Slot Cutter (Side Cutting Mill) to establish the Radial/Arc tabs in just 3 passes while finishing the backside of the part. Cut first Side, then 2nd Side leaving a small continuous .015 thick ARC serpentine tab, then come back and mill away the majority the tab's center of the ARC serpentine tab. The deeper you push the depth of the cut the shorter your tabs will be. At this point the remaining tabs will be short little "ARC" tabs that are more rigid than typical linear tabs. Though style works great.
These are the kind of videos we want more of
beautiful machining
That's a very beautiful part and a job well done.
Great machining. I put my hat off ❤
Definitely amazing what you can do on this type of machine.
This is outstanding!
👋👋
I have used tabbing for a few years. I do love it when my part barely hangs off of my 4th axis and I can rip it off.
I love❤ how you film and edit videos in this channel 😊
Pure genius!
Tabs saved my butt so many times I love this method
Amazing work
Genuinely impressive
Nicely done.
Absolutely amazing work! 👍
5D Perfect synchronizacion Never ceases to amaze me 🤯
Greetings to all CNC operators from Poland🇵🇱
Beautiful work
I've found that on harder materials (stainless and Ti) it works well to come in and tab with a 3/16" to about 0.125" thick and then follow up with a 1/8" down to about 0.03" thick depending on that part weight. It tends to prevent the part from bouncing into the endmill and chipping it.
i like how you machine this parts, thanks thats an educational video
Realy nice job❤,well done
Impressive for sure
Thanksgiving Day and I’m not watching the parade…I’m watching this awesomeness.
Very nice!
Very, very, very cool!
That is a thing of beauty
You should make an academy video for programing this one! Thanks for the content this helped me a lot with my project.
This video gets my biscuits burning!
Great video
Ive heard my machine tool teacher talk about these break away tabs so neat to see it applied tool lofe equals extra $$
Just Perfect ;)
Every time the passion goes out you go back to igniting it guys Mr. Barry have to be careful now because Mr .Jessie hits hard today BOOM 💥♥
Nice finish
Tha ks for sharing guys
The goofball at the end with the hands ✋️ 🙌 😳 😂😢😅
Great watching every single episode 👌 👏 👍 😀
Engineering?Fabrication?Machining? “Witchcraft” - that’s what this is.!! Even more impressive is how you manufacture a machine with so many moving parts with the play required to allow those parts to move but then end up with something so precise this stuff makes my head hurt.😁❤️💪🏻
We just made and machined like this 40 years ago...!
Good job!
Questa è arte! Spettacolare
Very good 👍
I saw something when you did the second operation. Instead of making steps with the roughing tool, how about ramping with it instead? Saves alot of air travel which is an efficiency killer. if you approach on the lower end and use the side to ramp up that should be the most efficient way.
I have thought about it quite a bit since one of our shops' programmers regularly makes programs with 60-100% clearing distance(which isnt what i'm talking about here but still something that adds time) and on aluminum with fast feeds it doesnt matter too much but with 60 mm air travel both into and out from the part several times on a steel part with a big mill then it adds time. So if take long cuts instead of alot of air travel then good efficiency. Makes the mill work more like a lathe :D
I love expanding mandrels for fixturing.
Hi friend amazing nice vidio and great machining complex great vidio and good luck
Incredible 🎉
6:16 OH YES THAT SOUND.
When are you making a video about all the pleasing and scifi sound metal can make :D
Tabs are the absolute WAY TO GO. I love your second OP fixture with the collet. I need to start doing that. Great milling method. I just wonder why you wouldn't use HYPERMILL instead of MCAM. Your life would change.
Awesome
This kind of part is my favorite part I would like to do.
Honestly, I'm more excited about the expanding bolts. Those would be great for a lot of fixturing
That’s bad ass!
Very cool
Do you have a general rule on how thick you’ll make tabs on each different material?
great work! do you zero-prob the machine for the second op?
That was an awesome demo Jessie. Do you know what the part is for? Ciao, Marco.
Personally do alot of 1 op vice ops. I prefer to use snap offs on an edge rather than tabs. I create a snap off of 0.275mm that leaves almost no burr on aluminium aerospace parts
Beautiful piece.
Watching the spindle and table move in unison - like dance partners in perfect time. We don't have a 5 Axis CNC machine, but watching that would never grow old either.
I was wondering what the issues were that you had using a larger endmill at the start of the video.
Vibration/ chatter..!?
OMG you are perfect
Everybody is just talking but Jessie is working
haha 11:40 when he's complaining that it's not going to be in spec then feels up the part
Nice, milling
WOW! 🥰
Very cool simultaneous machining but I do feel it was over kill as you can get tools to break edge the part on op 2 with a double angle cutter. Way quicker. But it was a good process
Where can I learn more about the tabbing and picture frame methods?
I have zero desire to learn how to run a CNC mill but dammit if I am not addicted like crack to watching these videos and learning all about it pretty strange Dynamic I guess but it's where I'm at LOL
Класс! Мне бы кое что для вела замутить из В95.
Where do you purchase the expansion pins?
Hmm with which cutter are these dovetails made?
I use tabbing to get two 19ft. long spar caps out of one billet. I leave a .100" tab about every foot or so. Might be able to go a little more thin, but with material that big I don't need shit flying around lol.
MasterCAM
You guys still use MasterCAM yes?
With C having some RPM on the 8000T does MC require you to have both a Mill & a Lathe seat ?
Here’s a tip use minimum 3 tabs on 2 different planes. No part wobble and able to have thinner tabs.
I didn’t realize these things move the table while cutting at the same time and with precision.
What will this part be used for?
Thanks for taking work away from small companies like ours. I thought you guys transitioned into teaching and not taking contract programming away from companies like ours. Well thank you for raising the bar and 5th Axis CG Inc. will keep plugging along getting our work word of mouth like we always have.
Every time anyone does a job they're taking it away from someone else.
@@mikep3813 Yes that is the nature doing any business.
Cool video.
Only thing I can’t for the life of me understand why he clocked the part in on the second op.
Then used to probe to set the zero point anyway.
Why not just set the rotation with the probe ?
Jessie, on the second op how exactly was the part being held down on that fixture? The tab thing was cool.
The pins expand in the holes holding the part
@Dakota Reid ahh, okay that makes sense then. Thanks
Min 7, why didnt you turn the table 90 and use the probe to center the part on milled surface ?
Do you use the rest of the Part for other Parts? or you have to throw it away?
Odd shape so they probably send it out to get recycled/scrapped
Es aluminio?
Seems like you could have left the left-over dovetail piece in the vice and used it for the secondary fixture instead of setting up a new piece of aluminum and indicating etc.
If this was in stainless steel, would making those same tabs be possible, or cause too much vibration?
I do it on stainless and titanium all the time, but I usually will add more tabs that are a little smaller and thinner.
10:10 Always. Making parts with efficient strategy is easy, but the tolerances is the big issue. When the tolerance unable to achieve, change back to traditional strategy again.
Cool. What is it?
Dang, that part has to be $$$$! Nice to know what all the costs are, material and labor, machine time... Yikes! 😳
In my past experience the 6061 aluminum at this spindle speed will tend to melt and stick even to a carbide E.M. under full flood. I would not dare! This to me would be OK in 7075...
How do you prevent surface marring from the end mill chattering against the part when you do the final pass in that last operation and you leave just 50 thou ? I stopped doing this as the last op because of that issue and started using cutting saws to leave a very amount of material that I could tap off
Simply use a smaller endmill and stay away from your finished surface. You'll finish it in the next operation, so don't worry about some more allowance there. Process safety above all.
No one does it like TITANS. I'm jealous
You are the man Jessie! But I don't get one thing - if you have a lot of these to make why won't you make a casting and then just perform finishing operations and make holes? It doesn't feel right to have this much leftover material, i get that it can be made into something alse but still you have to store it. Greetings as always, a pleasure to watch!
Material spec may not allow for casted material. Also casting has longer wait times, where I am the lead time on casting is 3 months from the date ordered to delivery, I can however order solid stock and it be delivery 1-4 days later typically.
@@karl6313 thank you for the response. You are most likely right but what do you think about an aluminium forging then? The due time should be shorter at least
It would again have a lot to do with the customer and what they require. A forging or casting would be very reasonable solutions, assuming the customer/engineer think so. The one customer we work for requires the part to be made from a 304 stainless casting, does not matter to them we can produce the same part out of bar stock faster and cheaper than having it cast, not to mention the lead time just to get the casting is 3 months, but the process would be more efficient to use bar stock simply because it can be bar fees into the machine, so my door would never need to open except to check on tools. The engineer said casting, so it must be casting and no matter how many times we have pleaded to have the drawing changed, it must be casting according to the engineer. We make other pieces almost identical to the casted ones, but those engineers said casting or bar is ok. Sooo sometimes your hands are tied as a machinist, you must follow the print regardless of better methods sometimes.
couldnt this part have been run in one operation if you flipped the tabs on the other side? with some minor hand grinding