Axe from scrap rail

gentlemen's welcome back to the shop retreat that's best y'all today in the voice scabby but is it scabby enough old hardened rail we are gonna make a thing if and you clicked on the thumbnail you very likely already know that it's gonna be an axe head specifically a hatchet head minus the board hole normally when i don't bore the hole i blame the wife but in this case i blame the fellow what did the modeling there is no borehole in there no we're just going to quickly go through some new devilry there is nothing more important in the entire world than going out into the unknown and reporting what you found at the edge of the world in this shop we have never run one of these mills it is a high feed mill ah so skip with me now through the proscenium arch holy oh this thing's a killer machine cost you an arm and a dick but with the high feed mill opposite the strategy of the typical milling tragedy that is the bigger chunk ascend taking a bigger chip slow and low this one whisper cuts fast as through spindle air blast comes out beside the tool evacuates those chips travels 366 inches per minute spin them a thing and 4500 rip ems a depth of cut this is the trick depth of cut of only eighteen thou three four percent of the diameter with a step over of a hundred percent of the diameter speed of the tool on that high alloy hard work hardened rail ridiculous 1200 surface feet per minute i dialed it back because of the poor fixturing right around 750 feet per minute now we got our stonk i was going to face mill that no longer three minutes and the difference there's no point and i was also going to take off extraneous material with the face mill i don't see any point we're gonna use the high feed mill to do it all got the digging of ice bucked off for the five axis twist at the top so we get enough white travel hopefully it's getting late in the day on account of confusion three sucks the mother wouldn't post wouldn't do this wouldn't stock to the mothership i even had to buy you spend some of my auto desk cloud credits you can't make this up and son of a bleaching thing doesn't have enough why travel we're gonna have to cheat that a little bit it's 5.3 inches in the girth and it appears as though we don't have enough here i might end up turning this sidewards but not tonight no fusion for the money can't be beat tough to get good operators so see that there the problem is it's doing a flippy floppy instead of a barrel roll be doing one of these and instead let's do one of these [Music] couldn't figure out how to get the software not to do the flippy flop so i locked up the c-axis at 90 dungarees called a large christian anderson there the handsome danish fella expert not answering my calls anymore and the other fellows they just do live streams you gotta sit through two hours to learn one thing [Music] brainiacs gotta learn how to edit what am i saying here i got a good feeling about this one get close the home time never give up when is it okay to give up it's getting pretty close there two o'clock in the morning i had a dog with a boner i changed the post processor i updated it that's the instructions tells the confuser to give yeah yeah together didn't work i just want a result so i think i'm going to mash the go button all right conveniently every time you redo the post processor it resets everything i'll leave this for another time i think get some shutdown amazing what a few hours of sleep and a double shot of espresso dude this was the fault code generated when running the post so fusion 360 is the software what models everything and then it does tool paths and in order to get that tool path onto this machine there needs to be another little piece of param parametric software what tells it go here go there that is called the post-processor so fusion speaks to the post-processor the post-professor converts that into language that the machine can run on that post processor isn't set up right here is the fault code interestingly and beautifully for debugging is that after you post and it fails it gives you a log of the failure this was the code it was looking for a180 and c0 those are the axes so if we look here at a180 that's uh that's the big chungus one it was trying to go to 180 degrees by the light of the moon we counted ourselves lucky that it didn't post because it would have tried to go straight through the table it's sitting at 90 here to get to 180 it's going to go bango i'm glad it stopped i'm going to show you a little trick here what for subverting software an electro hydraulic electromechanical system you got a component not working what do you do sniffy snip snip you cut it out shunt it jumper it out in a software system we do the same thing the software ain't working the ones and zeros we are going to do what the software won't do that is do the flippy floppy manual so i've broken up the program instead of one program now it's two programs with two different work offsets and i will manually move the work piece [Music] going in there carefully carefuling the confuser needs to know where the work piece is so it can do its dingle dancing in the right spot if and you don't program in this g54 and g55 right off that nothing's gonna work you absolutely well the confuser needs to know where the work piece is yeah we power problem here the lights went out the compressor stopped running so we got a shutter down the machine's running great that high feed mill incredible however the tool paths are not perfectly tweaked so we gotta take some of that material off so it's not to damage our cutter you saw we took uh quite a big cut there a few little spits and sparks and uh pucker puckered up and hit the stop button real quick but first things first we got to get the power back on have i mentioned it never ends got a power issue with the vfd that drives the scroll compressor this machine doesn't run without air at 120 psi in the tank enough to get this thing cleaned up and put to bed but for now we're dead in the water a lot of moving parts a lot of things got to go right and it only takes one thing to go wrong high feed mills though skookumer's frick thanks for watching your decking device but wait there's more i think i got the compressor fingered out nice so i got a vfd 30 horsepower and it's got some big nasty capacitors in there they're essentially a short circuit when you first clock them on the wife was saying she heard this buzzing noise and the lights flickering i was wondering if she had her best friend plugged in but uh apparently outside up on the pole it blew up the isolation of the high voltage transformer and we got that figured out so now compressor is running again i asked her if she thought to get up and look see if anything was a miss city kid apparently that's what i'm for i gotta jam out with my climbo and have some fun finish up that wedgie i think that's her future's bright boys gotta wear shades [Music] [Music] 100. most expensive bands on history right [Music] here yeah that high feed mill dancing around so quick quite sketchy something goes wrong it goes wrong in a hurry i managed to catch this one took a heavy cut over this side tweaked the work piece in the vise and i see there is a problem here's the center of the web should coincide with the center of the accent it doesn't why is that because when i did the work offset g54 i did the center of this web but when i rotate the a-axis the center of the web isn't necessarily the center of the vise and because i'm doing it manually it the confuser doesn't automatically uh account for that so what i got to do is i gotta measure how far off this center line is and then when i go to do the obverse i just put in that offset to make sure that the center lines line up um you really gotta watch it because apparently didn't select the model or it wasn't model aware because it was boring right down facing right down into the center of the universe there so missed on that one and also got some funky happening there a little woopty woos in the tool path but me running partner hi feed mills and throw up we'll have another kick at the cat in a future iteration we're going to change the design a little bit and the reason i'm using the five axis is because we're building up to it i don't need to do it for the prototype of course i'd be far better off just using the vise and then flipping it but i'm doing it not for no reason so thanks for watching keep your deck in advice

Channel: AvE

Views: 300,991

Rating: 4.9347482 out of 5

Keywords: axe, forge, machining, rail, scrap

Id: jpYTjva8m8o

Length: 14min 46sec (886 seconds)

Published: Fri Apr 16 2021