Making a BIG Hydraulic Cylinder Rod & Eye | Part 1

[Music] [Music] hey going guys curtis from cutting edge engineering uh today's job is an ex 1200 bucket cylinder rod and eye so this rods out of a cylinder on an ex1200 atashi excavator this cylinder crowds the bucket in and out so the ex-1200s are commonly found in mining not generally civil works being the size of the machine mining is predominantly their main operation so the customers brought it in with a few minor problems [Music] so as you can see the rod's got a lot of scoring a lot of scratches and a lot of damage to it and so that's pretty serious but the other problem is the eye fell off so this is pretty common getting a rod to our workshop in this sort of state we do get them coming through quite regularly with um you know damaged rods bent rods eyes ripped off the eyes ripped in half a lot of people might think that the weld has failed here that is incorrect the weld is actually intact so from there to there that is the weld joint on the rod and the eye is actually broken about 20 mil away from the weld joint it is common we do find that a lot they generally don't break through through the weld it either breaks the eye off or it breaks the eye in half as you can see by the eye you can see the fatigued areas here so it's actually broken one side completely and the other side started to go then it finally broke off and that's because of a side loading that's been applied to the rod while it's being operated on the machine so being in the industry as long as we have been you do get to know a lot of people we have a metallurgist he's actually a good friend of mine he came in to have to inspect the eye we did some testing on the eye to find out exactly what material it was he determined it would be in our best interest not to use the old eye on a new rod as it was the apparent material that failed it wasn't the welded joint the customers agreed rather than risking a new rod using the old eye we're going to manufacture a new eye and a new rod [Music] so oh [Music] yeah it's a problem that's chipped at all crack right guys so this is probably going to be a two-part video the first thing we're going to start on is we're going to start by machining up the new eye so the eye material we keep in stock for these cylinders is a piece of 200mm 350 grade plate so we get these flame cut from our local supplier we just supply them a pattern or a drawing on what we want and this is what they supply to us so the first thing we've got to do for this we're going to grab a grinder clean up all the edges clean up all the faces we've got a few marks right there from the cutting process we'll tidy all that up they're going to settle up in the lathe we're going to skim both faces to bring it down to a final dimension then we'll throw it in the mill put two center holes in either end then we'll start turning it in the machine with a four jaw [Music] [Music] so so [Music] [Music] [Music] so [Music] so [Music] [Music] [Music] [Music] so [Music] [Music] so [Music] so [Music] right guys so we've faced both sides of the eye now we've got that down to size while it's set up in the machine we're going to put the big boring bar in we're going to bore it to size we're going to take it from a 160 mil flame cut hole out to 174.8 that's our crush on our bearing so we're going to get started on that [Music] uh [Music] [Applause] [Music] [Music] [Music] 196.1 going to be somewhere down there so done so bigger one [Music] so [Music] about to put the grease socket in the end of this eye we're going to have a lot of dramas trying to drill that with say a high speed steel end mill or something to put the recess in so because there's a flame cut edge there it's very very hard and the high speed steel end mills just don't like it so we're going to go in with an indexable end mill first probably a 16 mil indexable end mill and then once we open up a little bit we'll put in a 25mm index blend mill and then we'll open the hole up rather than destroying a high speed steel cutter we'll just use our indexable end mills good so fantastic [Music] [Music] so [Music] back thank you [Music] so [Applause] [Music] [Music] [Music] so some more right guys so we've got the eye set up in the machine now we're spinning it with our four jaw with our centering plug and our heavy duty live center i've welded some blocks on the on the back side of the eye here just to give a little bit more support and pick up those other two two jaws so plenty of support now we're going to get in to start machining the weld prep on this end [Music] [Music] do [Music] foreign [Music] oh [Music] my [Music] so [Music] [Music] [Music] [Music] which so [Music] [Music] [Music] so [Music] so [Music] [Music] foreign so [Music] so just [Music] so so um so so [Music] so uh [Music] [Music] just don't lean it looks really good that's fine that's fun so this rods off and so this rods off an ex-1200 uh [ __ ] this cylinder crowds the bucket in and out so on the machine this cylinder this yeah what i'm going to show you what it's all about i don't know what i'm [ __ ] uh so what was it going with that [ __ ] i don't know i'm not with that so we'll show you what they're about wait what are we doing now do we do that the eye fell off generally [ __ ] [ __ ] oh [ __ ] so we oh [ __ ] we we i'm all [ __ ] up all right guys so the piece of material oh this is hey mate what's happening well that's it nice and simple [ __ ] yep right guys so we've now got it set up set up [ __ ] right guys so we've actually got a [ __ ] righto guys we've got the eye set up in the machine [Laughter] so we gotta just gonna make it look good what are you hiding from ready no really yeah is that recording oh no i don't think so what are you doing what's that mean oh was meant to stay in the office but i didn't

Channel: Cutting Edge Engineering Australia

Views: 1,306,228

Keywords: cutting edge engineering australia, machinist in australia, machininst, abom79, cee australia, machining, Making a BIG hydraulic cylinder rod and eye, hitachi excavator, hitachi ex1200, ex1200, mining excavator, awesome earthmovers, making hydraulic cylinder, cylinder repair, hydraulic cylinder, broken cylinder, broken hydraulic cylinder, hydraulic press, heavy duty machining, metal work, lathe work, heavy duty turning, interrupted cut lathe, workshop asmr, interrupted cuts

Id: MDx40qJd0zE

Length: 36min 37sec (2197 seconds)

Published: Fri Apr 30 2021