Making a New Cylinder Piston | Satisfying Machining

How you going guys Kurtis from Cutting Edge Engineering today's job we have two 651 Apron cylinder pistons to be remade so what the apron cylinder does is it closes the apron door on the front of the scraper while the machine is taking a cut the apron door is open it fills the bowl up with dirt the apron door is then closed so they can carry it on to another part of the job site when they get to where they want to go they lift the apron door push the ejector door out and it spills the material out the front of the bowl the apron doors do cop a hell of a flogging because they are trying to pick up big rocks and can't really see what's happening in front of the bowl so if there is a big rock there you're trying to close the apron door on it and it shock loads the cylinder there are two main failures with apron cylinders and they either rip the rod in half or they start to stretch out the rod what actually happened to these pistons is known as metal fatigue over time material starts to move and stretch what started this failure would've been the tapers in the piston becoming loose because the rod has begun to stretch once the threaded end of the rod starts to stretch that allows the piston to move down that taper just a little bit and then everything starts to move around so the piston starts to kick sideways as it's cycling then there's interference between the taper and the piston it starts to create metal fragments the metal falls down in beside the piston and the barrel and then you have the three main components to a cylinder that are then destroyed so we do have the two barrels here that need to be re-barrelled the insides of them are totally destroyed and we do have the rods here in order to be reclaimed as well so the other way this failure can happen is if the nut on the bottom of the rod that holds the piston on is not done up to the correct torque if it's over torqued you can pre-tension everything and things will start to fail early or if it's not done up tight enough this failure can occur so this piston was damaged far worse than the other one they actually had to bash it off with a hammer off the end of the rod because it had created so much metal they just couldn't remove it and this piston here it is probably borderline repairable you could go through the effort to clean it up machine down the od use silicon bronze or some other sort of filler material machine it back to size and it would probably run again but the customer doesn't want to do that because we are building two brand new barrels and two brand new rods they don't want to put a part that's already been through the process of being repaired back into a brand new cylinder so let's get start on making our two new pistons and the material we're going to be using to make our new pistons it is a 1045 grade it is 240mm in diameter and it is 110 mil thick righto guys so we're just doing our final measurement on the length of our piston because I can't get my calliper in behind the piston because the chuck is in the way I know this machine very very well and I know from the face of my chuck to the bottom face of that jaw is 9 millimetres so what you can do with your standard callipers is you can put your fixed jaw up against the face of the chuck and then your sliding jaw you can bring it up to the job so we have 111 point 3 mil we minus the 9 mil off that and that will give us the size we are currently at then we can adjust our tool and make the final cut righto guys so i've finished all the turning on the ID for this piston so what I need to do now I need to get the second piston up to this stage then we can change the setup and we can do all the turning on the OD righto guys so we have machined our two grooves for our pressure seals what I need to do now is machine the groove for the wear band the wear band is a super critical measurement because the wear band material is so hard it has no give which means it does not compress at all if that groove is slightly oversize and I mean a couple of thou you pretty much won't be able to reassemble that cylinder and if you do get it assembled it is going to have a lot of trouble trying to cycle super important we get that measurement spot on righto guys our two pistons are now complete but because I still need to make two new apron barrels and two new rods I've sprayed these down with a rest preventative and have wrapped them up and we're going to put them to the side until I get those other parts completed but that's the pistons done so thanks for watching my hat on straight yup yep righto guys so we're up to the last step on the first oh are we t first piston right so the wear band material is a very hard ma ugh [ __ ] hang on righto guys so our two pistons are now complete umm oh [ __ ] where are we going with that wait where am I starting from righto guys so our two piston [compressor air] ugh [ __ ] up man hmmm yeh you're going good right ugh oh yeh ah [ __ ] oh [ __ ] hang on you ready [Laughter] that was good and the material we're going to be using to make our new pistons it is a 1045 grade it is 240 mil in diameter and it is 110 mil thick very good amazing your hats not straight [ __ ] [giggles] we're going to put these to the side so I can now continue on with the rest of the rebuild thanks for watching what mmm [giggle] bars too big that's what she said [ding] just chipped it argggh yah [snuffles] ah ah sit [chomp chomp] oh my god all gone so this is the result of those two pistons and one other small job after every job we sort of empty the machine throw it in the bin so now we can mess it up for a new one

Channel: Cutting Edge Engineering Australia

Views: 529,841

Keywords: cutting edge engineering australia, machinist in australia, machininst, abom79, cee australia, Satisfying machining asmr, satisfying machining, most satisfying machining, precision machining, hypnotic machining, machining asmr, workshop asmr, satisfying lathe work, satisfying manufacturing, cylinder piston, making a hydraulic cylinder piston, making a cylinder piston, caterpillar scraper, 651 scraper, making a new cylinder piston, cylinder repair, hydraulic cylinder fail

Id: 4aw-6Zn-q64

Length: 33min 57sec (2037 seconds)

Published: Fri Sep 16 2022