The CNC was not Designed for this!

this is a big CNC machine in truth when we cobbled it together I didn't know what we were going to be using it for it defies the first law of CNC building which is to decide what you'll be cutting and then calculate and design your machine around that when you're interrupt cycling and using reclaimed materials this Tile tool is a powerful tool this video is about exploring that power thank you a while ago I sent these big player knives from the thicknesser a way to be sharpened and they came back looking a lot rougher and admittedly they are sharp but they're just so much rougher than they were before so anyway high speed steel this grinding disc the CNC machine oh and one other thing I was given this a magnetic Chuck it doesn't work at the moment it doesn't switch on or off it'd be quite cool to be able to use that somehow in the whole process let's see what we come up with here judging by the other side there was some kind of tapped hole there at some point but it's just full of congealed something you know what that stuff is [Music] now we've got some cleaned up threads on the edge of the magpies let's make some brackets to hold the whole thing a nice angle for planar blade sharpening here's what we've got from that scrap the makers of this thing sure didn't want people going inside as well as the obligatory the world will collapse in if you open it up warnings there is also epoxy covering some of the screw heads and one screw that was just very well seized in once the screws are out there's the magnetic force holding it together but also some very tightly fitting metal bowel pins foreign reason I was expecting more magical Pixies inside that make this work simply a block of magnets spaced out with not very magnetic material and that whole block is shifted side to side to line up or not with Magnetic material in the top and bottom plate it's really super simple if you pretend we understand why magnetism works the reason this Chuck wasn't doing anything was simply that this middle block was seized in place it's designed to kind of sit in a bath of oil rather than sitting on a stiff paste of Rusty sludge after cleaning and flattening down all the mating surfaces verifying it actually works we can put it back together with some liquid gasket type material that you get for car sumps and there's a little oil plug where you can fill the whole thing now all we need to do is flatten the surface I know what you're thinking flowering elbow why aren't you using a surfacing bit to make that flat spot on the end yeah I'm glad you asked let me tell you a story about slate this little would-be house sign is a tester and it gave us confidence that the machine could actually cut slate problem is if the surface is this uneven turns out Engravings look really sucky leaving you to do all kinds of barbaric chiseling and remedial God knows what for the next test the obvious thing to try was flattening the Slate on the machine the way you would a wooden slab or the spoil board and in fact that's the same bit I'm using here it's nothing special a carbide surfacing bit and in fact it was a bit blunt before we started not quite the pushing went past the carbide bits into the backing behind if you don't mind the unintentional carbide regrind and the slight undulations that actually worked quite well considering at least they were proof of concept for something way more intimidating back when we were in fully fledged lockdown here around about the time when our humble leaders were taking a well-deserved party as it turns out like too many other people Sam's dad passed away in hospital where we were forbidden to visit so yeah if you have any idea of the price of a memorial stone you'll probably guess what we're up to here okay oh good lord after explaining what we were up to and selecting this enormously heavy chunk of slate at the Slate yard the guys kindly offered to surface it with their massive Diamond grinder wheel thing and honestly I wasn't going to be doing any more flattening on the CNC machine not of stone anyway and stone is a shade over three inches meaning I had to get creative to get the whole way through luckily with a lot of patience it's soft enough that it's possible after agonizing over fonts for a good while knowing full well they'd look a bit different engraved on a Surface we tested some out on the off Cuts we liked them well enough that halfway through we decided to repurpose them as bookends for a slightly morbid bizarre wedding present for Sam's sister can it be the heaviest thing that's gonna have gone on here almost just the right height I'm a bit nervous aboutging this up while Sam's away oh yes okay okay it's a bit shoddy on the back side compared to the front now so we'll have to give it a good sand down okay put it back gently it's not laying exactly flat so we'll have to narrow make sure it's parallel with the actual spindle well that is way more all over the place than I've hoped we'll just have to zero in each either letter or word foreign having a moment of oh is this really gonna work and I might just try it on some wood just a layer of both first to see what happens okay well as this is supposed to be about the CNC machine not my headstone related anxiety here's something to note the way it clamps in here it's just some opposing wedges used against the concrete side rails I've used this method a few times now on quite big things especially it works well it's interesting because despite the obvious mechanical advantage of having raised up side rails versus tall moving Gantry side plates is that they get in the way and make it harder to access work pieces and that kind of thing and there's a good deal of Truth in that but the raised rails as well as keeping the chips further away can actually be handy for clamping things up now the next new experience of working sleet are as well pleased with how it stands it comes up really nice there was some chip out from where we cut these triangles off and after looking at it some of me both kind of liked it so we ended up making that a sort of feature of the top bevel so yeah hopefully that explains why we were using that inappropriate cutter to make this flat spot for the mag Chuck now before we attempt to grind it in because I don't want to annihilate the CNC machine with horrible grinding dust we need to go on one of those highly rewarding but slightly inconvenient side quests to make some kind of dust shield that's big enough to fit the grinding wheel in [Music] [Music] another one down just as a quick tip if you're lacking material then check out your local Art School skips the dross and flutes them of creativity turns out to be quite rich in raw materials the idea of reusing old crap like this is wonderful the implementation sometimes is just a bit hateful foreign [Music] [Applause] [Music] we might be on a complete bungling Fool's errand but we're going to take this rectangular section and try and taper it down to a circular section I've wasted an obscene amount of time already on Fusion 360 learning how to model that without getting into the weeds too much this is the part with the piece we've already made if we look at just the transition it's designed to be a sheet metal part as far as Fusion 360 is concerned it has a seam so it makes sense as a sheet metal part and if we unfold it and look at the flat pattern there's a problem here that you can see when you go to the side and I just couldn't get it to fold flat I don't know why and I never got to the bottom of it sometimes you just got to live with these Mysteries I think it'd be really cool to see through it so we're gonna try and cut it out of the same material considering how difficult it was to bend this to shape we'll see how it goes these will be the folding guides I think I'll need to have even a remote hope of making this work these single flute bits are turning out to be quite fragile they were very cheap for a pack of 10 but this one broke and I've no idea how I was not even in the machine [Music] okay there is our transition piece oh it's cool boy error ah [Applause] foreign [Music] well it's not exactly how I envisaged it but I think this is as good as it's going to get so I'll put some super glue on see if we can't hold it in this position here we're using thick viscosity let's try out the dust shoe by the time it was ready and some other hijacking jobs were done it was time to re-level this patch of MDF spoil board before we could grind in the mag rice anyway still it gives me a chance to see the swirly suckupy magic in action and it looks quite promising in terms of the Dust extraction [Music] height [Music] now the mag chucks in place but unfortunately the dowel pins are sticking up proud of the surface now so before we can put anything on it although it's still very flat we just need to clean up the surface or grind it in as they say this really should be quite a test for the spindle not only are we going at only 3500 RPM which is crazy slow for a 24 000 RPM spindle it's going to maintain that for roughly about 45 minutes according to the Machining time let's see how warm it gets or whether it can manage at all see that there that's what they're aiming for okay I Think We're Off to the Races what becomes immediately evident is the slight tram of the spindle which sends the sparks in a particular direction the dust shoes connected to the shop vac via a cyclone and it is pretty cool to be able to see into the dust shoe to see that sucking up in action unfortunately because the dusty is hanging off the side of the mag Vice the vacuum forces on the grinding dust are just way reduced in an attempt to capture more of that you can see I've rigged up a bit of MDF here just at the same level foreign dowel pins I thought this was actually working not too bad started getting to the main body of the material [Music] things went downhill from there I tried various different things using little bits of coolant on the thing different feeds and speeds including slightly naughty ones that were overeating the grinding wheel the more things I tried and the more I continued the more hesitant I got the more spots I saw flying out uncaptured the more grew that sinking feeling that I was making a terrible mistake the poor spindle grinding to a halt and moaning incomplete each time it hit a high spot it was not a reassuring experience so how did all that go it went absolutely awfully that's how it went surface grinding on that edge of a grinding disc just doesn't make sense too much of it is contacting the work piece and I really struggled with it heating up more on that later because of the very slight tram on the spindle the Sparks were going in a different direction so Sparks and abrasive dust went flying all over the place just like a Catherine's Wheel too much of this is in contact with the Chuck at once versus if it was spinning that way it heated up lifted higher and so then tried to grind more heavy the spindle is completely not designed for this stayed nice and cool and I was piddling around with this for a good few hours so I'm actually quite impressed with the spindle and also my own food hardiness trying to get it to do something so silly this thing should be used with flood coolant it can go dry but I was warned it would be much better with blood cool and that would have improved this whole thing no end and it might have even worked flood coolant on an MDF spoil board doesn't go very well I think we might have got through all the reasons why this was a complete false errand I thought that was going to be quite nice turns out those are magnetic field lines don't seem to extend towards the edge so this is hardly held on a tall at the top and I can't have it down here for obvious reasons the grinding will snag you can't have it that way around unless it extends over so yep okay so we need to abandon this method let's carry on with the four Hardy optimism I've got full speed steel here that I'm going to try cutting a v-groove in so that we can sharpen the planar blades you'll see how that might may not work I don't know what type of Steel it is other than Rusty and mainly I just want to try out the CNC machine cutting some steel again let's see how we go I must admit I'm quite excited this is going to be the second time cutting steel hopefully it's clamped down firmly enough I've been through chip Lube calculations and blah blah that might all just go out the window when we start cutting we'll find out we're gonna use this again just to try and keep the chips from spraying an upwards trajectory which sends them a long way you can see the helical entry there is quite dramatic this is an eight millimeter carbide bit after that is settling into a tracoidal or adaptive Tool Part which I think is probably the way to go and steal to remove a good bit of material at least on machines where you're slightly unsure of their steel cutting prowess it's a sort of roughing out strategy and it can then be finished off with a straight path like this [Music] okay how did that go let's have a look let's have a look I think the bluish purple issue means they got very hot but then I think the fireworks were quite a good indication of that anyway finishes perfectly reasonable a bit better than whatever it was that did that Machining anyway so we've just changed bits we're going to need to do some modification to get this to go up a little bit further or it's gonna snag this is going at 12 000 RPM and only one millimeter depth of cut this time so hopefully it shouldn't be over stressed only 400 millimeters a minute so this is going to take a while of course if I was doing this again now I would be using the mql system you saw me set up in part one of this video the cheap Amazon ones there it's just so awkward I'm not using it okay here we go we've got those chips bottoms perfectly reasonable it was very smooth that edge is ready for the chunk for yeah I'd say that needs to be a bit more sleek [Music] foreign [Music] [Music] [Applause] [Music] either welded in there or the mag Chucks holding them in it wasn't a great way of cutting it was re-cutting through these I think the mag Chuck was holding them down so there's that stupid strategy there's the chips do you seem kind of welded together okay hmm what a blundering kerfuffle the very root of the regroove just got way too hot and it kind of looks like a weld seam or something more importantly the whole Chuck has shifted so almost a millimeter I might explain why the very end here is just incredibly uh rough and the rest of it's really quite a nice finish surprisingly nice considering all those Sparks so now it's a question of realigning it perfectly we're gonna have to make the whole feature a little bit bigger and I'll also make a relief cut with like a four mil anime or something just in the root of that v-groove and hopefully that'll solved the problem what I've discovered is that the bottom edge here which I just assumed would be parallel with this fence and they're completely not out by about a millimeter in fact so when I placed my bit of Steel on here it was actually a millimeter off Square so I guess what I'm gonna try and do is just machine this piece and see if I can't get that straight the problem is this is clearly going to be some kind of hardened bit of Monster metal instead of squaring up the fence I decided I might as well square up the side of the Chuck that it actually mounts to then now be parallel to the base just below it [Music] could have finishes I've ever got on steel you can see there's something coming out of the screw holes the bit of Grease or something in there that's put a streak line across the whole thing but it is very smooth I can't really get much from my fingernail we should be able to see how accurate this piece is that was rather good but then we found the edge of the steel was a little bit wonky so it wasn't sitting against the fence nicely so let's clean that up [Music] right now we have that clean tight and bright in places let's clamp it down and begin our shameful remedial work [Music] it doesn't help with rigidity and hardcore Milling but one of the cool things about having this big eight by four bed is you can leave things set up and get on with actually useful jobs on other parts of it with that v-groove finally done and satisfyingly accurate I may say it's time to try drilling some thick Steel this is a carbide stubby drill bit I forget the exact pack settings but they're almost certainly not Optimum t-slot block we're using to clamp it vertical very nearly gets clashed into with the Colette nut with the holes done we're off to the mini Mill to do the tapping that's something even I'm not crazy enough to try on the high-speed CNC spindle and then almost unbelievably we're ready to try the original goal of sharpening some planer blades it would have been nicer to have bolts that press down exactly perpendicular to the blade but that was going to be hard to arrange 4.2 that side so we've got 3.6 in the middle we've got three point five [Music] everything was good because of how this was ground in the past that side's about a millimeter higher than that side which is a huge amount to grind off I'm tempted to try [Music] well for a first go Milling high speed steel it was all very exciting and kind of went okay I think it's left a little bird there I wonder in fact if just getting that Burr off it would even constitute a sharper blade than it was just from this Milling there's one bit over here where I didn't catch that divot [Music] yes I realized I should have got a smaller diameter grinding wheel by now but mercifully this is actually working quite well here comes the closest we came to stalling with a nice surface where we ground hopefully you can see that but the mother of all bears on the backside that I thought I might be able to leather strop off but not happening at all with it simply flat on the mag Chuck removing a small Burr like this actually works quite well it's as good as it's going to get right then I think what we've learned is if you want your planar blades sharper and straighter than they need to be then build yourself a giant CNC machine an overcomplicated mag Chuck jig holding Contraption use that with a poorly matched grinding wheel and a dust extraction that doesn't work and there you go

Channel: FloweringElbow

Views: 185,047

Keywords: cnc, woodworking, cnc router, Flowering Elbow, cnc fails, cnc machine, DIY CNC, DIY, How to, Learning CNC, Building CNC, Magnetic chuck, how a magnetic vice works, Grinding, CNC CNC grinding, cnc surface grinder, surface grinder, cnc mill, millin steel, planer knife sharpening, how to sharpen planer knives, cnc machining

Id: O4sJTCd2mig

Length: 28min 57sec (1737 seconds)

Published: Wed Dec 14 2022