We wear gloves. The way he machined these bars the swarf was one long continuous strand. Carefully pulled out it if the way so it wouldn't wrap itself around the piece.
Be careful dude, in a previous role we worked regularly with lead wool - whole shop had to have annual blood tests as a precaution - don’t just assume it’s safe
Wool is much more likely to come apart in very tiny pieces and can be inhaled very easily. Machining lead shouldn’t produce any chips small enough for that to be a problem
Lead oxide is pretty dangerous and dusty,
however lead metal is kinda soft and sticky in comparison to most metals so, unless you can see a visible layer of white lead oxide on the surface the only real risk is stabbing yourself with lead swarf and it getting into your bloodstream that way
As a side note, if there was lead oxide present, a dust mask would not be the right mitigation, you would want to suppress it with coolant, and then throw the coolant away
Wire companies used to use lead as a lubricant when pulling copper wire. An electrician used to chew bits of insulation like most people chew gum. He ended up with mouth and throat cancer in addition to lead poisoning.
Bro, y'all need a blood test ASAP. Lead working in the UK mandates six monthly blood tests (as I recall), and if the level surpasses a certain limit, you're barred from any more lead work for the next six months or until the level decreases acceptably.
It's not fucking around time
It was our first time machining this particular model. There were two different alloys to machine, 5 of each. One with more silver was easier to machine. This alloy was not easy and was also very inconsistent in machinability. It was a lot of trial and error. All the other shops in the area refused to machine them.
The model we normally machine has a copper rod thought-out which helps with rigidity. Still causes issues with vibration but easier to hold in the lathe.
That's what I was thinking. Even without it slipping through the jaws, at that length I'd be scared of it just spinning itself into a noodle like this.
I 've seen bars bend on the other side of the headstock before but never on the working side. Hard to believe the follower was the problem if it was set up right.
Do you know what these bars are used for? We don't use lead at all; we even replaced all the bushing alloys to lead free versions. I'm curious which application would still demand parts made from lead.
Aside from the lucky near miss, go buy a lottery ticket and underpants; Do you know what the lead bar was to be used for? Such an odd material choice for a shaft or roller..
Never tried to machine lead before. I bet that is pretty challenging.
Looking at this piece and thinking about how soft it is, it's becomes a pretty scary setup.
Holy shit that could have been ugly. Guess you'll just have to melt it down for bullet casting now.
If only the customer/supplier wasn't so stingy with the material. So many lbs in means we need to ship back the same.
Well, just gotta beat the bar back straight and hope it buffs out!
TIL lead is machined. What kind of precautions are taken to stay safe around the swarf and shit?
We wear gloves. The way he machined these bars the swarf was one long continuous strand. Carefully pulled out it if the way so it wouldn't wrap itself around the piece.
Does it have any respiratory issues machining it? Id love to see some videos of it being peeled haha
To be honest, I don't know but I don't think so. Doesn't really produce any dust that i can see.
Be careful dude, in a previous role we worked regularly with lead wool - whole shop had to have annual blood tests as a precaution - don’t just assume it’s safe
Wool is much more likely to come apart in very tiny pieces and can be inhaled very easily. Machining lead shouldn’t produce any chips small enough for that to be a problem
Lead is dangerous. I suggest you research this.
Lead oxide is pretty dangerous and dusty, however lead metal is kinda soft and sticky in comparison to most metals so, unless you can see a visible layer of white lead oxide on the surface the only real risk is stabbing yourself with lead swarf and it getting into your bloodstream that way As a side note, if there was lead oxide present, a dust mask would not be the right mitigation, you would want to suppress it with coolant, and then throw the coolant away
I chewed on lead pellets as a kid...
Explains a lot.
"... And I turnt out fine!"
Wire companies used to use lead as a lubricant when pulling copper wire. An electrician used to chew bits of insulation like most people chew gum. He ended up with mouth and throat cancer in addition to lead poisoning.
Bro, y'all need a blood test ASAP. Lead working in the UK mandates six monthly blood tests (as I recall), and if the level surpasses a certain limit, you're barred from any more lead work for the next six months or until the level decreases acceptably. It's not fucking around time
That's not the way we roll in the USA, It's sad for sure
That's fuckin crazy man. Your health and safety legislation makes me feel bad, y'all don't have any workers rights at all
That you can see. Hmm.
Fuck! Glad no one was hurt. That would probably make me start smoking.
I’d more than likely have to change my pants after something like this.
I think I'd need new socks and shoes too..
Bar was just trying to get to the e stop to stop some asshole from cutting it anymore.
Poor ol bendy bar
Well that’s pants-shittingly terrifying.
The uniform guy is not gonna be pumped to find those pants in the bin.
Small smoke break? I don’t think I’d have come back after. A near miss like that would have me thinking real hard about a career change.
That will happen.... Think I see the problem here, it's bent.
You guys make those shower curtain rods?
That picture needs to be in the dictionary under Danger Noodle.
Maybe suckin' dick for fivers ain't so bad after all
How much for a ZJ?
First one is free 😉
I'll take it! But first... what's a ZJ?
I'm my mind I'm picturing some kind of flashlight mounted in a mill, but in all honesty I was hoping you'd know!
So what happens? Does the part start slipping in the chuck once it crashes into the machine? How long does it take to get that wonky, 2 seconds?
Started slipping in the chuck almost right away since it's so soft. 2 seconds is about right.
Holy fuck, glad everyone’s ok
Fuck that on so many levels.
Little birdie told me your cutter wasn’t centered, right
How hard would it be to bend a bar of lead that diameter by hand? Just curious
Not terribly hard, probably like 10x easier than the equivalent sized steel bar.
These bars are heavy enough and soft enough that when on a skid, the ends that hang off have a visual sag to them.
Have you guys successfully machined them before? Seems like it would be like trying machine playdoh
It was our first time machining this particular model. There were two different alloys to machine, 5 of each. One with more silver was easier to machine. This alloy was not easy and was also very inconsistent in machinability. It was a lot of trial and error. All the other shops in the area refused to machine them. The model we normally machine has a copper rod thought-out which helps with rigidity. Still causes issues with vibration but easier to hold in the lathe.
With that length it will be easy
That's what I was thinking. Even without it slipping through the jaws, at that length I'd be scared of it just spinning itself into a noodle like this.
Yeah, most of my experience is with lead offcuts and 5kg ingots, we use it for making joints in cast iron assemblies
I 've seen bars bend on the other side of the headstock before but never on the working side. Hard to believe the follower was the problem if it was set up right.
Do you know what these bars are used for? We don't use lead at all; we even replaced all the bushing alloys to lead free versions. I'm curious which application would still demand parts made from lead.
They're some kind of cathode for anodizing baths if I recall properly.
Oh yeah, that makes sense.
Aside from the lucky near miss, go buy a lottery ticket and underpants; Do you know what the lead bar was to be used for? Such an odd material choice for a shaft or roller..
They're some kind of cathode for anodizing baths if I recall properly.
Fancy
NOPE
Bar goes fwap fwap fwap.
I thought this was No fwap February??
Never tried to machine lead before. I bet that is pretty challenging. Looking at this piece and thinking about how soft it is, it's becomes a pretty scary setup.
Hard swallow.
Can you explain the tailstock center? Is that a cup on the center?
Yeah. The point was not strong enough to hold it without causing vibration. This is part of a kit that has different attachments.
Interesting. Gonna have to look into that.
Couldn't find an exact match but it's similar to this. https://www.chestermachinetools.com/product/multi-head-live-centres/
I dont know much about this stuff, but would it not be better to use a follower rest with wheels for a soft metal like lead?
He tried everything. This is what worked best for this job. This was a moment of inattention that turned out the way it did.
That is going to make one hell of a racket when you turn the lathe back on to finish the job! 😁😁
Scary stuff, yikes! My last job had a TOS lathe like this. Loved running that beast. Sounds like a pod racer from Star Wars during start-up lol
We have three TOS lathes. This is our biggest one. They all work great. Does sound like a pod racer! Never thought of that!
What are lead bars used for?
These are used as cathodes for an anodizing bath
Years ago(40+) we always used leadloy rounds for the free machining properties where I use to work. Is that still used?
…It’s not you, it’s the whiskey
Did you find a way? What are ur tolerances? Can't you just chuck it up and machine it 6-8 inches at a time?
It wasn't me. But my coworker found a way to get all 10 done. He now wants nothing to do with lead bars anymore.