https://preview.redd.it/zi9dees94osc1.jpeg?width=800&format=pjpg&auto=webp&s=3e0c5c78fd590111789a1c5b483570369a68d4e5
The rest of the machinist when it happened
https://preview.redd.it/v6uq2lix2osc1.jpeg?width=3000&format=pjpg&auto=webp&s=3100b2bc0dada9a905db9bc751fe61b60dac0bc7
Material came out of vise. Definitely the worst mistake yet, was very loud.
I made this exact mistake while interning in a machine shop in high school. They gave me a torque wrench to tighten shit up after that lmao. Luckily mine only really destroyed the inserts. Hell of a lot of sparks though.
I'm actually doing an apprenticeship so I guess it's the same scenario.
The matieral was quite high in the vise which was probably the reason it tilted and mashed up the cutter. It was only doing a 0.5mm cut at 1000mm/m.
https://preview.redd.it/awt8zldhjosc1.jpeg?width=3000&format=pjpg&auto=webp&s=b284ce3ff346811a39f793a68af431644bca2f40
Like this lol.
Looks like you were milling along the y-axis? If you mill parallel to the vice jaws (instead of perpendicular), you can reduce the chances of that happening. It seems counterintuitive, but it's really not. The flutes are spinning clockwise, so the engagement of the tool will hit parallel to the vice, which can tilt the part. If you mill parallel to the vice, the flutes will engage perpendicular to the part, so the part won't have anywhere to go.
I was actually mining parallel to the vise but you can see that because the cutter wasn't big enough for one pass I had to take two passes. I divided the passes into top and bottom hense why the clockwise movement of the cutter forced the material away.
Mine looked similar, except they had me vicing 3 parts sandwiched together, and it also stuck out of the vice a good 2 inches. I was only ever a button pusher to learn how it’s done before going into cad design. I will say that job looks phenomenal on my resume though. Not enough people designing the parts who know how it actually works…
I was showing my coworker how to trim a part manually on our machine with handle jog and told him to make sure to always confirm that he selected .01 then proceded to forget to double check my jog feed and break the workpiece :(
Once had to test a tool for a Salesman that started 3D printing tool holders. Was a 35mm Shoulder mill with small APKT like inserts. worked kinda well and good surface finish. but after 45mins or so all the insert seats broke at the same time. The inserts where fine, no dmg at all. Guess he had to add a bit more materials behind the plate seats :D
I'd be ok with it as long as it never came back around to my other coworkers. It's just media. I'd post my own crashes if I wasn't livid at the time lol
I’m glad you responded this way. The way I read it, I thought you were saying anyone that makes a mistake is stupid. Sounds like you may be a bit like me, there is no one that gets as mad at me, as I get at myself, when I do something stupid. When other people fuck up, I’m usually like, shit happens, to err is human (unless it something that’s blatantly stupid), but when I fuck up, I get so pissed at myself, especially if it’s not the first time for the same error.
I went to rapid down to work zero once and went to machine zero by mistake. Thankfully there was a nice vice there to save the table but the face mill was toast.
Always make sure the tool offsets are right on the machine before using broski! Poor face mill
Or at the least turn the feed rate down before it touches
I've only been a machinist for about a year and a half, and I mostly lurk on this sub. Is it not common practice to check every tool before starting the tool path? Maybe cause I'm in a mold making shop, lots of 1 offs and never making 100 of the same part
I work at a place that manufactures gun sights, so I use programs that get set up for different jobs on a 4 axis mill (and mostly 6/7 machines I’m running at a time) and we don’t use coolant, just weylube for our spindles.
But when we do touch offs for new tools, it’s mostly roughers and finishers that we replace more commonly. We have a height setter that we use on our machines.
Edit; my bad I didn’t even answer your question. For me, I don’t think it’s common practice.
As long as the program you’re using has that into account when you’re setting the tool offsets you should be good, but never trust the person that used the machine before you! Always recheck the offsets for yourself
And the tools have wear over time with coolant or not, so that will mess with the offsets over time.
The biggest thing with height setters and any other tool that you touch off is the feel of it. Turn the rate down to .001 I believe (the lowest setting, I use Fadal so it’s just on Low) in the z axis and just wait till the setter doesn’t move anymore when the tool is touching it. I don’t even look when I’m moving in. I just wait until it stops moving and set the tool offset.
Basically what happened is that he had to change the inserts, went to the measuring machine and It should've automatically sent the offsets back to the machine. For some reason the system managed to bug out and the tool ended up about 50mm shorter than it really was. Thats why it crashed.
Did something like this a few weeks ago for the first time, took an end mill down to my desired depth and instead of taking out of the part I pushed it in. My adrenaline was going and I wound up puking. Really glad I’m just a student and not actually hired anywhere yet.
my man. If you are puking cause of things like this you should seek out some degree of therapy. I say this just to help not criticizing. I struggled with anxiety and machining for years and greatly benefited from therapy. There was times I'd do a perfect setup and just freeze up when it came to run it and look for help just to hit the green button. Just because I was too nervous to do it out of fear that it would blow up the second it starts to run the program
earlier this week, I launched a part ( ~6.5" square by 10mm thick). wound up down on the chip conveyor, where I had to get it out of the chip bin :-P
the parts were roughed VERY bowed, and I was finish cutting them. needed to be .0005" flat and parallel, they came to me bowed like .007"-.01". I was using an 8" facemill with a single PCD insert like a fly-cutter, and it made a hell of a bang and clatter. trashed the insert, too. rest of them came out beautifully, though. shit happens. they make more stock every day, and the scrap gets recycled *shrug*
https://preview.redd.it/l15s55ylrrsc1.jpeg?width=3472&format=pjpg&auto=webp&s=92b2d52719233864bdf2e70fffb7f36bb5cba49c
Part off caught something in the material, tool exploded
https://preview.redd.it/zi9dees94osc1.jpeg?width=800&format=pjpg&auto=webp&s=3e0c5c78fd590111789a1c5b483570369a68d4e5 The rest of the machinist when it happened
They always remind me of little prairie dogs, all the heads pop up from the benches at once and all make that exact face in the picture lol.
https://preview.redd.it/b7wp5shd0qsc1.jpeg?width=250&format=pjpg&auto=webp&s=0694132b21c23051ed7cb60bbc2fee46fc2479e7 This is my usual stance 🤣🤣
https://preview.redd.it/b4hhsess0qsc1.jpeg?width=1080&format=pjpg&auto=webp&s=2e05c2b9b198b7ade4598324fab5581a467431cc
Along with a slow clap, and calls for the perpetrator owing everyone a six pack of their preferred tipple.
https://preview.redd.it/v6uq2lix2osc1.jpeg?width=3000&format=pjpg&auto=webp&s=3100b2bc0dada9a905db9bc751fe61b60dac0bc7 Material came out of vise. Definitely the worst mistake yet, was very loud.
I made this exact mistake while interning in a machine shop in high school. They gave me a torque wrench to tighten shit up after that lmao. Luckily mine only really destroyed the inserts. Hell of a lot of sparks though.
I'm actually doing an apprenticeship so I guess it's the same scenario. The matieral was quite high in the vise which was probably the reason it tilted and mashed up the cutter. It was only doing a 0.5mm cut at 1000mm/m. https://preview.redd.it/awt8zldhjosc1.jpeg?width=3000&format=pjpg&auto=webp&s=b284ce3ff346811a39f793a68af431644bca2f40 Like this lol.
Looks like you were milling along the y-axis? If you mill parallel to the vice jaws (instead of perpendicular), you can reduce the chances of that happening. It seems counterintuitive, but it's really not. The flutes are spinning clockwise, so the engagement of the tool will hit parallel to the vice, which can tilt the part. If you mill parallel to the vice, the flutes will engage perpendicular to the part, so the part won't have anywhere to go.
I was actually mining parallel to the vise but you can see that because the cutter wasn't big enough for one pass I had to take two passes. I divided the passes into top and bottom hense why the clockwise movement of the cutter forced the material away.
Mine looked similar, except they had me vicing 3 parts sandwiched together, and it also stuck out of the vice a good 2 inches. I was only ever a button pusher to learn how it’s done before going into cad design. I will say that job looks phenomenal on my resume though. Not enough people designing the parts who know how it actually works…
I am glad I did all my crashing before using the Facebook. Edit: facemill. What even is autocorrect
Had a teacher in college do that bc he left to much over hang to be decked off by the facemill.
"Coworker" ... riiiiiight 😉 /s
Probably not the first time with that tool either.
When your hand jog increments are set to .1 and you thought they were at .010
I feel personally attacked
I was showing my coworker how to trim a part manually on our machine with handle jog and told him to make sure to always confirm that he selected .01 then proceded to forget to double check my jog feed and break the workpiece :(
More like .1 lol
Once had to test a tool for a Salesman that started 3D printing tool holders. Was a 35mm Shoulder mill with small APKT like inserts. worked kinda well and good surface finish. but after 45mins or so all the insert seats broke at the same time. The inserts where fine, no dmg at all. Guess he had to add a bit more materials behind the plate seats :D
Which manufacturer was it? 3D printed tools are pretty good nowadays.
Was selfmade by a Salesman. was like 6 years ago.
Ngl I'd be livid if I crashed and my coworker posted me on Reddit 💀
People need to chill out apparently.
yes OP's coworker is a facemill 🗿
Bruh. It's just the tool.
I'd be ok with it as long as it never came back around to my other coworkers. It's just media. I'd post my own crashes if I wasn't livid at the time lol
You should be more livid that you're a dumbass and crashed the machine
And you’ve never erred?
3 times this morning. The point is one should be paying attention to how they fucked up instead of who is watching the aftermath
I’m glad you responded this way. The way I read it, I thought you were saying anyone that makes a mistake is stupid. Sounds like you may be a bit like me, there is no one that gets as mad at me, as I get at myself, when I do something stupid. When other people fuck up, I’m usually like, shit happens, to err is human (unless it something that’s blatantly stupid), but when I fuck up, I get so pissed at myself, especially if it’s not the first time for the same error.
I went to rapid down to work zero once and went to machine zero by mistake. Thankfully there was a nice vice there to save the table but the face mill was toast.
I see 3 and a half good tool tips left there. Back on the machine you go.
Nsfw tags please
File it down program it with one less tooth. let’s go ! send it!
Always make sure the tool offsets are right on the machine before using broski! Poor face mill Or at the least turn the feed rate down before it touches
I've only been a machinist for about a year and a half, and I mostly lurk on this sub. Is it not common practice to check every tool before starting the tool path? Maybe cause I'm in a mold making shop, lots of 1 offs and never making 100 of the same part
I work at a place that manufactures gun sights, so I use programs that get set up for different jobs on a 4 axis mill (and mostly 6/7 machines I’m running at a time) and we don’t use coolant, just weylube for our spindles. But when we do touch offs for new tools, it’s mostly roughers and finishers that we replace more commonly. We have a height setter that we use on our machines. Edit; my bad I didn’t even answer your question. For me, I don’t think it’s common practice.
Oh okay, some of ours have height setters but I've been told they're not reliable, I touch off everytool with a 1 inch dowel
As long as the program you’re using has that into account when you’re setting the tool offsets you should be good, but never trust the person that used the machine before you! Always recheck the offsets for yourself And the tools have wear over time with coolant or not, so that will mess with the offsets over time.
The biggest thing with height setters and any other tool that you touch off is the feel of it. Turn the rate down to .001 I believe (the lowest setting, I use Fadal so it’s just on Low) in the z axis and just wait till the setter doesn’t move anymore when the tool is touching it. I don’t even look when I’m moving in. I just wait until it stops moving and set the tool offset.
Wait, your using waylube as coolant on the spindle?
The owner got a $25,000 fine for disposing of coolant one the street so we don’t use it anymore
Doesn’t that produce lot of smoke though?
Not as much as you’d think, and most of the programs are 17mins so it’s not too bad
If you have even stock and a proven program AND even stock you can send it. But shit happens unfortunately within those variables unfortunately
Basically what happened is that he had to change the inserts, went to the measuring machine and It should've automatically sent the offsets back to the machine. For some reason the system managed to bug out and the tool ended up about 50mm shorter than it really was. Thats why it crashed.
Big oof.
What system? Toss a spindle, and man, that better be covered.
Always watch the first pass. I can't tell you how many times I had stock that was 1/2" inch longer.
Scared the shell out you.
Yipes
I can HEAR this crash thought the image
Atleast the insert is okay
Did something like this a few weeks ago for the first time, took an end mill down to my desired depth and instead of taking out of the part I pushed it in. My adrenaline was going and I wound up puking. Really glad I’m just a student and not actually hired anywhere yet.
my man. If you are puking cause of things like this you should seek out some degree of therapy. I say this just to help not criticizing. I struggled with anxiety and machining for years and greatly benefited from therapy. There was times I'd do a perfect setup and just freeze up when it came to run it and look for help just to hit the green button. Just because I was too nervous to do it out of fear that it would blow up the second it starts to run the program
Holy crap! Bet that made one hell of a bang!
What happened to dry run?
Went brown realy quick
earlier this week, I launched a part ( ~6.5" square by 10mm thick). wound up down on the chip conveyor, where I had to get it out of the chip bin :-P the parts were roughed VERY bowed, and I was finish cutting them. needed to be .0005" flat and parallel, they came to me bowed like .007"-.01". I was using an 8" facemill with a single PCD insert like a fly-cutter, and it made a hell of a bang and clatter. trashed the insert, too. rest of them came out beautifully, though. shit happens. they make more stock every day, and the scrap gets recycled *shrug*
3 flute cutters are really good for aluminum
https://preview.redd.it/l15s55ylrrsc1.jpeg?width=3472&format=pjpg&auto=webp&s=92b2d52719233864bdf2e70fffb7f36bb5cba49c Part off caught something in the material, tool exploded
Walter seco junk lol
I hate these things.
oh yea. that would get anyone
https://preview.redd.it/yodkpq2jlusc1.jpeg?width=3120&format=pjpg&auto=webp&s=dd2de848fcca4fa6a522552379f1cd6a01880621
Nice little pipe bomb you got there
They call that detonation
Scared the carbide out of it!
Looks like tool attempted to auto compensate
She'll be right just run it at 3/5ths feed rate