Fairbanks Power Hammer Cross Head: Part 2

Abom79

150tn visningar10

    Part 2 of our @Hand Tool Rescue collaboration machining project, we'll take the Fairbanks Power Hammer Cross Head over to the K&T milling machine and get 3 of the machining ops finished up, including some deep slotting with an 8" slitting saw. This mill has always been great to operate. It's got the power and rigidity that your normal turret mills don't have.
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    Publicerades den 3 månader sedan

    Kommentarer

    1. William T. Musil

      Hiya Adam

    2. Josh Sanchez

      Awesome video. I've always wanted to see how you change from vertical to horizontal 👍 love the videos Adam keep it up buddy

    3. Royer ringo Polo

      Y como sabes q esta al medio del torneado interior ..estas maquinando al ojo..que tal la fundicion esta tirado para un lado..🤷‍♂️🤷‍♂️

    4. Harry Wagner

      It looks to me like the slitting saw is not concentric with shaft it's mounted on. If you watch the chips you can see there is a variation in the amount being cut which coincides with the same spot in the slitting blade on each revolution.

      1. Alex Ku

        Thats actually quite common with those saws and with the sloow feed you have on this operations, it does not actually mater.

    5. Coby Smolens

      Weird that the casting folks didn’t arrange the casting marks on the side of the head (below the clamping slot). Why would anyone put their mark on one of the surfaces that MUST be machined in order for the part to be usable. Don’t get it...

      1. tortron

        because its someone elses problem, typical huh

    6. Анна Котова

      Интересно, может в конце пропила нужно было просверлить отверстие, чтобы избежать трещины впоследствии?

    7. GRT Ranch adventures

      Just curious, you dident run coolant on the slitting saw is that because your cutting cast iron so the graphite is enough to self lubricate the cut?

      1. Charles

        Yes, I'm not a machinist, but I'm pretty sure cast iron doesn't need lubrication.

    8. Thunder Dick

      I thought he would have stopped the blade and drilled like a 1/2inch hole at the base of the saw blade cut it would have been easier to get the split as far as he wanted and would also prevent the casting from cracking in the sharp corners of the blade cut it would look like this basically o----

    9. Steven

      Seems like it would have been better to cut downward against the machinist jack instead of upward and away from the machinist jack as you did.

      1. Alex Ku

        @Ariskava Good theory, maybe someone else can chime in on this as I was wondering why he was cutting upwards as well. to mee a downward cut pushing into the jack would be more logical at the first glance.

      2. Ariskava

        My guess is that he did a upward cut to protect the machine should the saw bind. If he was cutting downward and the saw bound, it would push the part into the table and put the force on the arbor, where the upward cut might just kick the part out of the clamps and prevent so much force from going into the arbor.

    10. vince gallegos

      0001

    11. Francesco Di Giovanni

      Hi, as amateur, I am fascinated by the many useful tools you use. I always learn something new when I watch your videos. Astounding!

    12. aldaris38

      Cute the mini threaded jack ;)

    13. Nigel Beal

      Another great video as usual, but I have a concern about whether the longitudinal slit extends far enough beyond the clamping ears to allow the bore to readily clamp onto whatever rod it is meant to clamp onto. As can be seen at the 30:00 minute mark, the inner extent of the slit next to the bore, stops right beside the clamping ear. The uncut section at that point will tend to prop the bore open against the action of the clamping bolt. The slit that Adam has provided may be all that the the drawing called for, but it is a less than optimal design. The design provided to Adam may be just a copy of the original part, but if that is the case, I wonder if maybe the original broke because of this issue. In an effort to stop the part slipping along the rod, the operator applies more torque to the clamp bolt and eventually breaks one of the ears off. Subject to any other constraints, a better solution would be to extend the longitudinal slit so that the slit section of the part with the clamping ears is freer to clamp onto the rod. The alternative of putting a cross slit partway through the bore to isolate the clamping section from rest of the part is undesirable in this part because it weakens the part against longitudinal forces, which is presumably what the part has to work against. In the video link below, at exactly the 10:01 minute mark, you can see a similar Fairbanks crosshead, and it is apparent that the slit extends well past the clamping ears. (The extent of the slit is only visible at that exact second.) seprom.info/clone/video/xqRop7WSYHdqm58.html Cheers

      1. Nigel Beal

        @Charles I agree. Extension of the slot by just about any means would work, just so long as it happens before one the ears is broken off, by trying get the clamping action to work. One other point, that I wondered about is whether the original part was grey cast iron or something more ductile. The cross head that can be seen in the video link that I provided, looked pretty bashed and battered, which made me wonder if the original part might have been malleable cast iron or cast steel.

      2. Charles

        Well, at least it won't be too hard to extend the slit if that's true. An angle grinder would do the job nicely. It's not like the slit needs to be a precisely machined surface.

    14. Javier Aviles

      Amazing jobs , great talent . Gorgeous tools , Love them .!

    15. jonka1

      @31:42. There is an external casting flaw at the side of the casting right by the clamp on the right. Also I see another flaw at the root of the clamp flange where it meets the rest of the casting I'm concerned that these are perfectly placed to encourage crack failure during use under clamping and shock forces. Would it be worth brazing over them before considering the part ready for use?

    16. GETREAL!

      not only a professional craftsman but also a very clean guy!!! bravo

    17. Terry Howlett

      That was pretty cool!

    18. Peter Spain

      apart from the rotation of the machine is there a reason why you are cutting upwards instead of downward if you know what i mean?

    19. Peter Spain

      Why don’t you use coolant on such a large cut etc?although cast iron + coolant = slurry i suppose eh

    20. Peter Spain

      Knife butter etc comes to mind

    21. Peter Spain

      Great set up no chatter with such a big face cut what a tool that end mill is but what a powerful milling m/c awesome

    22. Peter Spain

      shows you how good the square is eh.Looks quite an old tool but quality.

    23. Jonathan Baxter

      That's a saw.

    24. The Fixer

      The markings are on the patterns to identify the pattern for the casing.

    25. Adrian Kowalski

      Very bad quality metal

    26. originalmarsbase

      My boss says he quotes jobs by allowing 5 minutes per operation. i wish i could have taken the time to do things correctly instead of "that's close enough "

      1. originalmarsbase

        that includes setup

    27. Johnny Gann

      Love your work. I see a big green grinder on a stand in the background. I have one like it and I was wondering where you can buy new grinding wheels and a wire wheel. I'd appreciate it if you could give me a idea where you can get the wheels. Thanks

    28. irritablearchitect

      Amazing watching that slot cut. It was like watching a chainsaw cut through wood with all of those chips flying.

    29. Ivan Waupoose

      Shorten up the set up. Move table, saw and bearing in as close as set-up will allow. Then you can let’er eat. 😎👍🏽

    30. dale benson

      no lubrication on the slitting saw ??

      1. Doug Bourdo

        Usually not for cast iron

    31. Q

      The master is in the shop.

    32. Life ****

      Let's hear it for the Toe Clamp... hip - hip...

    33. jlucasound

      @21:57 Genius.

    34. jlucasound

      Tony. Tony? Hey, Tony! Get back here! Don't you want to learn? Ah, sorry, Adam. Tony thinks your tool is bigger. He said if you need him, he'll be out on the trials course.

    35. jlucasound

      You Son of a Gun!! You have the door open and the fan going! I'm freezzin' my fri..you know. I started my bike today so it will run this spring. I have a cover on it (no garage) and it is surrounded by snow. YES. I am moving to Florida.

    36. jlucasound

      So satisfying seeing that huge end mill doin' it's thing. Nice.

    37. jlucasound

      @2:56 on. I would call that "Dead Nuts"! :-)

    38. A HILL

      Would oil or coolant help? Or is it a waste of time, curious?. Just trying to learn.

      1. A HILL

        @Doug Bourdo good to know .thank you have an amazing day.

      2. Doug Bourdo

        usually not for cast iron

    39. Able Fox

      Forgot which Tube site I was on when he whipped out that end mill! LoL

    40. EX-Bahamutgamer

      Curious question. How you make 1/4 inch gap with 3/16 saw ?

      1. EX-Bahamutgamer

        @Jack S I know it sound like the simplest question lol. Oh god sometimes I find these factions post to be impossible to convert like 3/16 into 1/4 and yet get prove it not impossible lol. Sometimes learning new things does to bring a joy at times

      2. Jack S

        you make a cut and move over 1/16th

    41. anthony kotsop

      Craftsmen bring us closer together..if we are shaping metal (etc) then we are not looking to smash our follow humans into shape ...

    42. John Roberts

      Great content thanks for sharing

    43. Dug6666666

      It is most likely that numbers put on a machine face of a casting are only there for internal use of the foundry. They are called heat numbers. Records are kept of the numbers so if a sample from a pour doesn't pass meteorology the others from that heat can be identified. Not sure about the conical peaks on the face, perhaps measuring across the peaks gives high definition features to check shrinkage/contraction is as intended.

    44. Salem Straub

      This is my kind of machining content. Hypnotic shots of power hammers parts being worked on in classic manual machines. Bravo.

    45. Marek Slazyk

      SUPER PROFESIONAL..

    46. Finno Ugric Machining

      Looking You parking the vertical milling head of Your K&T made me think:"Lucky him, he has the quill". I thought so because I just assumed that there MUST be a quill in a setup like that. Obviously I was wrong. Those who have not operated a milling machine that does not have the quill cannot possibly understand why we try to find alternative solutions to vertical boring in such a machine. It is just a pain to do that. Threading under power is VERY difficult. I have a Schaublin SV-51 from 1955 in my workshop. This is an universal milling machine. It does not have the quill but instead it has an articulating milling head. Changing between vertical and horizontal milling configurations takes about 1 minute including tramming the head if it was in some strange angle. No parking needed. Just turn the head on a suitable angle and reel it into the machine.

    47. Scott Schradle

      Thanks for showing how you convert the mill to horizontal. Never seen that done. Very interesting.

    48. Josh Schneider

      16:12 Did you make that overhead swiveling assembly or was that a KT factory setup?

      1. Finno Ugric Machining

        Adam made it himself. Borrowed an original part and then cloned it. There is a playlist of this task: seprom.info/build/PLaNH2qXIMRq-oyae6IZ_DpDDc_7jDoFe9.html

    49. Josh Schneider

      Three sixteenth in one pass cuz stone cold said so. Can I get a he'll yeah??? Hehe

    50. george fulk

      I stand corrected. I had to go back and watch episode two to realize I had missed you cutting and grinding down the other side. That’s the only downside about longer episodes. Anyway you look at it Adam it’s a good video a good project I just got to go back and watch it over multiple times when you put out different episodes. Thanks for the good video

    51. Robert Landrum

      Looking at the setup, is there a reason not to face off the round end (the top, if I'm not mistaken), and clamp that down to the mill? That would give you access to all the faces and even allow for the cut (I think), with just a few clamping changes.

    52. Radoslav kefilev

      How did you get the center coordinate, Is all the measurement based on casting not the center hole?

      1. jonka1

        @Rudi Christensen I did not say that he had stopped.

      2. Rudi Christensen

        @jonka1 When did he stop answering comments.

      3. jonka1

        Yes, I asked myself the same question. My money is on the centre of the casting. Adam rarely answers so I think only he knows.

    53. L A

      That clam but just eats metal. Wow

    54. john90430

      The saw chatter sounds like the Tardis from Doctor Who, which I used to watch before it got all Woke® like everything else coming from the BBC.

      1. john90430

        @Robert Housedorf II LOL Not exactly a fan, but I watched it sometimes back in the days before cable and/or VCR. Often it was the only thing watchable in the moment.

      2. Robert Housedorf II

        I don't think he had the brake on, but maybe? ( yeah, you ARE a Dr Who fan if you know that reference... )

    55. CaptainCarling

      That's not an end mill, that's a space station

    56. Andy Keen

      That saw machine is like something out of a James Bond movie 😱 “No Mr Bond, I expect you to die.....” 💀

    57. yambo59

      Laymans question mid video -- how about the saw cutting down into the table instead of up-??

      1. Finno Ugric Machining

        In fact, You just might be able to do that. However, this requires even more rigid setup than that Adam had. For some reason slitting saws are almost always operated to that direction. The slitting saws will protest very loudly if they do not have enough many teeth making contact with the material. On the other hand, the more teeth there is in contact, the more the saw tends to chatter. The truth is somewhere there ...

      2. Josh Schneider

        I'm not an expert like Adam but I do believe the swarf (wet metal chippings) would clog and distort the cut

    58. Jared Fox

      Crocodile Dundee would be proud. "That's not an end mill...That's an end mill"

      1. jonka1

        In all fairness the other guy did have a very small knife.

      2. Stacie Dziedzic

        I love this comment! That’s hilarious! He definitely would say that!

    59. ROBRENZ

      Nice work Adam! ATB, Robin

    60. David Grimble

      I was wondering when you put the blade on backwards if it was going to lift instead of pushing down.

      1. Finno Ugric Machining

        Climb milling with a slitting saw is something that You might try once. Yes, it tries to lift the part and therefore the second support helped so much as it keeps the part from lifting up.

    61. Tom P

      for a second when that jack moved, I thought we were going to see a machine crash...

      1. jonka1

        Yes I began to wonder if I was watching Mr Rucker.

    62. Andrew Operacz

      A video from Abom27 a day, will definitely inspire!! Yeah I know, it doesn’t rhyme. What an amazing video. The swing you added to the head for change out is amazing!! Thank you for sharing all you do!!!

    63. A K

      Was that an "INSIZE" caliper? Happy with it?

    64. Andrew Cran

      Man, that's driving my brain nuts. You can see that the chuck is going clockwise, but because of the direction of the cut on the bit, it looks like it's going anti-clockwise.

      1. Tom P

        same here.

    65. MrDarkhammer

      Wouldn't it work better with the saw, if you turned the sawblade and rotation to have it actually push the part you're working on Into the crosstable of your mill?

      1. Finno Ugric Machining

        @MrDarkhammer A slitting saw with that big radius tends to really climb on top of the workpiece if climb milling is used. If the milling machine would have a neglible backslash then this would not be a problem. However, since most manual machines of that age do not have the ball screws but rather have an ACME or some other "normal" screw, those need some backslash to operate. In addition to that needed backslah there is the wear and tear which adds to the backslash. Now, in case of climb milling, the workpiece can "freely" slip backslah amount under the blade which then can cascade into a more severe situation with blade shrapnels flying around. With older machines climb milling is usually used to peel off miniscule amounts of material. Adam did that with the spring passes.

      2. MrDarkhammer

        @Finno Ugric Machining can you explain why? I've read some stuff and don't have a real conclusion...

      3. Finno Ugric Machining

        Climb milling with a coarse slitting saw is something You can try once only.

      4. JDM

        @Josh Schneider It would? Why?

      5. Josh Schneider

        That would increase vibration and knock the cut out of true.

    66. Dead Pixel Media

      love it... we need to take about 1/16th of an inch off...... pulls out a 2in end mill... :-D

    67. Eric Martin

      Camera angle at 2:38 is perfect, when the angle touches the square blade it looks like they become one piece. Nice!

    68. salsyou

      so cool to see that saw just make nothin outa that part

    69. Reini Grauer

      Any problems climb cutting with a saw like that? Seems like it would push the work down into the jack and potentially reduce the vibration.

      1. Finno Ugric Machining

        Climb milling has the word "climb" in it. A coarse slitting saw in a milling machine that might have some backslash. Thats a recipe for a disaster. For some funny reason nobody does climb milling with slitting saws. I tried it once and it did not end well. Nothing got destroyed but I was really lucky.

    70. gentlemen sheep

      Got to love machinist jacks theres a machinist best friend.

    71. wristpin38

      Is it standard for horizontal saw teeth to cut upwards like that? My gut feels like cutting towards the workpiece and table would be more stable? Not second guessing you, just genuinely curious.

      1. wristpin38

        @M I Holy cow; thank you for the explanation! I appreciate it.

      2. M I

        What you are describing is called a climb cut in machinist terms and what abom is doing is a conventional cut. A climb cut is where the tool cuts into the workpiece and the cut tapers off, a conventional cut is the opposite so the tool cuts away from the work and the chip is thickest at the end of the cutting motion. Your gut feeling is right, a climb cut is more stable and easier on the tool. However it reguires a feedscrew with no backlash because it has a tendency to grab the workpiece and cause the table to vibrate back and forth. Most modern cnc-machines have ballscrews so most of the time a climb cut is used. Most manual machines have trapezoidal or acme feedscrews that reguire some backlash to function properly. So this machine is propably not capable of safely climb cutting such a heavy cut. You can see the same stuff with how adam does the side milling, when he's taking most of the material off he's conventional cutting and only does a very light climb cut for finishing and he can get away with it because the table has enough mass to prevent it from bouncing.

    72. Kurt Fattig

      It was interesting to see you set up for horizontal milling.

    73. spambot71

      i'm curious, if you've restrained a workpiece as good as you can and you still get high frequency vibrations, would it be possible to damp it by sticking some soft rubber or silicone to the piece? they sell these sticky pads that drummers can stick to ride cymbals to shorten their sound, i'm curious if that effect is ever practical in a machining context.

      1. jonka1

        I seem to remember Keith Fenner using a lump of lead strapped to the piece to kill harmonics in some of his older videos.

      2. Josh Kinney

        I don't have any personal experience with this, but one of Abom's older videos shows him putting a short length of garden hose inside a pipe to keep it from ringing while he's cutting on it. I don't know if it does anything to reduce chatter, but it makes the cut significantly quieter.

    74. Wolf Party

      The shell ruffing mill is the cats meow!❤️🔥🤣

    75. JB Lewis

      I'm curious about the pulsating sound from the 2 in. end mill.

      1. jonka1

        Total perfection in running true is unlikely with any mill and you are hearing this effect as it cuts.

    76. J Waterous

      I liked the way you worked through the vibration issue. When the machinist jack moved I wondered what you would do. The shots after the wheel cut showing all the old school pieces that went into that best process are excellent. I was after thinking your work and thought it might be interesting to take a four flute end mill straight down through there to create an anti stress shape. Good to come from a family of machinists! BTW I do think the iPhone shots are better stabilization wise if only a different shade of light because the two different sensors - software - bios. I hope you can get a selfie stick maybe with a battery inside it to keep your mobile charged in case you need to be the "go - getter" at the drop of a hat.

    77. fuxluck1

      I wonder if you had reversed the direction of the saw so it was pulling the casting down towards the table instead of pulling up maybe the chatter would have been less? Nice work, looks fun!

    78. J LV

      I don't know what is happening, other than things being cut but this is amazing work .

    79. dingus153

      With the slitting saw could you have gotten a more chatter free cut by reversing the cutting direction so the force was going down into the machinist jack rather than up and away from the support?

    80. Gene Nall

      Love the quality of the picture it looks like I am standing in your shop making chips.

    81. mugmiso

      Is that crane for the 90 degree head something you designed & built? That is mighty slick. I know that head is a 150lbs+ (at least the one on my Van Norman is...) Might have to copy that.

      1. Kepo Irvine

        There was a series of videos in which the parking attachment was produced: seprom.info/clone/video/0ppqgbFsYnl5qK8.html

    82. Geoffrey Shipton

      Hairy stuff! and a great video. Did I miss the bit where the slot was cut relative to the bore centerline? The cheeks were machined relative to the casting I think? But maybe its not important.

      1. haphazard1342

        Given the purpose of the slot (relief to allow clamping the bore tight), I think it probably doesn't matter. I'm slightly more interested in whether the faces were machines relative to the bore. I know that the size of the casting only allows so much fiddling there, but I don't know how much I would trust the casting either and these faces seemed to have a good amount of material left.

    83. Scott Recker

      I'd be so nice to have a 50 taper machine. Wouldn't dream of having an end mill that large in a R8 spindle.

    84. eric hoff

      Adam, a masterful set up holding that awkward part!

    85. Thatcher Cardon

      When that end mill started to roll!

    86. Gokhan K

      That parking attachment sure does come in handy

    87. Jared Z

      Awesome video as always, admire your ability to problem solve and find a solid way to hold such an oddly shaped large part.

    88. OG Milkbag

      this was mad dummy lit nice video abom

    89. Dale Allen

      Totally fascinating , Glad there are still guys out there that can be creators . I just got a Sheldon lathe and a small Smith milling machine . I am looking forward to learning . It's much harder than people think , and to see you do what you do is a gift . Thanks for sharing , good camera work to .

    90. Mopar Stephen

      Not a machinist so forgive me if this is a dumb question. When doing the saw cut, why was it setup to do a climb cut, rather than pushing the piece down on the clamp?

      1. Mopar Stephen

        @sean tap Thanks for the explanation.

      2. sean tap

        Because of the backlash in the table. It would probably break the cutter. This is not actually climb milling what you proposed he do is climb milling.

    91. May the Schwarz be with you

      The sawing action was insane! Like cutting wood

    92. Dale Pomraning

      did Windy Hill make the casting pattern?

    93. Hä? Wassdalos?

      Too many ads man :-/

      1. Digger Dig

        addblocker I never see adds

      2. Keith Hansen

        Blame that on greedy youtube

      3. Gladiatus121

        es kommt nur von youtube

    94. Petey Bones

      7:04 Who else thought, seprom.info/clone/video/lcaFn8-Jp4iVlo0.html

      1. Petey Bones

        @jonka1 Never 👊😉

      2. jonka1

        Have you tried growing up?

      3. pingable

        i dont think anyone thought that

    95. Will W.

      Beautiful, I don't know which was more memorizing, the slice with the blade or the machine change over. Question; I notice many of your clamp down nuts/bolts for both machine and work seem somewhat lightly torqued down. Not loose mind you but if I was using grunt measurement I'd call it 1 grunt. Maybe I've been over tightening mine all along ?

      1. Steve Doran

        You probably have, as a toolmaker I only tighten down enough to hold the work, I used to be appalled at how studding and nuts used to be distorted due to overtightening, I never allow a milling m/c operator to use my clamp equipment for this reason.....

    96. David2021

      Oh yeah I think I’ve got a 2” end mill kicking around here somewhere too! Lol

      1. Gary Drake

        New with a radius corner to boot.

      2. Mitch Kronowit

        When he pulled that mill out I almost got sexually aroused. 😂

    97. Dave Gill

      Absolute quality manual Machinist 👌👍

    98. 5X5

      This was one of your best yet Adam---in my know nothing about machining opinion. Great shots! It was very cool to watch you convert from vertical to horizontal and use your "new" shop built parking-crane too.

      1. yambo59

        If you havent already you should go back and watch some of this big metal videos from when he worked at motion industries, some really big lathes and big work.

    99. Roger Frizzell

      Love your videos, saw your video when you were at the KOA in Black Mtn. I live in Asheville sorry I didnt get to meet you. I had an idea, I have been around machine shops all my life and I also do wood working. Here is my question, would it be beneficial to take a "CYCLONE" dust collection system for wood working and adapt it to machine shop use so it would collect the metal shavings?

      1. Roger Frizzell

        @Keith Hansen Thank You for responding ! Yeah, I had not factored in the coolant problem. What if you centralized the vacuum source, ie. the cyclone? Then plumb the vacuum to each machine to a say 5 gal. container, with a short flexible hose with a magnetic mount on the end of the hose. That might alleviate the clogging problem, but would still provide continuous suction during operations. Especially in the big shop where there are multiple machines running at one time. Like in a hospital room, where the suction is continuous but the nurse can plug in a small container to the port for cleaning stuff up ?

      2. Keith Hansen

        Excellent idea Roger, thought about that many years back. The problem really is that the chips tend to collect like a bad artery. Especially when either coolant or cutting oils are used. We use a number of shop vacs and before long the hoses get heavy and it's darn near impossible to clean them.

    100. Randall Goodwin

      Another great video. The resolution on your cameras are outstanding.