Had to laugh when you said “straight forward” . That part is a beast to us mortal machinists 🙂

I'm pretty sure I will never do anything close to this precision. But I sit here intrigued, captivated, absorbed, fascinated, and entertained by the level of experience, expertise, and knowledge of your work. I have manually machined hundreds of parts and pieces but watching you is awesome!!!

I always love it when you receive a drawing/model from a designer who has never made anything in their lives. Anything can be done in SOLIDWORKS

This is nearly unreal what you are able to do. Thanks for sharing your skills.

Ah, another one of these Swiss cheese oil and gas parts. Those fittings are similar to cone and thread fittings, which as you said are used for very high pressures. The taper on the tubing is slightly less than 60 degrees, so the two surfaces theoretically intersect along a single circular line, allowing for very high sealing pressures with relatively low torque. These are typically rated for up to 60,000 psi, but some specialty fittings can handle up to 150,000 psi.

Thank you again for sharing not only your machining but most importantly your thoughts on how to solve difficult problems in subtractive manufacturing.

Man I was just checking your channel yesterday thinking he hasn't made a video in a while. Glad to see you're still at it. I was Mfg. Mngr. at W.L. Doffing Co. for a little over a decade and not too many people do what we do much less bring it to this audience. Love your content. At WLD I was spoiled. I had a team of tool and cutter grinders and a nice EDM Dept. We would grind the Autoclave tools to do the thread minor and floor angle and top chamfer in one shot and on the narrow angle intersecting holes, drill up to the intersection and burn the bottom out on the Sinker EDM with a Teflon guide bushing. Please do not think twice about repeating yourself with content. Every part poses it's own unique challenges and it's entertaining/educational to hear your thought process on getting past those challenges. Our community needs more people like you Dude! Thank you.

I hope we get to see you grinding the tools and making these parts! Appreciate all the content you put out, always things to learn!

I don't mind you going over something you've done previously. You are an incredible machinist.

This is triggering my machining anxiety🤣. It is however great to see a true expert working.

And this is what keeps me coming back to your channel. I always walk away learning something new and for that I am very grateful, thank you. Can’t wait to see the machining process.

You sir are a machining master.. I have a very complicated love/hate relationship with machining fiddly stuff like that.. on one hand I love it when things work out as planned and makes me think I'm a genious.. on the other hand when my plan fails I just want to cry.. huge respect for taking such work!!

Seeing how you are going to handle the intersecting holes is really helpful. Charles

Hi Peter, another involved plan. Really enjoy your take on how to. I hope the filler rod doesn't spin, the bend will be enough. Good luck.

Welcome back and please don`t be concerned as to repeating one`s self task wise. As all you work iI find is first class, well thourght out and inspiring to me anyway. To be honest that's all that concerns me, as to my learning curve. My tasks are in no way whatsoever or in any way so complicated or interesting as your task always are. The most complex of mine are just a few holes, a few pins or spindles required upon my modeling interests as to materials employed, well much of what is in Brass, titanium rod and white metal. There again I may attempt to modify a milling cutter or grind a tool from a small section of a TIG welding tungsten rod or even attempt to regrind an insert that has been chipped or to a form required. Finding all you do is so fascinatingly interesting. Thank you, take care too.

Most well explained machining channel on the Net. Legend

Great content. The jobs you show are interesting and I can usually learn an interesting tip

Really cool that you share this. I hope you show grinding the special tools as well.

Hello, every time I see your projects I think about how free engineers feel knowing that there are people like you to do their crazy things. The comment among my colleagues is, we have another god level machining video to enjoy. thanks totally.

Good to see you back. Water jets use a metal to metal taper seal like that. They run from 40 to 900000 psi.

Really nice plan, and great thoughts! Consider radially surfacing the 5deg port bottom with a square end mill. Custom ground is better but ive got away with it when lead times on tooling where bad

Nice to see people that understand the forces in play... some people would just go with it and not understand why a drill was detonating

All that I want is information, to learn something new. When you pop up, I turn up the volume. My thinking is very unique, your experience, your intellect, is well absorbed sir. Thank you..

I've done something similar more than a decade ago on a deep drilling machine, IMSA 1250 BBLL (made in Italy), and the part was half of a mould (German automotive client); you brought back memories with that intersection at 6:00 don't remember if they were Ø8mm or Ø12mm, but it was quite a nightmare because I had one shot only without breaking any parts inside (talking about more than 1mt x 1mt x 0.6mt of 1.2738 or 1.2311 steel). Managed to do so with, if I recall properly, aluminum rods I've previously turned to have a bit of initial slack till three quarters of the length and then pushed it with force for it to fit as the last part was precise, with the very last part slightly bigger than the drilled hole. The back of the aluminum rod had an internal thread to pull it out. Very low feed and spindle speed during the intersection as it was cutting soft and hard material in an unsupported manner...

My plan would be to drill and plug the straight hole through hole first as you could use a pin punch to drive the sacrificial rod pieces back out if necessary. All good fun.

Another possibility for holding in the drill rod would be to super glue them in. After the machining a soak in acetone would dissolve the glue.

next level job! look forward to seeing the machining

Thanks Peter, very good info.

This is a good birthday gift. Thanks!

Great plan. Can't wait to see action 😊

Impressive part, especially those long holes which meet eachother.

Fascinating! Thank you.

Glad to see you doing good

I was thinking the holes would be drilled in the other order - but then realised that would leave the support rod end still inside the part with no way to remove it. I am not a smart man. Thanks for the videos. Stay safe out there.

For us up and coming: when you get a job like this, how much lead time do you tell the customer? With setup and grinding form tools is it weeks? Or do you have open terms as long as you are making progress? Very insightful, thank you as always for the wisdom

Very awesome to see you, Mr. Peter, love your content.!❤ will you be showing the drilling operations on that part?? Would love to see how those rods work down the holes. HOW”S MEXICO GOIN😊??

Good morning brad this video are educational about machine shop...

thanks for the video, we are waiting for the continuation.

If concerned you could always drill and tap a hole into the large face pocket stock that will be removed later when you mill the feature. Use this hole to secure a narror piece of flat bar that you have slotted a bit over your rod diamter to allow room for the angle of the holes. Have one or two setscrews perpendicular to the slot across where you can pinch and hold the rod tight. I am sure one narrow slotted clamp could be designed to accommodate both holes to hold the rod secure. This would ensure the rod is just held in place and no chance of it rotating and still have easy removal afterwards.

Welcome back.. been waiting

Some interesting parts there. I would not like the pressure with the what ifs - (i.e. ruining the expensive, already partially machined parts and Titanium). The planning and experience of anticipating any potential problems, thanks to your great brain, will no doubt make it just a bit of a challenge for you. Can't wait to see the machining !

Mind blown!🤯

Thanks for doing another great video Peter! I know you dont like to add feeds and speeds but i will appreciate if you could add some for the gun drills because i never gun drilled before. I know they differ upon the conditions and would like to get this details if possible.

I run into those fittings on waterjets, those intersections are pretty nasty, i hate having to make deep intersections at a good cross angle much less that shallow. Always great to see a video from you, cant wait to see more on this. Btw i wonder if a little superglue would be adequate to hold the fillers, then do the final bore to remove any residues

Hadn't even thought of the coolant trying to push the rods out, I was just wondering if the drill was going to end up spinning the drill rod when it made contact. I imagine your solution will avoid both of those problems. A few of these features would cause me some stress on their own. Combining them on a part that was provided and that the customer already has money into would keep me up at night.

What an interesting part I will be most interested is seeing how all the machining works.

That is a very interesting part to fabricate. The next video should be a good one. I like the way you solve the various problems the part presents. KOKO!

You have probably got it any way but clamp rod ends together or in a specialy machined end plate extension, to stop roration -jamming when maching. Always interesting stuff thanks.

hi ,Pete nice job 😀

Good to hear your alive Peter. Give us an update on Mexico when you’ve chance

Nice video. Really like how you thinking and planning it. How you have to take in to account so many factors. I was thinking if you drill the longer hole first, put sacrificial part in it, and drill the angle hole. But the you will may endup with part of that rod stuck inside. Btw, I had recurring job with 2 intersecting holes, that alway give me some issues. Then I saw your video on sacryficial part, and use that idea. It killed many birds with one stone. Can hold part better (part is 0.150 x .130) and hole are clean (no secondary scraping necessary), so thank you very much for sharing the knowledge

Ждём продолжения.

What about welding something to the end of the sacrificial rod that will keep it located/not spin. Also will help to get it out.

Wonderful content Peter. I recognize your challenges and love and learn your fixes. I don't own a fifth axis so I would have to build a fixture first for all the angled holes and I'm not sure if have the z reach on my machines to clear the part from the drills. And it would be a tight butt exercise. Coolant? Please don't jam, please don't dwell on the inserted rod, kind of deal. I know you worry a bit if all goes well but repeating an extra part on the Mazak helps to vary a little along and maybe still make money on the parts. In a conventional manner it's more high risk. I would certainly start with extra stock and add one or two to the amount to deliver (depending on the size of the order and the presumed risk for not succeeding on the first one). Thank you Peter! (How does your remodelled car behave and the milled anvills?)

Great see that you are still making the engineers look good. would Loctite bearing lock work for holding plug rods?

Kinda curious, whats your stance on customer supplied stock or in this case customer supplied parts where this is already turned and now you have to work on it? These parts seem like it would be a breeze for you to have made from raw in like 2 setups and know everything is true to itself.

I am thinking some sort of endcap to act as a guide bushing for the gun drill to get it started on location, and an end cap with the drill rod attached to it with some sort of jacking screws / wrench flats to remove after the op. Maybe there is some way to utilize some of the required hole locations with sacrificial undersize taps to hold the cap. It would definitely would take some planning. Good luck. Cool part.

At first seeing these holes i thought wtf. But as you explaining it seems sooooo easy 😂😂 nooot

Could you use an epoxy or low melting point solder in the c’bores to hold the drill rod in place? It may be difficult to clean out afterwards though.

at 7:01 I don't quite understand argument for drilling shorter angled hole first. In my opinion it would create more misalignment issues for long hole which after meeting with short one, should continue straight for some time still, which could not be happening. If you drill long one first, then put sacrificial filler rod into it and then drill short one to meet in the middle, its misaligning would not be as impactful. Other than that, both are relatively to each other meeting same way, so it should not matter which one first to drill. At least thats my unprofessional opinion :). Cheers!

"it's pretty convenient to do on a five axis machine" Classic :-)

good vieo Peter

Nice challenge! Do you have an endoscopic camera to look at these intersections once finished? WIthout these drill rods that you plan to use, i would also expect quite serious problems with "push over burrs". With the rods it should be way better. Would be extremely interesting to see the intersections. But: What if the intersections will be in need of deburring? Deburring done by the guys of centerline? :)

If that is a standard autoclave iscar sell a tool that does thread, 5° flat and the 60° all in one.

Lovely to see your thought process on parts - Any plan on how to hold the drill rod in place? Or is that of little concern?

Just out of curiosity, won't it be easy to 3d print such intricate parts ?

Thats a really good idea, to fill the holes again with some material, but i would fear that these rods are spining inside the holes, when the drill hit them - did i miss it, or did u plan to use some loctite or something else to fix them? I really wish you, that this strategie is working.

Good grief, that looks like a nightmare. You sir, are a wizard.

Reminded me of the old adage: 7 P's

How are you planning to stop the drill rod from rotating when the gun drill hits it? Just hoping the bend will be enough to stop it from rotating?

Make a cap that fits over the end to hold the rod in place?

Considering the slugs:maybe cut one end open with a band saw and drive a wedge in there once they're inserted?

Are those holes that come at an angle into the threads incase there is oil in the holes so you can still thread the fitting into it.

Surprised you didn’t use a plug with a center in it to use the tail stock when you mill the key feature.

I miss your video❤❤❤❤

Won't the drill rods twist with the drill and crack the cutting edge? What about sinker EDM?

Can I ask you a question. What you do when OD of a stock is really really bad. How u cantering it on 4 jaw chuck?

Rather you than me!!

Holding in double chuck. What is the benefits?

Use a tail stock with a flat face or another chuck to grab the end. That part ain't going anywhere when milling that way. Save you messing about with clamps.

May be use EDM drill?

Can you comment on using Ansys software?

I am expecting an interesting drilling process!!!!!!

My biggest fear would be the drill rod removal, burrs can really hang u up.

Why does that part have to go to 2 shops? Couldn't the first shop finish the job? Why not give it to you for all the ops?

Why use Ansys

It's nice to see another machinist taking things to the turbo autist level that normies can never achieve. People like us are the cobalt binder of society.

*Abstract* This video discusses the planning and challenges involved in milling titanium and 174 pH stainless steel parts. The speaker focuses on workholding strategies to ensure part stability during machining, especially when milling a keyway feature. A major challenge arises from intersecting gun-drilled holes with minimal drill support due to shallow angles. The solution involves a novel technique of inserting drill rod as temporary support during the drilling process. Additionally, the video covers the design and manufacturing considerations for custom tooling needed to create specific part features, such as undercuts and high-pressure ports. The operational order is outlined, and the video concludes by highlighting the key challenges and previewing the upcoming setup and machining demonstration. *Summary* *Introduction* * Speaker will not repeat previously made content. * Aims to provide new, valuable information for viewers. *Job Introduction* * Two titanium parts, two 174 pH stainless parts to be milled. * Concerned about existing chuck holding strength for part shape. * Plans to add clamping system across flange as well as continue chucking. * Planning stage of job, focus on gun drilling process due to potential issues with hole intersections. * Will push drill rod as support during intersecting drills. *CAD Model Examination (174 pH part)* * 00:04:00 Plans to remove OD to form key shape. * 00:04:30 Counterbore and holes on part end likely done with chuck as-is. * 00:05:00 Plans to mill OD near flange with long end mill while rotating C-axis, then square sides later. * 00:05:30 Concerned about manual chuck holding power during the process, will add clamps. * 00:06:00 Issue due to intersecting gun-drilled holes at a slight angle with little support for drill tip. * 00:07:00 Plan to drill short hole, insert drill rod, then drill other hole. Rod should support intersection point. * 00:08:00 Same logic for other intersecting holes * 00:08:30 Special tools needed for autoclave engineering ports: * Threaded port with a tapered area for conical tube tip to create high-pressure metal-metal seal. * Will make end mill to create 5-degree taper in part as per specs. * 00:10:00 Some ports have closed tolerances and will be bored later, other features are straightforward * 00:10:30 Intersecting hole arrangement causes complexity. Must drill in correct order to avoid breaking drills. *CAD Model Continued* * 00:11:00 Further detailing of how intersecting angled holes create issues * 00:11:30 Unsure of customer's plan for high-pressure sealing at other end of part. * 00:12:00 Small angled holes near ports are for leak detection * 00:12:30 Blue holes are for a spanner wrench * 00:12:30 First operation will be on part face with keyway milling * 00:13:00 Five axis machine better for angled holes, simplifies positioning using offsets etc. * 00:13:30 Will first drill holes where orange slugs appear in model, then support with drill rod, then drill remaining intersecting holes. * 00:14:00 High-pressure coolant at 1500 PSI may push out support rods * 00:14:30 Potential solutions for holding support rods (bending, banding, etc) being considered. *Pulling out support rods* * 00:15:00 Plan to leave drill rod slightly exposed for removal * Will use vice grips attached to a slide hammer to extract * Believes friction, combined with a bent rod shape, will prevent coolant from dislodging them *Additional Tooling Needed* * 00:15:30 Part has a pocket with an unknown function * 00:16:00 Requires custom tool due to undercut feature * Speaker drew up design for a cutter, to be ground * Option to purchase this type of tool maybe exists but grinding is easier in this case *Operational Order* * 00:16:30 First operations will focus on milling both parts on one end * Parts then flipped, chucked on new diameters, and aligned using keys (internal or external) to establish reference point * 00:17:00 Work continues on the opposite end: ports, various holes *Key Challenges and Wrap-up* * 00:17:30 The main challenge is intersecting holes causing insufficient drill support (risk of breakage) * This is due to the very shallow angles of intersection * 00:18:00 Next video will cover setup, programming, and the actual machining process Disclaimer: I used gemini ultra 1.0 (2024.02.08) to summarize the video transcript. This method may make mistakes in recognizing words and it can't distinguish between speakers.

What's with the designs. who designs this stuff. do they even have any experience making anything like this or is it just wishful thinking. do they think you can do anything?

Хм, не простая деталька.

Watched many videos from this guy, super talented. But please clean up that workshop, looks like a bomb 💣 has gone off. You must work alone I guess. Great content otherwise