Machining Videos

Seeing is believing, or at least learning. These Modern Machine Shop articles contain video so you can watch machining in action while you learn more about the technology.

Composites Machining

Video: Cutting Out A Composite Structure: Milling cuts out features of a composite structure, then cuts the structure itself out of the setup.
Video: End Mill Comparisons in CFRP, Part 1 - Carbide Tool: Part of a series of tests in carbon fiber reinforced plastic, this video shows the performance of a coated carbide tool.
Video: End Mill Comparisons in CFRP, Part 2 - Diamond-Coated Tool: Part of a series of tests in carbon fiber reinforced plastic, this video shows the performance of a diamond-coated tool.
Video: End Mill Comparisons in CFRP, Part 3 - Conventional PCD Tool: Part of a series of tests in carbon fiber reinforced plastic, this video shows the performance of PCD tooling.
Video: End Mill Comparisons in CFRP, Part 4 - Veined PCD Tool: Part of a series of tests in carbon fiber reinforced plastic, this video shows the performance of a veined PCD tool.
Video: Exit-Side Drill Penetration Without Delamination: Slow-motion video shows the effect of a micograin tool coating in drilling CFRP.
Video: Five-Axis Milling And Drilling of Composite Component: This video from machine tool maker CMS shows high speed five-axis milling and drilling of composite component.
Video: Five-Axis Trimming of Composites: Here is video of the five-axis motion required to trim a relatively simple composite component.
Video: Through-Spindle Dust Collection For Composites And Graphite: A vacuum system for the machining center draws particulate through the center of the tool.

Cutting Tools

Continuous Turning On TurnMills: Advancements in CAM software enable turn-mill machines having a B-axis milling head to perform all finish-turning operations using a single cutting tool.
Taking The Plunge: It doesn't take sophisticated technology to perform plunge roughing effectively. In fact, if you are making due with a less effective machine, plunge roughing deserves even more serious consideration.
Developing A Safer Way To Machine Magnesium: Small chips and fine dust generated while cutting magnesium are highly flammable and pose a serious fire risk if not properly handled. This video shows an example of an internal chip extraction system process to remove the particles.
Stepping Up To Hole-Making Challenges: This video demonstrates the use of stepped insert designs in hole-making operations.
Tools For Titanium: Watch the chips pile up in this video to get a sense of the metal removal rate this 10-flute end mill achieves in titanium.
Face Mill Video: This 24-inch-diameter face mill is used in a steel scalping operation requiring 300 hp. Depth of cut is 0.75 inch. Metal removal rate is 300 cubic inches per minute.

Grinding

In It For The Long Haul: Curt Reed uses advanced grinding techniques in the pursuit of short-run, sub-micron work that other shops can't perform or won't attempt. His shop's commitment to its customers is reflectedin the high level of equipment sophistication and applied grinding acumen. View the accompanying video for a grinding application.

High Speed Machining (HSM)

Delicate Features: Electrodes with thin walls, ribs or other delicate features can be machined in one piece with HSM, because the light cuts put so little pressure between the cutter and the workpiece.
Helical Interpolation Vs. Drilling: A machining center able to maintain precise control at high feed rates makes it practical to machine holes through helical milling as an alternative to drilling.
Hole Making: Combination Tools: This video demonstrates hole making. Hole making often involves sequential operations such as drill-then-tap.
Incremental Pocketing: These videos show one level of a workpiece machined through incremental pocketing. Every pocket is machined, but only one level down. For each subsequent layer, this order of pockets is repeated. And an incremental pocketing variation employing a user-defined sequence. Here the program alternates pockets to reduce heat build-up in any given wall. Video courtesy UGS.
Milling At High L:D Ratios: The shop machining this mold uses HSM for fine details instead of EDM. Details like this one are machined using a 30,000-rpm spindle to run end mills as small as 0.010-inch diameter at 0.002 inch step-over and depth of cut. Photo courtesy Haas Automation. For footage of high-L:D milling, scroll down.
No Need For Speed: Machining An Unsupported Floor. This online video shows some of the rules of high speed machining in action—make the work as stiff as you can where you are cutting, then don’t return to that area once it’s cut. These disciplines affect the way an unsupported floor is machined. Programmers make extra manipulations within the CAM software to get the tool path to move this way.

Machining Centers

Five-Axis Machining Has Special Workholding Needs: This article and video demonstrates how this clamping system helps keep the worktable out of the way of the spindle and cutting tool as they approach multiple sides of a workpiece.
Turning Without Rotating The Part: A lathe with live-tool capability is not the only type of machine that can turn, mill and drill in the same setup. Parts that are too big or too unbalanced for chucking in a lathe can also benefit from combining these operations into one cycle.

Measurement & Quality

Revving Up The CMM: An online video shows this high speed motorized CMM probe rotating in space, spiraling in a bore and sweeping across a surface.

Turning

Automated From The Start: Turning automation helps this shop produce parts more efficiently.
Machining A Non-Round Part On A Turning Center: This intricate machining cycle on a CNC Swiss-type lathe reveals how a turning center capable of X-, Y- and Z-axis motion in milling can be effective even when the part is not round. The part, a spinal hook, does not feature anything like the axial symmetry typical of a turned part.
When Four Spindles Make Sense: For the right applications, four-spindle CNC chuckers offer practically zero delay for part loading. That’s because two spindles can be loaded while the other two are making chips.
The Role Of The Subspindle In CNC Swiss-Type Machining: This video shows a machining cycle on a CNC Swiss-type lathe that takes advantage of more sophisticated features involving the subspindle. The subspindle's support of the workpiece allows long axial flats to be machined. The subspindle driving workpiece during the last machining operations reduces the length of remnant that has to be left behind.
Bone Screw Machining On A CNC Swiss-Type Lathe: View this video to see clearly how a CNC Swiss-type lathe works. On a machine of this type, the guide bushing moves the part along the axial direcation so the tool can remain close to the point of support. Thread whirling is one of the operations in this machining cycle producing a bone screw.
Machining A Non-Round Part On A Turning Center: This intricate machining cycle on a CNC Swiss-type lathe reveals how a turning center capable of X-, Y- and Z-axis motion in milling can be effective even when the part is not round. The part, a spinal hook, does not feature anything like the axial symmetry typical of a turned part.
Sawing On A Turning Center: This part machined on a CNC Swiss-type lathe includes 0.008-inch slots machined through precision sawing. The lathe performing this work uses linear motors in place of ballscrews.
The Multi-Process Machine Mindset: An online video shows a boring bar being retrieved from the storage compartment on the multi-process machine mentioned in this article.
Hard Turn Without Leaving Feed Marks: Lead-Free Hard Turning Video.
Applying Turn-Milling: An online video shows turn-milling in action, including turn-milling to produce off-center features of the part.

MMS InMotion Presentations

Automated 5-Axis Machining: Automation and 5-axis machining continue to gain popularity due to their favorable impact on productivity and manufacturing cost reduction. This video seminar presented by Makino will illustrate how to combine both technologies to achieve high productivity while also providing high flexibility and ease of use.
Weldless Molding Technologies: In this seminar, Makino will demonstrate weldless molding capabilities only possible with new, cutting edge technologies and techniques.
Equipment ROI: Machining Cells and Management Systems: Learn about the advantages and features of the Makino Machining Complex(MMC2) palletized part-delivery system and Makino's Advanced System(MAS) cell controller software.
Buyer Beware: Are Specifications Really What They Seem?: When buying a machining center, you’re bombarded with specs. What do they really mean, and how do the inconsistent ways of measuring performance truly stack up? Makino's inMotion offers a review issues and tips for buying.
Economic Stimulus Package: In this video presentation Chris Lyle, Customer Finance Manager at Makino and Tony Schweier, a CPA of Clark, Shaefer, Hackett & Company discuss the Economic Stimulus Package 2008 Tax Bill, and how it relates to your business.
Error-Proofing Your Production Manufacturing Operation: Makino presents error-proofing your process to maximize throughput and speed up your entire operation. You learn how to eliminate common problems in production operations to make a more efficient, lower cost process, as part of the pursuit of zero defects.
3 Keys To Successful High Speed Machining: Steve Ortner, president of Absolute Machine Tools, studies the three major components necessary for successful High Speed Machining: Programming, Tooling and the Machine Tool itself. This presentation was filmed at the 2006 Mold Making Exposition.
The Benefits & Techniques Of Hard Milling With Ceramics: Ron Malone, applications engineer at Greenleaf Corporation, explores The Benefits & Techniques Of Hard Milling With Ceramics. This presentation was filmed at the 2006 Mold Making Exposition.
Advanced 3D Solutions For Manufacturing Engineers: PTC demonstrates the latest techniques and tecnology in production and multi-axis milling, moldmaking, machining, and sheetmetal programming. No matter what role you play in the manufacturing environment, you'll benefit by discovering today's best practices in Computer Aided Manufacturing.
High Energy Applied Technology (HEAT): Makino demonstrates how High Energy Applied Technology (HEAT) smokes the Wire EDM Competition in poor flushing conditions, cutting parts 35% to 50% faster while holding tolerances of form and straightness to 0.0002" with one roughing pass.
Solutions For Hard Milling: Makino demonstrates the latest techniques and technologies for high-speed machining of hardened materials for die or mold applications. Check out tips, tricks, and new technologies you can use to mill the toughest steels, shortening your lead times, lowering your costs, and eliminating bench work.
Innovative Fixturing: Makino demonstrates the latest techniques and technologies in fixturing. Check out presentations on fixture economics, fixture design, modular fixturing, new technology in CNC workholding as well as case studies of shops using innovative fixturing.