Friday Morning LOL's

[gcode]

We are doing an Inconel job that requires some pretty heavy roughing
squaring up 14" round bar stock
The bosses are very unhappy with the cycle times.
Early this week they called me to a meeting, showed me this video

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and ordered me to replicate it on our part
I tried to explain that the 80's vintage HBM we were using did not have sufficient torque but my warning
fell on deaf ears.
We programmed the roughing op with a 6" Sandvik button cutter taking full width  .080" deep cuts
The part was round so the first couple of passes ran really well
Each cut got wider and wider. At 3.5" width of cut the spindle stalled, the machine blew a fuse
and it's  currently DOA. I had to walk away before I said something stupid.  :p

[Shazam/TPP]

are "they" taking responsibility or walked away pointing the finger at you? hmmm let me guess.....

[DUM1]

the shit never stops , I saw it on you tube , its gotta be true !
few years back my supervisor made a program and I wouldn't run it , I told him it would explode , and that i cant blow op a machine , so he pushed the button .... it exploded , he went on vacation while we waited for the $50,000 spindle replacement and the three weeks of down time , meanwhile I kept getting asked is it done yet every five minutes .

2" 3 flute face mill spinning 10,000 rpm 1" deep in 2" hole 120"fpm full radial cut lasted 1 second ,
ceramic bearings boom boom face mill little pieces


feel you pain G

edit the face mill was 10 "' extension holder

[YoDoug]

I worked at a place like that. The boss would walk by a machine and see the machine roughing, he would then instruct the machinist to stop running it and send it back to programming because the load meter was not running high enough. I would reprogram, send back out to the machinist. He would run it. It would stall out the spindle or blow out the tool. Then he would edit the cut depths manually to make it work. All this would add hours or even sometimes days to get a finished part. The real kicker is that often the changes to the program would only save 30-60 minutes on the couple parts that need to run. We would spend more time effing around than we would save from the proposed increased cuts. They were really stuck in their ways and about the most stubborn place I ever worked at. They would insist that small (5-15lb stock) steel parts needed to be run 25 year old 50 taper machines. The whole process from eng-prog-setup-production-quality took forever. If one of the Haas mills was open I would just do it myself. Several times the boss would come to harass me about when the program was going to be released for setup, I would tell him it's already in inspection. Then he would say I wasted time running it in a Haas. I would show him cycle times that were achieved by running HSM toolpaths. Then he would say I was abusing the machines, versus routinely stalling out the spindle in an old machine. I quit that job in 8 months. When I started they had 2 locations and 10 brand new machines. Today, one location was permanently closed and all those new machines were auctioned off, skeleton crew and barely in business. It was sad to see the second generation drive the business into the ground.

[gcode]

2" 3 flute face mill spinning 10,000 rpm 1" deep in 2" hole 120"fpm full radial cut lasted 1 second ,
ceramic bearings boom boom face mill little pieces

That's crazy.. people can get killed doing stuff like that

[gcode]

The boss would walk by a machine and see the machine roughing, he would then instruct the machinist to stop running it and send it back to programming because the load meter was not running high enough.

I prefer a reliable cut over a maxed out spindle.
The maxed out spindle approach usually ends up taking more time because the machinist is stopping to change inserts more often.
Another danger of too hot programs.
Machinist #1 proves it out running at 60 or 70% and doesn't tell anyone
The next time the job runs, Machinist #2 runs the "proven" file at 100% and bad things happen.

[Jon@NOWHERE]

The boss would walk by a machine and see the machine roughing, he would then instruct the machinist to stop running it and send it back to programming because the load meter was not running high enough.

I prefer a reliable cut over a maxed out spindle.
The maxed out spindle approach usually ends up taking more time because the machinist is stopping to change inserts more often.
Another danger of too hot programs.
Machinist #1 proves it out running at 60 or 70% and doesn't tell anyone
The next time the job runs, Machinist #2 runs the "proven" file at 100% and bad things happen.

I have always told our setup guys they need to run my program at 100% cause if there is an issue I need to know about it so I can fix it.

[beej]

there are perpetual motion machines all over Youtube.  the bosses should get some of those too.

[YoDoug]

The boss would walk by a machine and see the machine roughing, he would then instruct the machinist to stop running it and send it back to programming because the load meter was not running high enough.

I prefer a reliable cut over a maxed out spindle.
The maxed out spindle approach usually ends up taking more time because the machinist is stopping to change inserts more often.
Another danger of too hot programs.
Machinist #1 proves it out running at 60 or 70% and doesn't tell anyone
The next time the job runs, Machinist #2 runs the "proven" file at 100% and bad things happen.

I have always believed you make a good part first, then a reliable process, then work on speed. If you go into it trying to break speed records you sacrifice the first two. Here we run 10 machines for up to 16hrs a night with unattended automation. A reliable process is about the most important thing for us.

[neurosis]

The bosses are very unhappy with the cycle times.
Early this week they called me to a meeting, showed me this video

Some times I feel lucky that my boss spent 20 years in the shop (I was his boss for those 20 years until he inherited the shop) before taking it over.  

[CNCAppsJames]

The boss would walk by a machine and see the machine roughing, he would then instruct the machinist to stop running it and send it back to programming because the load meter was not running high enough.

I prefer a reliable cut over a maxed out spindle.
The maxed out spindle approach usually ends up taking more time because the machinist is stopping to change inserts more often.
Another danger of too hot programs.
Machinist #1 proves it out running at 60 or 70% and doesn't tell anyone
The next time the job runs, Machinist #2 runs the "proven" file at 100% and bad things happen.

I have always believed you make a good part first, then a reliable process, then work on speed. If you go into it trying to break speed records you sacrifice the first two. Here we run 10 machines for up to 16hrs a night with unattended automation. [size=200]A reliable process is about the most important thing[/size] for us.

A reliable process is THE most important thing period. At least IMNSHO.

[Jeff]

I have always believed you make a good part first, then a reliable process, then work on speed.

That's always been my logic as well. Being in a job shop I have to get the parts ran NOW because everything is hot and the customer needs it yesterday. It never ends.
But luckily most of our work is repeat jobs, that's when I work on reducing cycle times.

[crazy^millman]

Not your shop where tools can be 4" longer than called out on 5 Axis head going inside of part and crash the back of a head into the part and it is bad programming. They are more reasonable that that.              

I think they watched the Titan Video where in 10 days of using Fusion you to can be a full 5 Axis programmer.

Maybe they watched the sales add where even a 6 year old can program anything and everything in Mastercam error free and never make mistake and get 400 hours program done in mere minutes.        

[neurosis]

I think they watched the Titan Video where in 10 days of using Fusion you to can be a full 5 Axis programmer.

I'm almost embarrassed to admit this.  lol.

We were running a Ti job a few years back.  We took one of our Kennametal face mills and used the Speeds and feeds off on one of the Titan videos.  We were getting crap insert life.  I called the Kennemetal guys in to see if we could get this figured out.  The first thing out of his mouth was "you've been watching titan videos, haven't you?".  LOL.  Their suggestions was to stop watching them.

[DUM1]

That's crazy.. people can get killed doing stuff like that

THATS WHAT I WAS THINKING !
When he pushed the button after arguing with me for a half an hour , I was cowering behind him with my hands over my ears , over to the side a bit.
It was seriously scary and it also broke the safety glass  . should have seen his face .
needles to say I didn't get a raise for three years , till I got a new supervisor.
Ever have one of those supervisors that takes a part you programmed, setup and made take it to a meeting and say look what he did ?
ya , he was one of those guys. :bird: