New Machine Day

[YoDoug]

Scary story time. In our oldest M560, while we were waiting for a custom dual tip flycutter to be made, we were running the old school type boring bar fly cutter. It was a 1.0 diameter, 10 inch long boring bar with three set screws holding it in. The operator fat fingered 12K rpms instead of 1200. When the boring bar let go it went through the ATC door, through the side sheet metal of the machine, and through the sheet metal of the machine next to it. We found the boring bar in the chip conveyor of the machine next to it. I just happened to be standing in front of the machine that got hit at the time. It sounded like a bomb went off. We showed Okuma the aftermath and they added the option to specify max RPMS for each tool in the tool setup page. This option is in all of our vertical mills now.

[Newbeeee™]

I get it and I was (kind of) joking about disabling the safety interlocks. That being said, every new machine has become a bigger PIA to set up and program than the last because of "safety" features, whether they are mechanical or programmed into the control.

Look, I'm a professional who's been doing this shit for more than 30 years. If I want to program the machine to break endmills in half and fire them at the operator in rapid succession, I want the ability to do that, and I will deal with the consequences. I honestly don't give a shit about some inexperienced dipshit in his garage who watched Titans of CNC (or some other bullshit) who gets hurt making "billet" parts for his Harley.

And don't even get me started on the term "maker" or "maker space." It's a goddamn shop, motherfucker, so get out of my way so I can get to work.

You write that like you're 20 something....

[Newbeeee™]

Get used to running machines with the door closed. Resistance if futile. Insurance Companies rule the world now.

This x 10000
 

[JakeL]

Scary story time. In our oldest M560, while we were waiting for a custom dual tip flycutter to be made, we were running the old school type boring bar fly cutter. It was a 1.0 diameter, 10 inch long boring bar with three set screws holding it in. The operator fat fingered 12K rpms instead of 1200. When the boring bar let go it went through the ATC door, through the side sheet metal of the machine, and through the sheet metal of the machine next to it. We found the boring bar in the chip conveyor of the machine next to it. I just happened to be standing in front of the machine that got hit at the time. It sounded like a bomb went off. We showed Okuma the aftermath and they added the option to specify max RPMS for each tool in the tool setup page. This option is in all of our vertical mills now.

Not nearly as scary, but when I first got moved onto one of our Okuma MA-600HIII, the door interlock was bypassed. About a month later, I had a 5/8 reamer sticking out 18 inches in the spindle... and I accidentally started the spindle to 8k RPM. In about half a second I watched the reamer bend until it hit the ATC door, broke off, and shot at the operator door. Because of the bypassed door interlock the door could have been wide open, luckily it was shut. That afternoon the door interlock was put back on the machine.

[beej]

Not nearly as scary, but when I first got moved onto one of our Okuma MA-600HIII, the door interlock was bypassed. About a month later, I had a 5/8 reamer sticking out 18 inches in the spindle... and I accidentally started the spindle to 8k RPM. In about half a second I watched the reamer bend until it hit the ATC door, broke off, and shot at the operator door. Because of the bypassed door interlock the door could have been wide open, luckily it was shut. That afternoon the door interlock was put back on the machine.

great! you ruined it for everybody! 

[DUM1]

 This option is in all of our vertical mills now.
[/quote]
scary shit ! almost got me a coulle times I tell the programmers the max rpm and they kinda forget sometimes
I do that on all the weird tools in our okumas too probably saved a machine or 2

[Newbeeee™]

Talking Fanuc....we had 4x chevaliers, previously 2x robodrills and 1x Leadwell, and none did this....but new Feelers with 15k spindle came in and in MDI i had run the spindle at 1000 for a edge finder, handwheel and all ok.
Phone went...got back to machine, still in handwheel hit the spindle start CW button, THINKING it would run at 1000 as that's what I'd just had running....Nope, straight up to 15K in 1/2 a second before it shattered into many pieces.
So that was a parameter to change as the CW / CCW button was defaulting to last programmed speed....and good job door was closed

[CNCAppsJames]

We run the machine with the door closed. the problem is that now they are requiring the door to be closed during setup. We haven't had to use an indicator to pickup a part yet, but I honestly am not sure how we will do that. But it is still required a lot of times in our business. we use a probe on everything we can because it's faster, but you can't do that 100% of the time.

I've not encountered a machine yet that cannot handle jog with the door open. Maybe there's been an obnoxious dead-man switch. You're telling me the machine cannot move at all manually with the door open?

[CNCAppsJames]

I had to testify as an SME in a court case BITD. It was a fatality. A lathe... running with the door open. 2" diameter x 12" -ish steel bar hanging on .250"-ish. Guy didn't set spindle MAX RPM... end facing... and you KNOW Elvis left the building. 

The pictures were horrific. He didn't die instantly... I'll bet he wished he would have. Died on the way to the hospital IIRC.

Broke my heart looking at the widow and kids having to explain this was 100% his fault.

I have no idea what the outcome of the trial was.

This is a dangerous arena we play in ladies and gentlemen. We can die even if WE do everything right, there's still the turd next to us that doesn't give a shit. Use all the tools you can to go home to your loved ones.

[mkd]

Scary story time. In our oldest M560, while we were waiting for a custom dual tip flycutter to be made, we were running the old school type boring bar fly cutter. It was a 1.0 diameter, 10 inch long boring bar with three set screws holding it in. The operator fat fingered 12K rpms instead of 1200. When the boring bar let go it went through the ATC door, through the side sheet metal of the machine, and through the sheet metal of the machine next to it. We found the boring bar in the chip conveyor of the machine next to it. I just happened to be standing in front of the machine that got hit at the time. It sounded like a bomb went off. We showed Okuma the aftermath and they added the option to specify max RPMS for each tool in the tool setup page. This option is in all of our vertical mills now.

I did that to my personal Haimer 3D probe. Like an idiot, forgot to put in the max speed in heidenhains tool table. Went to measure in the laser... Needs to spin...for that☠️

[CNCAppsJames]

Matsuuras have a max RPM for tools as well. Only works when you use it.

Customer in SoCal ... strike 1 ...left their Lang chip fan in the spindle and turned off the machine, strike 2.... failed to set max RPM for the tool..  strike 3 failed to leave the machine in a safe condition for auto power-on and auto warmup.

They had the machine set to turn on automatically and run the spindle warmup... a 20k spindle.  Thing came apart, broke the rotary wiper... blamed us for it. Sales asked my opinion. I said 99% their fault. We could have put a T0M6 in the warmup cycle.

They broke all the rules, and we ended up paying. It's a long time Customer. Their MAM72-35V was the 3rd MAM I ever put my hands on in 2007.

[YoDoug]

I've not encountered a machine yet that cannot handle jog with the door open. Maybe there's been an obnoxious dead-man switch. You're telling me the machine cannot move at all manually with the door open?

We have a P500 Multus with the CE spec control. You can move the machine in both jog and handwheel with the door open. There is a dead-man switch for handwheel and for jog there is another button on the control you must hold for it to jog. 

[CNCAppsJames]

We have a P500 Multus with the CE spec control. You can move the machine in both jog and handwheel with the door open. There is a dead-man switch for handwheel and for jog there is another button on the control you must hold for it to jog. 

I need to do a better job of explaining differentiation between "Jog" and "Hand wheel" as they are two distinctly different features/functions. "Jog" is when the machine feeds, and handwheel is when the user feeds.

I never use "Jog". I'm always driving other people's Ferraris... manual all the way for me... no cruise control.

[Newbeeee™]

I never use "Jog". I'm always driving other people's Ferraris... manual all the way for me... no cruise control.

+1. I only ever used handwheel.
I've seen it many times where someone jogs a machine and they jump....either the rapid was unexpectedly high or they almost crashed it.
I've also seen the handwheel used where (old Business partner) would spin the wheel so fast the wheel would stop but the machine would briefly continue (catching up). That caused him to shit himself once....

 

[mkd]

Jog buttons on Okuma lathes must be the best in the industry. Very easy to use and not screw up going the wrong way.
Ymmv