Solving Complex Problems to Machine a Monster Blisk

[00:00:00]In this video, we're going to be taking a 700 lb piece of 4140 and we're going to process it in our brand new TreeMill VS1614.

[00:00:09]All right, the first tool we're using today is the Harvey 2TE. We're going to make a little 5-in circle that's just enough for our feed mill to plunge into and start working its way out. Now, the part that we're going to be making is 27 in in diameter and 5 in thick. And if you take a look at my screen here, you'll see the big blisk that we're getting ready to make. Now, for our first operations, we need to do a prep op so that we're able to get it on this fixture. Now, this fixture is going to be used for our second and our third operation. But for our first op, we're just going to toe clamp our stock to the table. So, in this configuration, we have a Peron HSK 100 spindle connection.

[00:00:43]And that's one of the most rigid spindle connections on the market. We got plenty of power. So, for continuous, we have 38 kW or 51 horsepower. For maximum, we have 44 kW or 59 horsepower. We also have plenty of torque available. So for continuous we have 302 new m or 222 ft-lb and for maximum we have 352 new m or 259 ft-lb. Then we also have 15,000 RPM. Now the table on this machine is also pretty impressive. Now we're holding a tiny little 700 lb part and this table can hold up to 6,000 lb. Now that's pretty impressive when you consider this is a five-axis mill. The table can swing 90° toward me or 90° away. So all of that weight is just hanging out there in space while we're machining. In addition, we have the new Hiden 9 TNC7 control. Now, this is a pretty powerful control. It's pretty userfriendly, and you can see my favorite part. I'm running it in dark mode. Now, the reason I chose that tool is because it's got great ramping capability and really good stepover capability. This is the tool you see us full slot with a lot. Now, you see our high feed mill. I didn't want to plunge straight into material with this and I didn't want to do a ramp because it was going to have to be a pretty wide diameter circle to make a ramp without the material getting wedged in the ID of our cutter. We're running it 60 thou deep at 350 in a minute. And that's cruising for a high feed mill with that big of a diameter. All right, here comes the high feed mill of doom. I haven't used this bad boy in a while.

[00:02:10]Yes.

[00:02:28]Now, if you look at my screen, you'll see we're leaving a cusp right there.

[00:02:31]That doesn't really bother me because we're going to come in and do a semi-finish pass with the Harvey 2TE endmill after this. The reason that we're using the Harvey 2TE to do the finishing is because I want to make sure that we have a very flat surface, or at least as flat as possible. By using an endmill, it's almost like hand scraping.

[00:02:47]And we're going to get a lot more surface contact when we flip this over on our Bos modules. Oh, it's like butter. Not even any steel there.

[00:02:58]Yes.

[00:03:02]60 horsepower and 260 foot-lbs of torque in full effect of fat.

[00:03:12]And just think, this is the smallest machine the TreeMill makes.

[00:03:25]350 in a minute of metal brutality.

[00:03:30]This This is it. This is what I love.

[00:03:33]All right, so now that we roughed away the majority of the material here, now it's time for us to come back in with the Harvey 2TE and get the angle corners that the high feed mill didn't get and give our floor a nicer finish. Now, everything that we're doing in this operation, I'm leaving about 100 thou stock. And that's because I don't need anything on this face to be finished.

[00:03:51]All I need is to be able to clamp this part on the VO s need a flat surface and the four counterboard holes. Now, even though big machines are a lot more fun, they're also a lot scarier. So, for our second operation, we're going to put this thing like 10 in up in the air on our VO s base. And when this table kicks 90, I'm really hoping that I remember to lock the V system and the part doesn't just go clunk into the bottom of the machine. Even though our viewers, I'm sure, would love to see that. I wouldn't.

[00:04:23]You ought to start making some pockets and some big blue chips again. Now we come to our 1-in go tip drill from Kenn of Metal. This thing is going to just pop a few holes, and these will be starter holes for our Harvey 2TE to come in and cut our pockets. What we're doing is really hoping that our post processor is set up correctly, and that this drill is going to drill a hole and then come back out before it rapids over and does another one. So, here we go.

[00:04:57]Ow.

[00:05:01]Go tip. Go.

[00:05:15]Yes.

[00:05:18]Success. All right. All right. Now, it's time to bring our 3/4 endmill back in, and we're going to make eight of out of our 12 pockets.

[00:05:25]Is that correct? Yes. 12. Now, the reason I'm putting these pockets in in the first operation is just because I want to kind of lighten this stock a little bit. We're going to be pretty far up off of our table, and this part weighs 700 lb before we start taking away all the material. When you have your B-axis flipping around, you want to make sure that you consider the centrifugal force that's going to be involved there because we don't want this part flying off the table and through [music] the doors onto my feet.

[00:05:57]Now, this machine is built like a tank.

[00:06:00]If you take a look at the way that that spindle's sticking out right now, it's like 5 ft long. But what they did is they put a linear guide on all four corners of the spindle. that way. Like with a traditional bridge mill, you only have two and your spindle's able to flex. Well, with this one, you're kind of boxed in, so it's super rigid. And that's why these cuts sound so great.

[00:06:32]So, we got our pockets to full depth.

[00:06:33]And now we're coming in with the same tool and just stepping up above the radius that's in the bottom of the pocket.

[00:06:44]All right. Now, we're going to rough in our pull stud holes.

[00:06:54]And then we're going to use a 1/2 in go pro with a square corner to come in and finish those counterboard holes.

[00:07:06]All right, time to drill our holes so that we can mount our pull studs to our part. We're going to bring in our go drill. It's a 312 diameter. And we're going to drill the holes for the bolt that goes through the pull stud.

[00:07:21]All right, for our threads, I chose to use a single point thread mill because we have the reach that we need to get at least an inch deep. I could have used a multiiform, but usually they only go up to three times D. And I wanted to go a full inch and a quarter deep with our threads.

[00:07:37]All right. Now, all we got to do is cut around our ID there and debur our holes and pockets. And that's a wrap. Let's go.

[00:07:50]All right. So, this operation of the part is complete. Now, nothing on here is finished yet. We still got like a 100 thou stock left everywhere. Where the four pull stud holes are, we're going to end up having pockets, but we're saving that for the third operation. As for the pockets that we put in, we still have over 100,000 stock left on each of those as well. So, our next part of this is we're going to get this out of here, put our fixture in, get it cut, then we're going to throw this bad boy onto the fixture, and we're going to start making a super sick part. So, stay tuned.

[00:08:42]You're not going to want to miss this.

[00:08:45]When we're running big tools and big machines and we're running through spindle air, we depend on Kazer compressors. They're super dependable, scalable, and they handle all of our compressed air needs. If you're in the market for a highquality machine just like this one, you can contact Keith at titansofcnc.com. He can answer all of your questions. And if you're looking to learn CAD, CAM, or CNC, while you're on our website, visit our academy. We have over 700,000 students currently enrolled, and it's 100% free.

[00:09:13]Hey, if you haven't already, make sure you check out our app, MFG Connect. It's on Apple and Android. It's pretty sweet.

[00:09:19]You can upload your projects, show off cool tool paths, and connect with other machinists like me and Barry. You can show off your work, upload your projects. I hope to see you there.