That thing is just showing off....how awesome it is! *promote

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I know absolutely nothing about CADCAM, but it just seems like that is a huge waste of metal when you think about how big the original hunk of metal was compared to the finished product. or can all that excess metal be re-smelted into another block?

*music

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they have a process known in the industry as recycling

That is just ridiculous! Love the show piece with all the different cuts. Very impressive!

In general, yes, it is quite wasteful. In theory, 3D printing is a much more efficient way to achieve complex shapes.

However, there are some applications which aren't suitable for 3D printing yet. It certainly won't have the same physical stability, etc as a milled piece of solid metal.

I think this one is even more impressive
*related=http://videosift.com/video/Bike-Fun-Machine-makes-a-helmet

Bike-Fun: Machine makes a helmet. has been added as a related post - related requested by ChaosEngine.

I knew

Aluminium is one of the easiest materials to recycle. Although I'd say molding most of the shape and "cleaning" up the piece would be less wasteful of cutting edges and power...

At least its good to know that SkyNet finally got a job after that whole Judgement Day thing didn't work out.

I'm surprised there is no cutting fluid being sprayed on it. Most all the multi-axis CNC machines I've seen (not many, admittedly--not my department), required a pretty constant flow of oil. Is this some advancement in cutting tool technology, or is it just that aluminum is soft enough not to need it?

I understand NASA has used 3D printing to create fuel injectors (or something like that) for rocket engines with considerable success. Since it's a solid metal shape with lots of vacant internal channels, there would otherwise have to be a lot of design and construction concessions if it's going to be cut or forged. I suspect that sort of 3D printing will be quite revolutionary for manufacturing once it doesn't cost stupid amounts of money.

What I find fascinating is how much thought and programming-fu that went on before the mill was even turned on. To break that complex operation down into a sequence and then write the code for it is mind blowing

Alluminium is a soft metal, doesnt really need an emulsion to assist the cutting edges (as they are far far harder than alluminium is).

If this were a steel casting, yeah it'd need cutting fluid.

That's some fiiiiiine engineering porn right there...

I work in a CNC machine shop programming lathes. That isn't aluminum they are machining. It's definitely steel, probably 4340.

Carbide inserts are more than capable of cutting metal without coolant. Well formed chips absorb and carry most of the heat away. You start to run into problems with gummy materials (like aluminum) that form a built up edge on the cutter. In this case high pressure coolant can be used to help break the long stringy chips and keep them from sticking to the insert.

One case where using coolant can be detrimental to tool life is when machining a part with an interrupted cut. Think of sliding your finger over a surface with a bunch of holes in it. Your finger switches back and forth between making contact with the surface and gliding over empty space. In the machining world, this motion would cause abrupt transient temperature changes, and coolant can sometimes exacerbate the problem and cause the carbide insert to crack or chip.

(pedantry) I would hesitate to call that machine a mill. You can see the machine switching freely between rotating the part to provide the cutting force (turning) to rotating the tool (milling). It's more akin to a horizontal turning center with a milling spindle built in as well. Pretty awesome stuff! (/pedantry)

In the description it's called "Токарно-фрезерный станок" (Turning and milling machine) with 12 position револьверной головкой ("tool turret?") in addition to the turning-milling spindle. Google translate may have mangled that somewhat, but to me it read quite a bit like your description.

Dat precision! Rule 34! Rule 34!

A lot less wasteful, yeah, but there's quite a big difference in the structural integrity of cast and machined parts, so for many applications casting is just not an option.

Still, recycling and whatnot.

What about forging and then machining then?

"They just finished you mom's new butt plug!"