Machining HUGE 10 Ton Bevel Gear with CNC Milling Machine

Thanks to ATA Gears for letting us film this project www.atagears.fi/ The bevel gear is going to be used on giant steel rolling mill which makes steel slabs for shipyards

The scale of this is absolutely insane. Would love to see the whole mechanism this thing was built for

Next they ship it to a volcano for heat treating.

To see those initial cuts being made in time lapse really shows how the table has to start/move/stop 10 tons every cut ! That it does it so precisely is a testament to how robust the motors, screws, ways and frame of that machine are. Remarkable.

I buy bevel gears from ATA regularly. There is no gear company in the world which can match their quality and workmanship. Great to have an inside look at the factory.

Knowing my luck, id set the program running, come back in in the morning and realise id set the wrong program and the ring has been reduced to a M10 washer

Finally, the last part of my wrist watch is finished

It's wild that the big stuff I mostly saw in 5 years of studying Engineering(4 years of Basic Engineering, 1 year of a trade skill) before starting university was usually a ~200mm diameter gear and stuff like that. At the end of the third year though, I spent the mandatory 4 weeks at the local power plant. I was sent to the Turbine Maintenance area, they wanted to send me to the Lubrication dudes, but since each area needs two people I was sent to the maintenance area. The power plant was in the middle of the maintenance of the 4th turbine. Size 70 screws and nuts, a "small" plate for the turbine cover was like 50mm thick and roughly 1.5 meter in diameter. These are common sight for those guys working there, it was a really good experience. Though, the gap between the floor and the turbine itself wasn't fun, you could see into the basement from the 5th floor. Also we visited those basements frequently, walking around in 40+ °C heat around the pipes doing maintenance on pumps, didn't matter how much I tightened my helmet, it was slipping around from the sweat. Working on the pumps near the furnaces was also interesting, one end of the pillar you are sweating from the heat, the other side you are freezing from the crosswind in the tunnel. Atleast I got to see the inside of the massive desulphurizating machine in the middle of one of the cooling towers.

Titan of CNC: look I'm cutting 150 pounds of titanium BOOM Beyond the press : Hold my beer

I once carved a stick - into a pointed stick.

I lime these videos of culture or machines or businesses from Finland. You are voted the Happiest People on Earth. So I like learning about your country. Thank you Lady Anni and Gentleman Lori!

I think one of the most interesting aspects of machining on this scale is the ability to control the inertia moving these heavy pieces and maintain tolerances. Either incredibly powerful actuators and screw gears, or very complex calculations.

Love the large machining. Cool video. I started my career at a machine shop programming 2 large lathes. I used to threaten the sales team that if they don't sell anything, I would put their car between centers and turn it down to a baseball bat and hand it to them...because I could. Lol That was a sweet DMG-Mori. The last company that I used to work for bought a lot of Mori. Lathes (2 & 4 ax), Mills (3 & 4 ax), Mill-turns (15 of them). They make good machines and had a quality support team at the office that I dealt with. I programmed everything in the building (all brands) at the last place except cylindrical grinders.

This really grinds my gears

Wow, suggesting thumbs down if we don't like it so you know what content to make in the future... that was refreshing. Thumbs up!

Trelleborg, Sweden. måndag den 27 april 2020. To Michael Green who asked ” Is there a reason the no lubricant is used during this machining?”.   Hello Michael! Generally you have misunderstood. When you see machining and they spool a liquid on the workpiece and the tool it is not for lubricating. The purpose is cooling. The liquid you then see is practically water which is an efficient coolant. (Yes, there are exceptions. Depending on which metal that is machined one sometimes ned both cooling and lubricating. Then you may spool with vegetable oil, kerosene or even alcohol. Such exceptions the mechanical industry know.)  But water on steel create corrosion and that is not desirable. Therefore the water is mixed with special anticorrosive oils that mix with water. Approximately 3 to 5 % oil.     This workpiece and the machine is very stable. The edges in the tool cut away “thick” chips and the chip is heated and removes most of the heat from both tool and workpiece. ( “Thick” in this case is perhaps 0,2 to 0,6 mm.)  This workpiece is large and the tool is small so the piece is  probably only “handwarm”. The tool they call “millhead” at 2:18 minutes have yellow details. Those are the cutting edges and are made of “hard metal”. In the middle of each “plate” is a screw.  When the sharpness begins to be bad the plates are easy to change for new ones. More to read at www.secotools.com In the beginning of 1900 or perhaps 1940 the industry had developed HSS, High Speed Steel for cutting edges. Also heat resistant.  Hard metal increased the cutting capacity 10 to 20 times. Best regards / tomasgidlof.se

I enjoyed this a lot, thank you for all the work and thanks to ATA for being so accommodating. I'm all for machining videos whether they're big or small or anything else!

Show us the lathe that turned the piece at the beginning of the video. What kind of steel are they made out of. This was so cool! More please.

Lauri: "Is it better to be large or complicated?" ME: "Yes."

Lauri: "Is it better to be large or complicated?" Subscribers: "Yes."