Appreciation of Engineering Tolerances
- Cav
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Appreciation of Engineering Tolerances
This is an Engineer's wet dream... [video]https://youtu.be/ULEJatGhcks[/video]
- Kwacky
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- Cav
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Re: Appreciation of Engineering Tolerances
Yeah but that will only get you to within about 30 microns, a great deal of time was taken to do these and you're talking less than 1000th of a micron to achieve this
- Kwacky
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- Cav
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Re: Appreciation of Engineering Tolerances
A large part will be high precision toolsetting (setting the tool length and diameter of a ball-nose cutter) and a lot of in-cycle gauging.
In-cycle gauging is used to prevent the removal of the part from the machine as you will never return it to the exact same position. It isn't typically used this way, but it can be used to measure the part after each cut, accurate to within 2 microns typically. A scanning probe was probably used to record form in a layer-by-layer strategy and then somehow used to adapt the program parameters OR the tool offsets.
I'm guessing it's a combination of these and probably more - it's not something I can do that's for sure !!
In-cycle gauging is used to prevent the removal of the part from the machine as you will never return it to the exact same position. It isn't typically used this way, but it can be used to measure the part after each cut, accurate to within 2 microns typically. A scanning probe was probably used to record form in a layer-by-layer strategy and then somehow used to adapt the program parameters OR the tool offsets.
I'm guessing it's a combination of these and probably more - it's not something I can do that's for sure !!
- Cav
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Re: Appreciation of Engineering Tolerances
Something else they can do is calibrate the machine bed and all it's axis (pretty sure this would be with a 5-axis machine). This would require high end software and strain gauge equipment used in conjunction with a high precision datum ball.
Essentially, they would calibrate it for the working volume of the parts in question and ignore any errors outside of this envelope.
Essentially, they would calibrate it for the working volume of the parts in question and ignore any errors outside of this envelope.
- Deegee
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Re: Appreciation of Engineering Tolerances
That is some very special engineering ability being demonstrated there, they can't leave those parts together for long, the clearances are so low that they can fuse together overnight, becoming one solid piece of metal, I've only ever seen that level of accuracy in Slip Gauges before, which are expensive to buy and generally only found in tool rooms and standards rooms in engineering companies.
P.S. Thanks for posting Cav, I love that!
P.S. Thanks for posting Cav, I love that!
- Cav
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Re: Appreciation of Engineering Tolerances
Exactly, DeeGee. Kept together they would fuse, however, kept apart and they will degrade. To keep any life in these parts they will have to be carefully stored and handled infrequently to avoid any oxide or nitride layers forming and changing the profile and/or dimensions.
Extremely satisfying to watch!
Extremely satisfying to watch!
- D41
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Re: Appreciation of Engineering Tolerances
Seemless. I had no idea that tolerances that fine were possible.
- kiwikrasher
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Re: Appreciation of Engineering Tolerances
I used to overhaul Skyhawk hydraulic pumps which had a metal to metal dynamic seal between the valve plate and piston barrel that handled up to 4500 psi (test pressure, operating pressure was 3000 psi) I had to lap them to 3 helium light bands which is about 0.9 microns. I thought that was high tolerance but that vid is next level!!
Happiness is not a destination. It is a way of life.
- Cav
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Re: Appreciation of Engineering Tolerances
What do you estimate those tolerances as, Kiwi?
My gut it saying about 0.1 of a micron (100 nano meters for everyone else)
I also don't know how they would lap the curved surfaces but it looks way too good to possibly have been machined.
SO MANY QUESTIONS!!
My gut it saying about 0.1 of a micron (100 nano meters for everyone else)
I also don't know how they would lap the curved surfaces but it looks way too good to possibly have been machined.
SO MANY QUESTIONS!!
- kiwikrasher
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Re: Appreciation of Engineering Tolerances
I wouldn’t have a clue to be honest. I even did some googling to find an answer and had not luckCav wrote:What do you estimate those tolerances as, Kiwi?
My gut it saying about 0.1 of a micron (100 nano meters for everyone else)
I also don't know how they would lap the curved surfaces but it looks way too good to possibly have been machined.
SO MANY QUESTIONS!!
Happiness is not a destination. It is a way of life.
- Monty
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Re: Appreciation of Engineering Tolerances
Loved that Cav, it's almost down to atoms!
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- Rossgo
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Re: Appreciation of Engineering Tolerances
I want one. That is extremely satisfying
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- D41
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Re: Appreciation of Engineering Tolerances
Skyhawk is a bad-ass jet!kiwikrasher wrote:I used to overhaul Skyhawk hydraulic pumps
"Hey..Viper is up here...oh sh!t!!"