300 HP milling cut

Watch the video, 24" dia cutter, 18" wide, .75" DOC, etc.
http://www.mmsonline.com/articles/0105ex1.html
JR

I ran this machine a few times before Ingersoll changed hands. The company that bought it is a tool steel foundry in Pa. Our test ingots were either d-2 or 4140. Cutting at 300 hp the inserts didn't last very long. Chips came off orange and if they stayed on the table under the rail, the oil in the return trough could catch fire. Finally Ingersoll had to change the type of oil used for the hydrostatic ways.
Cat 60 taper tool and a right angle attachment to go along.

Nice. Basically porn for metalworkers.

Watch carefully at the end of the cut, and
you can see the broom being used to clear the
chips ignite a couple of times, on the left
hand side of the cutter, behind it.

Jim

I want one.......will that fit on a bridgeport?

Nick

wow and i thought i was realy removing metal when i had that 10 inch dia carbide cutter mounted on the spindle of my horizontal mill, but the way my garage is i had a great fear of fire from a hot chip in the clutter so i backed off on the cuts after a few close calls. and then later i managed to have a hunk of slag wipe out a whole bunch of the odd, ground in place, carbide inserts so i dont have it anymore, but i had only paid $1.50 for it it did alot of cutting before that on my 5 hp cincinatti. that cutter actualy would make the machine bog down a little, something no cutter i ever had in the horizontal spindle did, heck the time i got stupid with a large hole saw and twisted the tangs off a morse taper holer the machine didnt even change tone just all the sudden the hole saw stopped turning!

HOLY MOLY BATMAN!
BANG, ZONK , WHAP
I want one!
DOug

Nice. Never mind the machine, the weight in chips they cut off probably costs more than I make in a month. I loved the shot of the smoldering chips. I didn't see any coolant there, I am assuming that was done dry? Was that just for the demo? In production why would they not use a flood collant system of biblical size?

Let's see, what size VFD would I need to run one of these? Now, assuming I'll need to downrate the VFD to run off single phase...what size cables will I need to run into my garage?

300 lb of chips a minute? Here's where a big apprentice with 24" biceps and a size 5 hat comes in handy with his shovel. On this machine a chip converyor is a must.

When I was 22 years old apprentice and my chest was still above my belt it was all I could do to keep ahead of a 50 HP machine working full time shoveling and hauling chips. We had 24" concrete carts we hauled them in and when full of 6's and 9's the tires woud squash almost flat and the heat would blister the paint.

This Ingersol must have had a real ship conveyor something like the track drive for a tank.

Scalped ingots and consinuous casting are reasons fine steels are so expensive. It costs a bunch of money to full anneal a 20 ton ingot, machine off 10% of the weight to clean metal, then re-heat it and roll it to merchant stock. But the metal is certianly clean and fine. It's been many years since I've run into included scale or pipes machining plate or bar stock.

I recall Jack Neimi once machined a big flat steel plate on a floor mill cutting many pockets in it for sonar transducers. The material was behaving strangely (it didn't bong or clang normally when suspended from the crane and knocked with the plate clap wrench) but Jack went on anyway to discover a large blister in the metal like a de-lamination in cheap plywood. It was lined with scale and later exploration revealed it to be about 3 ft x 4 ft shaped like West Virginia.

Apparently the ingot from which the plate was rolled was cropped too tall and it included a hunk of the "pipe" - that portion in the top center that feeds the lower part of the ingot with liquid metal as it solidifies from outside in after pouring.

This episode caused every piece of plate from that manufacturer in the system to be inspected. Huge plate fiasco of 1968.

At my real job we have two Ingersoll horizontal bed millers 100 hp spindles. Typical cut with 16 inch cutter was 750" deep 16 ipm 12" wide, rpm about 90. Facing and matching ends on die blocks that weighed anywhere from 1 to 100 tons. Chips would fall down into a conveyor that was usually filled with oil and we would have several fires a day. Worse part was that the operators platform was directly above the conveyor. After facing and matching we would cut the shank which is 2" deep and 8" wide, using a 7" cutter with inserts that are 2" long (Greenleaf). First cut is 1.900" deep about 4 to 6 ipm. Chips so hot you could almost see through them.
I hated that job because all that cutting was done without coolant. My employer is not too smart about coolant, they would prefer not to use it, $$$$. The job was so dirty with all kinds of stuff floating around in the air, due to the heat of the cut, you had to wear a filter mask to run the job, it sucked to say the least. In that video they are not using coolant either but that was probably for clarity during the taping of said video, I hope.

There is no coolant on this machine. The inserts are hot enough that if they were hit with coolant they would shatter. The cuts were heavy enough that you really couldn't get enough fluid to do any good. Removing chips meant pushing them off the table into large holes in the floor next to the columns. The conveyors were 4 feet wide chains that lifted chips directly up into rail cars for return to the furnaces at the other end of the facility. Chips came off about six inches long curls. It was fun to run for a little while, then it was just like any job shop- make chips, move the part, set up another one make more chips. Ingots were held on the table by magnets and side crowders.

WOW - Watched the video. What can I say. Brute American horsepower at work.

Reviving a long dead (but oh so worth it) post:
Unfortunately the link is dead.
Does anybody have another link to this vid?
I love watching it, and showing it to the unbelievers.

Thanks,

Doug.

doug925 said:

Reviving a long dead (but oh so worth it) post:
Unfortunately the link is dead.
Does anybody have another link to this vid?
I love watching it, and showing it to the unbelievers.

Thanks,

Doug.

Click to expand...

I have it saved on my hard drive somewhere... But it is on youtube I think...

can't seem to find that, and I'd really like to see it.
anybody got a link ?

In for link

YouTube - Heavy Cutting on Machining Centre

Here is another question-Whiuch is faster, milling plate on a beast of a machine like this or grinding it on a high horsepower grinder?? Our largest grinder now is 250 h.p. and my new one will be 300 or 350.

With the grinder I put the plate on the table, turn the magnet on and start grinding. At the end of the cycle wash the table down and my filtration system does all the work.

On a mill like this, unless you have it set up with magnets, there is alot of fixture work top do. Then after every part start shoveling the chips you did not get as the machine was running.

I see alot of spindle downtime here.

No doubt this machine is pretty darn amazing.

My thanks to Finegrain!
I did not see it on you tube on my search.
Thanks for the link!

Cash - do you have a video of that operation? I'd love to see it.