Impossible? Internal Twisted Square Corners

As machinists, we're always looking for ways to push what's possible. We've machined parts people said couldn't be made. We've found ways to do things people said were impossible to do. We're taking that a step further. This part we're making isn't necessarily practical. It's about thinking outside the box and finding new ways to make it happen. This part wouldn't be possible to make without a 5-axis CNC. So we'll be making this part on our YCM-CX4 to see just how far we can push it. So earlier this year, we made this part. And this part is just basically showing how we did different styles of corner release. And we have regular corners, relieved corners, milled corners. And then we showed you how to make these square corners in this box. So when we machined these square corners last time, that was hard enough as it is. But this time, we're going to take it to the next level. And we're going to be machining these same square corners, but this time with a little bit of a twist. Now, originally, what we were doing was we were using a traditional dynamic toolpath to approach from the top and do all this roughing on the outside. That didn't work out so well. So that's why we ended up going with that 5-axis toolpath, which removed the material a lot faster. And it was able to remove some operations as well. So overall, it ended up being really good. After that, we're using our 1-3-8 drill from Kenna Metal to go ahead and drill out five holes, one in the center and four chain drills on the sides. So as you can see, we're using our high-pressure cooling system from Hennig to be able to just blast those chips immediately out of that pocket. If we didn't have a high-pressure cooling system like this, we wouldn't be able to drill those holes nearly as fast. We'd end up having to peck it, get all the material out, make sure everything's clear. But thankfully, we have that high-pressure cooling that can just immediately evacuate all those chips and keep our drill going all the way down to the bottom without stopping. And then we'll go ahead and mill the inside. And then we will go ahead and finish the outside before we go back with our ball end mill to finish the inside. And then we swap to another tapering mill to finish these corners right in here. After that, we swap to our chamfer mill to go ahead and do the chamfers around the top on the outside of the part and on the inside of the part. Then we switch to our final chamfer mill to go ahead and mill the insides of these corners right here to give them that absolutely square, perfect corners inside of this twisted box. All right, so over here at our computer, and I'm going to show you exactly how this toolpath works. So it's very similar to the first toolpath that we did in the first video where we took the 60-degree chamfer mill and cleaned out those corners. This is doing essentially the exact same thing, only the rotary axis is twisting along with the A-axis tilting and the Z-axis pulling that tool upwards. We're also using a different tool this time around. We're using a single flute quarter-inch countersink that allows us to access this corner and be able to get full flute length in order to get total cleanup inside that whole corner. Okay, check this out. So this tool is getting super close to this part right here. This is why we need to make sure that we pick the right tooling and make sure that we have the exact right tool holder and the exact right tool length. If we didn't have the chamfer on this part right here, the tool would probably crash into it, and that would just be a total disaster. We would have to restart cutting the part. We may even have to replace the tool holder or the tool itself. And so we really want to make sure that when we're coming in to do this corner right here, which is the most important feature of the part, that we have absolute clearance so that it can get in there and make that feature. And you know what they say in machining, clearance is clearance. So as long as we're clear, we should be good to go. So what we were trying to achieve while making this part was not just making a cool looking part with a twist or even an art piece or even these corners in here. What we were trying to do was show you a new technique that you can take and use in your own machine shop. Now, what we're hoping is that you'll be able to take that, use it to your own advantage. You'll definitely need a 5-axis for that. And by the way, if you want to get a 5-axis like this, be sure to check out our website or reach out to keith at titansofcnc.com. If you liked what we did today and you want to see more, don't forget to like and subscribe and we'll see you in the next video. Well, this year I'm excited because we're doing something crazy at Boombastic. Every single machine in this entire shop is going to be about teaching you to run on an extreme level. We're going to be pushing the limits. So I want to personally invite you guys to Boombastic. It is unlike any show that you've ever seen before. On November 11th, 12th and 13th, every machine is going to be stacked with material from aluminum to steel to titanium to composite, all of it. You go to these other machine tool shows, you have salespeople paid to say that it's the best machine tool, the best tool, the best everything, and it sits there dry running. We're going to have crazy skill sprints throughout the entire company, running all the machines aggressively, taking all the ingredients and all the variables to the highest level, showing you what extreme machining really is about.