Machine failure...WOW

[89GLH]

Not mine, found on Reddit...

https://old.reddit.com/r/Machinists...math_of_catastrophic_tool_failure_from_large/

12k RPM put holes on like 4 walls?! Sweet baby ray's that's moving. Yikes.

 

[mitusa]

From the guy's description, I would think it's time to say goodbye to that machine......who would want to operate the thing????

 

[Jack84]

Seen this before. The cutter head went through the bottom of the machine and the counterweight into the operator.
Guy survived, they had to remove his spleen and he had some other organ damage. Also his elbow was shattered.


Had a near miss myself, the locking bolt of my flycutter came loose and had the cutter heads rattling on my tool. Lot smaller though.
Sent from my iPhone using The Garage Journal mobile app

 

[tarmy]

Holy ****...

File a claim, toss the machine...

Makes me wonder if containment on these machines is even considered in their design...

 

[bullnerd]

Bummer.

2019 and the machine is glitchy?

I was standing in front of a fadal when the resolver on the Z came loose and it went full rapid into the table. I was able to hit the e stop before too much damage. Just a tool and vise.

Seen inserts come out and go through glass, the machine door and the door to outside.

 

[bonneyman]

Just amazing how it went through several walls and didn't hurt anyone. God was looking over that place that day!

 

[fnieto]

Wow! Impressive amount of kinetic energy. They truly dodged a bullet.

 

[Corvair]

Wow, amazing that no one was hurt!

 

[American Locomotive]

Holy ****...

File a claim, toss the machine...

Makes me wonder if containment on these machines is even considered in their design...

Most machines will have ballistic windows. You're not really going to easily contain a flycutter that big spinning at 12,000 RPM though.

 

[zkling]

Wonder who gets to parse the code to see why it randomly went to 12k on the spindle?

In the early days of CNC window glass wasn't up to the standards it is today. Hence they would put a welded grate over the window for protection. Pretty wild going from that to some of the modern DMG lathes that have what feels like a picture window in front of the chuck. On the back side is a different story though, most of those are just enough for chip and coolant containment.

 

[Farmall450]

From the guy's description, I would think it's time to say goodbye to that machine......who would want to operate the thing????

Agreed, unless they messed up their code/file.

 

[gearhead1]

I can’t get to the video.

 

[KBigg]

Worst Thing I ever saw was an older guy picked a disc up off the surface grinder about 30” diameter, it was still sharp and slid down his arm. Not pretty, lots of blood, everywhere. He lived, with 200+ stitches. My boss put his vice hand through the window on our mini mill once, sent glass across the shop. Other than that my machining career has been uneventful, knock on wood.

 

[like2wheel]

I can’t get to the video.

Page removed.
Lawsuit?

 

[matt_i]

I didn't see the video but a turning center has a lot more potential for a crash if the tool-move knocks the workpiece out of the chuck.

Even the earliest turning centers have "jail bars" on the inside of the view-window....

 

[JoeMcGov]

Spend some time over on www.liveleak.com. Raw user uploaded videos. Usually short. NO ****. Incredible some of the machine disasters from China.

 

[stioc]

Couldn't see the video/pic etc. However, a 3" part/tool spinning at 12k RPM is going 214mph. Lots of potential for damage.

When I have the flycutter spinning at 2600 rpm putting on a helmet and hanging a 3/4" plywood around my neck does cross my mind lol

 

[davethorik]

I didn't see vid either, sounds like a lot of destruction.

Newer machine tools usually have something like a keylogger in the control, due to human's nature to lie when confronted with a mistake lol.

Older CNC equipment can do some very weird stuff while operating, stuff it's not programmed to do. I occasionally have to run a Mazak mill made in 1986 at work, and if you don't go through the proper procedure for measuring tool offsets on the touch setter arm, it will touch the tool off fine then when it returns tool to the tool changing carousel, it will slam it home too hard and break the cast iron "tool pocket".

Oh and it breaks the pockets on either side, so now you have 3 tools laying in bottom of machine, if carbide they're probably chipped. A bunch of chunks of cast iron everywhere. And a bare spot on the carousel. Lol.

 

[kazlx]

https://www.facebook.com/Dandjpreci...557260342694/2294066584184740/?type=2&theater

No doubt it would have killed someone. Don't think anyone would have survived any sort of body shot from that thing.

 

[Bigblue&Goldie]

Damn, the energy behind that tool is astounding! I'm gun shy now to use a fly cutter!

 

[kazlx]

IMO, I would never use a tool that size on a Cat40 machine. If I was really doing that specific work that it looks like they do (decking diesel blocks), get a machine more suitable for the job.

 

[dr_clyde]

That tool was too big for a CAT 40 machine, imo.

And I'm sure that was a program error.

Glad no one got hurt.

 

[stioc]

Personally I never liked Flycutters because the way they spin the weight isn't balanced unlike an endmill. It's like putting a metal ball on the end of a chain and spinning that at 100mph. Although, sounds like the one they had did have counter weights which came off and the rest became history. As others said perhaps too big a tool and sounds like way too high a speed for that size of tool but who knows how long they've done this successfully.

 

[kazlx]

If you read/watch the details, they supposedly run it at 1200 rpm. He says there’s some sort of issue with the machine that sent it to full speed, which is 12K rpm. Sounds like a fat fingered mdi problem to me on a tool that you know would have to be loaded manually.

 

[stioc]

Ah! I totally missed that part about 1200rpm...which makes sense. I was thinking man, that 12k is some crazy speed for a tool that big. I agree, 1200 vs 12000 was probably a fat-finger deal.

 

[Robert Haas]

It is the beginning.


The uprising has began.


I must get to Cyberdine before it is too late.



"John Connors"

 

[Flail]

Discussion on the Practical Machinists website: https://www.practicalmachinist.com/...i-have-ever-seen-need-help-diagnosing-364001/

 

[Willie Makeit]

there are some people in this world that are too stupid to own and/or operate machine tools

 

[Robert Haas]

Operator error seems to be the consensus, however misapplication is also a factor with a tool that is designed to never exceed 1200 rpm firing up at VMAX on a 30 HP machine something terrible happened.


It happens more often then you think. Today we have operators that are not actually trained machinists. They are more like parts makers taught how to get their part in and mounted in a complex machine, push a button and wait. The code writers are equally at fault as well as the shop manager that allows these deadly cocktails of ignorance and under-training to produce this exact result.

 

[pamike]

Operator error seems to be the consensus, however misapplication is also a factor with a tool that is designed to never exceed 1200 rpm firing up at VMAX on a 30 HP machine something terrible happened.


It happens more often then you think. Today we have operators that are not actually trained machinists. They are more like parts makers taught how to get their part in and mounted in a complex machine, push a button and wait. The code writers are equally at fault as well as the shop manager that allows these deadly cocktails of ignorance and under-training to produce this exact result.

Amen brother! You nailed it. Really wondering why they were even using a flycutter. A circular interpolate with an endmill would probably get the job done...

 

[Bigblue&Goldie]

I read on another site that the guy loaded the tool and hit a button that brings the tool up to the last speed used; in this case 12k RPM. Supposedly this tool is designed for surfacing blocks for a specific head gasket finish, at a specific RPM, which is why it's larger than what would typically be used in such a machine. Of course, I can't verify any of this and I don't have any real knowledge of CNC machining.

 

[PugetDude]

25+ years ago we were watching a prototype machine undergoing full-load testing on the plant floor. Two big hydraulic cylinders, test load was about 15 tons.
Something hung up, hydraulics kept going, a 6" diameter cylinder rod bowed and then snapped. it happened faster than the operator could punch the e-stop.
A piece of shrapnel the size of my fist sheared off the cylinder rod, went through two divider walls and ended up imbedded in a 1/4" plate that was standing vertical in a plate rack.
Scary ****. No one was hurt, but it could have turned out much worse.

 

[Robert Haas]

I have never seen a 12" wide tool spin up to 12,000 RPM but the actual speed at it's outer point would be nearly supersonic. (actually it would be around 475 MPH)

The mere thought of the energy of a 1LB piece of metal traveling at near trans-sonic speeds gives me the willies.

It would be in the realm of artillery.