SECRET Process Of MACHINING FLAWLESS Parts

Trevor shows how to achieve a PERFECT FIT. Machining a part to fit seamlessly into another using ONA’s AV35 EDM (Electronic Discharge Machine). A Precision Punch and Die that Fit together Perfectly using wire EDM technology.

0:00 This is Precision
0:41 How it’s made
0:44 ONA EDM
1:08 Tight Tolerances
1:19 Components Solidworks
1:31 Subscribe
1:51 Punch and Die
2:04 Mitutoyo Setup/Fixturing
2:30 Additive Machining
2:42 Slug Removal
3:20 Roughing Pocket
3:40 Offsets and Compensation
4:49 Clearance
5:03 How We Made the Perfect Part
5:22 Titan Tooling Promo
5:37 CNCExpert
5:54 Precise Fit
6:06 Outtakes

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[Kardos]

I spent many years in an EDM shop (wire and sink) and always thought that watching a wire EDM in action is equivalent to watching grass grow or paint dry. You (and your video team) made it exciting and very interesting.

[Jessie_Smith]

I mean super accurate tolerance and a disappearing act is cool and all but whoever ground that block to perfection is the real hero here 🤣🤣

[wickedcabinboy]

I am neither a machinist nor an engineer. I've watched many EDM videos and wondered how it could be done without leaving a kerf. Yours is the first video that explained the process and clearly detailing how it is done. I suppose others merely assumed that their viewers already knew that it required *TWO* different blanks.

[sferg]

The first piece I ever made like that was back in 1985 with our first SODICK 1WH Wire machine. First attempt was spot on with some attention paid to the details in the program while taking into account the wire diameter and the ensuing "overburn" as a result of the spark gap. The part was presented to the company President and he was amazed. That sold him on the technology and we over the years had purchased over 10 more wire EDM machines.

[AlexKarasev]

Growing up in the USSR, as an aerospace college student I had a summer job in 1990 at a plant in St. Petersburg (then Leningrad) making parts for various missiles. They had a row of basic versions of this same machine (among other cool stuff).

[adamfreeman]

Channel is seriously getting better at making content, and it was already great. Better than any manufacturing show on tv!

[tdg]

I must admit man has done some pretty cool things. The technology in that shop is top notch all of which are huge boat anchors out of water. What’s really cool is the brilliant minds designing the machines and the brilliant minds running them. Beautiful piece of art Trevor and thanks for sharing.

[NMCKE]

I'm not a machinist, just took some high school classes a while back. Zero tolerance is insane, especially with metal heating and cooling — great job!

[niloy.b]

Barry is going to make pixiedust out of trevor when he watches this! 😆😆

[xwhnlbx]

I remember when I was in machinist class and the instructor demonstrated zero tolerance. He had two pieces of perfectly machined surfaces of steel blocks. When you slide them across each other, they would stick together. Air tight contact.

[kevinwinwood]

This is a brilliant fit, very impressive, kudos to you. I was a prototype machinist in 1984 and learned to use a Charmilles wire EDM. We made some basic parts, but there was no skim cutting available. I made a “punch & dye” of my first name, but they did not fit together, close but no cigar. We then got a 4 axis Mitsubishi with skim cutting. Made a couple of name plates for senior managers. The die from steel and punch from brass, the fit was not as good as Titan, but it impressed the bosses. Can’t imagine what it cost, all the programming was manual, but then again, we were an expense department!

[QurttoRco]

Metric units would be nice as a pop up. Love Trevors presentation

[dakudsi]

Do you sell the punch and die itself? It so satisfying to have on my desk 😬

[mohammedalbattal]

Man, every day you are progressing more and more, you are going towards the top, for sure, in this way, you will reach one million subscribers very quickly BOOM 💥
For a few years, pieces like this puzzled me, but now I know the secret of this craft, thanks to you Mr trevor 🌷

[emilygoforth]

Ryleigh was in awe watching her daddy the whole time!

[MrGreen]

We already know your goal is more subscribers. I don't need reminded before and after the actual content...

[sparksandchips]

Man excellent job!
I miss working in a tool shop… for that reason.
Moved into quality later in life for automotive industry but still use that background to establish root cause and be able to explain to others how parts are made…..

[afelias]

ok ngl first 15 secs BLEW MY MIND. I thought it was CGI, like a Blender model, until I saw the hand.

I heard that super precision machined parts had invisible seams but holy shit man

[williamlow]

With this machine, the industry has reached a new level

[Hawkesey]

Customer : How efficient is the cooling system on the ONA?

ONA: Yes