Heavy Duty Machining 1000HP Tree Grinder Shaft | Part 1

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Back to see great repairs 👍
From CEE thank you for sharing 🤗

So I guess nobody wins if the material is no good 😮

Internal stress may have caused original shaft to fail? I love watching your reruns!

Great video as always, wondered though why you don't use duck-boards? Saves walking over the swarf.

I love the out takes 😂

Your work ive seen are excellent good quality

Lesson learned no more customer supplied materials......just saying......

Will you please get some duck boards to stand on at your machine's. You'll thank me for it.

What is the dogs name. I love staffys.

942kg...that's right at the top of my bench press weight 😅

What do you charge to remake that shaft, in dollars?

Stress relief before machining a large-diameter shaft is an essential step to minimize distortions during the machining process and to maintain dimensional accuracy. This is especially important for large shafts because internal stresses from manufacturing processes, such as forging, casting, or welding, can cause warping or deformation when material is removed.

### Steps for Stress Relief:
1. *Material Selection:*
- Understand the material properties of the shaft (e.g., steel grade, hardness, and alloy composition).
- Some materials are more prone to stress buildup than others.

2. *Stress-Relief Heat Treatment:*
- Heat the shaft uniformly to a specific temperature, depending on the material:
- For steel, stress relief typically occurs between **550–650°C (1022–1202°F)**.
- Hold the temperature for an adequate soak time (usually 1-2 hours per inch of thickness).
- Cool the shaft slowly, preferably in the furnace or in still air, to avoid introducing new stresses.

3. *Pre-Machining Stress Relief (if necessary):*
- After rough machining, conduct another stress relief heat treatment to eliminate stresses introduced during the initial shaping.

4. *Machining Considerations:*
- Ensure uniform material removal on all sides to minimize distortion.
- Use balanced fixturing to avoid introducing clamping stresses.

5. *Post-Machining Stress Relief (if applicable):*
- For components requiring high precision, a final stress relief cycle after machining can help stabilize the material.

6. *Shot Peening or Vibratory Stress Relief (Optional):*
- Shot peening introduces surface compression to reduce the risk of warping.
- Vibratory stress relief uses mechanical vibrations to redistribute residual stresses and is an alternative to thermal methods.

By following these steps, you can significantly reduce the risk of deformation and achieve high dimensional accuracy in your large-diameter shaft.

Dumb question: Does Homie ever cut his paws on chips? Or is that something he just knows not to step on? I figure you would have boots on him or something is it was a problem, so probably you solved this a long time ago?

I have watched your channel for several years, and I have built up the courage to make a suggestion regarding your method of using a 3 jaw chuck. I was taught years ago not to rely on the gears in the 3 jaw chuck to ensure a truly equal grasp on material being turned. I learned to apply a fairly strong grasp at the first of the 3 sockets, then apply the same presure at the other 2 sockets, then continue to apply an increasing presure to sockets 1, 2, and 3 again.  I couldn't believe this method would make a difference in how centered the material would be held in the chuck, but it did.

Give this a try.  You might be surprised. 

Good luck,
Richard Walker


Boise, Idaho. 83709

HI GREG HERE TO YOU AND YOUR PARTNER AND HOMELESS LOVE YOUR SHOWS CURTIS PLEASE KEEP IT UP P.S YOU SHOULD BUY YOUR SELF A IN DUSTRIAL VACUUM CLEANER IT BE EASY TO CLEAN UP YOUR JOBS P.S MERRY CHRISTMAS TO YOUR FAMILY 😊🎉

🤯🙂👍

When at tech college we made cold chisels and hardened and tempered them. My first try was chocolate, my second try was chocolate, my third try watched by the teacher with him doing the hardening and tempering and me cleaning up was chocolate. Turned out I had the end of the bar and wrong carbon content. Red faces all round.

Help me Christian! I have had a bent shaft for years!

Thermal power station boiler feed pump shafts are long and carry eight to ten impellers. They are assembled in stages stator, rotor, stator etc. even the slightest run-out will wreck the pump on first start.
Our shafts were made by the Royal Ordnance Factory with the methods used for large artillery guns.

This is amazing work again. But your weldings will be problem after a few use, at least put triangle metal pieces inside of black frame corners.

What do you do with that much weight in chips?

This is the correct way. The incorrect way is to wear pajamas and flip flops, work on the floor in the dirt, and weld ‘er back up.

Rewatching this 3 years later but if that tree chipper was at full scream eating a tree when that shaft broke, I wonder just how many of the people near it had to change their shorts...assuming they had time to load them (💩)...

That must have been a truly INTERESTING few moments in a MASSIVELY Terrifying way...

If it was working at full power, I'd like to see the machine itself after they finished taking it apart to get the shaft out of it...assuming it didn't take itself apart that is when that VERY heavy, spinning toothed drum broke loose and stated flopping around like a chicken with it's head cut off...

😄😁😆😅😂🤣

That’s my swarf 😂

DO YOU USE A WAX & WATER COMBO FOR COOLING YOUR CUTTING TOOLS?

Machining...yeah, milling...yeah, tapping...yeah all superb as usual, BUT HOW GOOD IS THE PACKING TAPE !

PLEASE STOP WITH THE MUSIC

Vermeer machines are the worst. I run a Vermeer horizontal boring machine and always having issues

i was taught to let big jobs normalise for at least 2 days after roughing.

This brought back some memories!

Been watching for a while and I just now came across this og vid… need more American measurements I understood bananas perfectly wtf is a milliliter 😩😩

Kurtis & Karen !
Felüdülés nézni olyan ember munkáját, akin látszik hogy nem csak ért hozzá hanem szereti is !!!
Köszönet a videokért !!! 😊

Great stuff. generally a great machinist. but I think if you miced the high and low spots on both ends, and user a 4jaw set true chuck, and dialed it in with the high / low points off set in regard to your points of contact on the 4jaw- you would have been much better off. just my crappy lil 2 cents.

Im willing to bet it was China's fault since that's where all the steel comes from now unfortunately

What a shame 😢

Gday mate, I reckon you’ve learnt a lot since this video! Strongly advise a 4 jaw for this job! Also would advise setting it up properly in the beginning, the runout when you machined the first steady track that was your first warning.

For such amount of machining, best and I have done it is to send your work piece out for stress releave....that should help but you said it did not....

I believe your 3 jaw chuck was a problem I always use a 4 jaw chuck so when I turn the shaft around after roughing out I can set the end up perfectly, I would of turned the shaft about 4/5 times before attempting to finish

Sorry you went about roughing out shaft the wrong way even with run out after machining with 5 mm left on it you still could of saved it your procedure was wrong sorry I have machined 100 of shafts for the last 35 years

Guess who the manufacturer is gonna blame!.

Hi Kurtis, Would it be possible to use your spray transfer weld on material process to add material differentially to make up deviation ? Then do a full rotary pass to also work as a heat treatment to equalize stresses in near final shape ?

Alivio de tensão,tem que ser feito,para dureza uniforme.

Sir,i'm from batam indonesia.l,m can used manual lathe so ,how l'm find job in your country.please give me information sir.thanks...

What an F===ing nightmare.

Curtis Love your Channel, not Sure how I missed this Video. My Company WorldWide Machining & Welding did a lot of this type of work with even Bigger Shafts, some with Helical Gears in the Middle. First we would turn down all the Bad areas, Then when we would weld up the key areas with Mig, then weld the Bad Areas areas with Sub Arc. During the Weld Process we incorporated a META LAX Sub Harmonic Stress Reliving System along with Adequate Pre Heat. We would then rough everything in the Lathe. Once this was complete we would then use the META LAX System Prior to finish Machining. All of the Shafts we did like this over the years never came back or Broke. We also did the META LAX System on New Shafts. We never ever sent anything to Heat Treatment / Stress Relieving. Other Shops said it would never work but we proved them wrong. For what it is worth you are extremely talented and hope my experience / method can help you in the Future. Reach out to me if you like I would be more than happy to help. All The Best John Anderson

by that really sucks

I would think setting up the bar with a 4 jaw chuck to find its center before starting to cut or drill any new center?
The bar would predictably break at the sharp transition, it needs a radius or taper to spread the force.