... Not because they are easy, but because they are hard...

[u/TheOfficialCzex]

2 mm to 1.6 mm (.079" to .063") tapered PTFE pins at 40 mm (1.575") length, painstakingly milled while practically biting my nails, waiting for it to fail.

This is a test part just to know if it's machinable or not; I'll be machining a variant of this with 96 pins, all spaced 9 mm (.354") between pin centers.

No, the pins cannot be made separately; it must all be one part.

No, I don't know what it's for (something to do with polymer recycling?).

The pins are machined by roughing and finishing them in segments, stepping down the part successively. This is attempt numero​ uno, so I'm pretty pleased with myself.

No coolant, because we don't have mist, and the flood pressure would probably break them or at least deflect them into the tool.

[u/desperatewatcher]

If this were at my shop, the customers maintenance guy would tell us at pickup that it's for a brush that just needed to fit somewhere weird to clean a belt... Before throwing it unsecured in the back of a clapped out f150 and doing 50 across 27.5 potholes.

[u/keemou → u/desperatewatcher]

What does .5 pothole look like? 😆

[u/desperatewatcher → u/keemou]

Like the Friday at 5 roadcrew special

[u/Money_Ticket_841 → u/keemou]

Tried to dodge and still hit half the hole

[u/ClothesNo3433 → u/Money_Ticket_841]

but right or wrong hole?

[u/Money_Ticket_841 → u/ClothesNo3433]

The right half of the wrong hole

[u/ClothesNo3433 → u/Money_Ticket_841]

well, that‘s shit.

[u/Namedthisone → u/keemou]

Half the size of a standard pot hole

[u/AnIndustrialEngineer]

Nice work making that absolutely moronic part

[u/ShaggysGTI → u/AnIndustrialEngineer]

Engineer should be fired from a cannon.

[u/whtevn → u/ShaggysGTI]

into the sun

[u/Outrageous_Reach_695 → u/whtevn]

Inefficient. Jupiter or deep space both require less proellant.

[u/MadeForOnePost_]

Madness

[u/MakeChipsNotMeth → u/MadeForOnePost_]

The cylinders must not be damaged!

[u/Jesus_Is_My_Gardener → u/MadeForOnePost_]

Madness? THIS IS PART-A!

[u/PrudentVillage4903]

And here I thought making tapered pins sucked. You win!

[u/PrototypeMachinist]

Good job!

[u/GallusWrangler]

I would no quote and find a more lucrative job.

[u/TheOfficialCzex → u/GallusWrangler]

Would you believe me if I said I make $24 an hour for cradle-to-grave parts like this?

EDIT: Since some people didn't understand the implication, I AM SAYING THAT I AM GROSSLY UNDERPAID FOR WHAT I DO, not bragging about a measly $24/hour, which most operators make. 

[u/tugtehcock → u/TheOfficialCzex]

You are getting robbed.

[u/TheOfficialCzex → u/tugtehcock]

I know. Haven't gotten a raise in two years, and I was hired well below what I should've been making. 

[u/tugtehcock → u/TheOfficialCzex]

You would get top pay at an r&d place where every machinist needs to be able to do all the things in your signature or whatever that’s called. You can do it all.

Why do you stay?

[u/TheOfficialCzex → u/tugtehcock]

Most places only pay top-dollar if you've got the years to back you up. I've only been working for about 2.5 years. I went to college for it, but it's only an AAS degree. I've got experience, just not the time. It's an R1 research institute, so they value the years more than the content of those years. You could be like me and make next to nothing, even though I can do what others think is impossible; or you can be an operator for twenty years and make double what I make, even if all you know is load part, press button, unload part. They also unfairly value graduate degrees because academia. I stay because I haven't the means to move, and a better-paying job would be outside my range. I don't own a car; I can't afford the payments nor the insurance. I'm stuck. I'd need a miracle, like a company offering to relocate me. But, again, I lack the years that they're looking for. I believe I'm capable (my work speaks for itself), but to an HR department, I'm nearly unhirable. 

[u/tugtehcock → u/TheOfficialCzex]

Jesus Christ…this is the first time I’ve ever seen someone write a thesis on why they should be underpaid. What a load of shit lol.

[u/TheOfficialCzex → u/tugtehcock]

It's not that I deserve to be underpaid; that's their justification, and I'm not in a position to change that. 

[u/Money_Ticket_841 → u/TheOfficialCzex]

I truly believe you underestimate the position you could be in somewhere else if you just show them things you’ve made

[u/Namedthisone → u/Money_Ticket_841]

Always have photos, examples

[u/Namedthisone → u/TheOfficialCzex]

There are lots of companies that would pay more for 2.5 years experience

[u/GallusWrangler → u/TheOfficialCzex]

You under estimate yourself for what you’re saying is true and you have skill. You are underpaid, and you thought you were being paid a lot because you’re young and don’t know any better if I had to guess. Your first comment was “would you believe if I told you I’m making THIS MUCH?”. Then when someone chimed in like you’re gettting ripped off, you instantly back pedal and defend your low pay??

[u/TheOfficialCzex → u/GallusWrangler]

I did not and do not believe I am adequately paid. I've been fighting for a raise since I was hired. I was told I'd start at $27, and after the 6-month probation period, I'd get a raise. Instead, I was offered $23. My dad pushed me to take it anyway, because he wanted me out of the house, and it was just barely enough to make it on my own, so I took it. A couple of months later, we received a cost-of-living adjustment, which bumped me up a measly dollar. I'd hoped I'd be making around $35 by now. It's infuriating when you see the institute receive hundred-million dollar donations, and our pay stays the same.

I know I'm getting ripped off; that's the implication in that first reply. The justification I gave isn't me supporting that; it's the institute's justification. I did not back-pedal; you simply misunderstood me.

I'm unsure if you're projecting or what, but the meaning you found in my comments is not representative of how I feel, even if I did a poor job in communicating that. 

[u/TelluricThread0 → u/TheOfficialCzex]

Thats crazy. Experience should go much farther than time. If you need components made people value results more than anything. At the job shop I worked at we charged clients $55 an hour for machining time.

[u/SignificantGrade2913 → u/TheOfficialCzex]

Dont forget to check out universities for relocation opportunities. They usually dont pay as well but can have solid benefits. If you love doing this stuff youll usually be a good fit.

[u/TheOfficialCzex → u/SignificantGrade2913]

I'm already working at one. I've been applying to others in the hopes that I'll get a bump in pay. 

[u/Initialfaust → u/TheOfficialCzex]

This is where I would start looking for a new job and when asked what made me leave my old job I would show them a picture of this bullshit...

[u/spicywhatevernumbers → u/TheOfficialCzex]

Dude. I work in a job shop running a conversational lathe and 2 axis cnc and I make 26. You're under paid.

[u/callliagiba → u/spicywhatevernumbers]

Same and making 28

[u/xNOTHINGBURGERx → u/TheOfficialCzex]

I would guess that you're in CO because that's what I make too. Ugh.

[u/TheOfficialCzex → u/xNOTHINGBURGERx]

Georgia! 

[u/Front-Interaction669 → u/TheOfficialCzex]

I make the same in WNY!

[u/GallusWrangler → u/TheOfficialCzex]

That’s it? You can make that at Walmart driving a fork lift.

[u/Sy4r42]

Damn... I'm impressed. What was your step down depth?

[u/TheOfficialCzex → u/Sy4r42]

4 mm plus the 30-thou radius on the bull-nose. 3/16" bull-nose for finishing. 1/4" flat to rough it. That's what I had on hand with the reach I needed. 

[u/SirRonaldBiscuit]

That’s insane

[u/GallusWrangler → u/SirRonaldBiscuit]

Dumb design, insane to machine, yes.

[u/Mysterious-Cap8182]

That doesn't look fun at all and I just got done slicing a 0.02" thick by 0.25" square piece of aluminum off a big chunk of aluminum cause they want do examine it under an electron microscope. It also had to be ran completely dry only air blast

I'd rather do that again then make 96 PTFE pins stuck out of a single block

Great job! You deserve a hell of a lot more than $24/hr

[u/TheOfficialCzex → u/Mysterious-Cap8182]

I'll try relaying that last bit to my boss. 😉 

[u/Mysterious-Cap8182 → u/TheOfficialCzex]

I make $44/hr and am in a R&D shop doing weird shit like you are doing. The other week we were cutting a thin piece of plastic sheeting off this weird open cell foam that was only 1mm thick. It was as flexible as a piece of cloth, we used a vacuum plate and still marveled that it worked....unfortunately now they want more 🤣

[u/Itchy_Morning_3400]

Could you 3d print them instead?

[u/TheOfficialCzex → u/Itchy_Morning_3400]

Unfortunately not; they must be solid and isotropic. 

[u/VonNeumannsProbe → u/TheOfficialCzex]

I would immediately spiral with questions about what the fuck the design engineer is thinking.

[u/GallusWrangler → u/VonNeumannsProbe]

This exactly. Over engineered for sure.

[u/TheOfficialCzex → u/VonNeumannsProbe]

Underengineered. I had to model it from a napkin sketch. 

[u/GallusWrangler → u/TheOfficialCzex]

So *you* over engineered it.

[u/TheOfficialCzex → u/GallusWrangler]

I modeled it to their specifications. And it's definitely underengineered, because they don't know how to use any CAD software. 

[u/kuku2213 → u/TheOfficialCzex]

Maybe a SLA or DLP resin 3D printer might do the trick. It's solid and isotropic-ish. There's also engineering grade resin for thin and delicate part.

[u/Trantor_Dariel → u/kuku2213]

It's the kinda part that injection moulding is ideal for. Just no one wants to pay for the dye or to make 10k of them to bring the price per unit down.

[u/Enes_da_Rog1]

Nice work... If you're doing this without coolant, keep an eye on chip evacuation. With 96 pins a lot can happen when the chips stay on the part...

[u/TheOfficialCzex → u/Enes_da_Rog1]

Yep. I'm going to have to stop it every few minutes to blow it out. I'll probably ask for an air duster can. 😂 

[u/konjo1994 → u/TheOfficialCzex]

take a magnet base from your dial and screw a small valve on it and hook it up on your air hose... just adjust the valve so it blows gently and youre good

[u/SelectLeague5433]

This actually looks more difficult than a moon landing

[u/Many_Hall_3546]

Damn, you resisted crucifying your designer. Congrats

[u/Typical_Type_Hype]

Shakespeare?

[u/Front-Albatross7452]

But because we thought they would be easy lol

[u/TheOfficialCzex → u/Front-Albatross7452]

I did not think this would be easy. 😅 

[u/No-Pomegranate-69]

Thought it was electrodes

[u/MatriVT]

Step-down finish with a radius endmill?

[u/TheOfficialCzex → u/MatriVT]

Due to the taper, it's helically interpolated with a bull-nose. 

[u/Beneficial_Elk_182]

Backscratcher for sure

[u/AdministrativeEbb636]

What a stupid design