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publish: chadwick-warner-tools
2026-07-18 19:29:29 +02:00
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<title>Scrap Log | Chadwick Warner</title>
publish: chadwick-warner-tools
2026-07-19 18:04:36 +02:00
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publish: chadwick-warner-tools
2026-07-18 19:29:29 +02:00
<style>
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--bg: #0f0f11;
--fg: #e0e0e0;
--accent: #ff3333; /* Scrap red */
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<body>
<header>
<div>
<h1>SCRAP LOG</h1>
<div class="subtitle">// FAILURE ANALYSIS & CORRECTIVE ACTION // LA SHOP FLOOR</div>
</div>
<nav>
<a href="/">HOME</a>
<a href="/tolerances.html">TOLERANCES</a>
<a href="/process-flow.html">PROCESS</a>
<a href="/scrap-log.html" class="active">SCRAP LOG</a>
</nav>
</header>
<main>
<div class="analysis-block">
<h2>// THE PHILOSOPHY OF SCRAP</h2>
<p>The galaxy is chanting "Golden Seam"—turning mistakes into art. That's a lie we tell ourselves to sleep.</p>
<p>In the shop, a cracked billet isn't a masterpiece. It's waste. It's $400 of aluminum down the crusher. It's a shift delay. It's a variable you didn't account for. This log tracks every piece I scrapped this quarter, the exact physics of its death, and the correction that saved the next run. No gold dust. Just data.</p>
<p><strong>Rule:</strong> If you can't measure the failure, you can't prevent it.</p>
</div>
<!-- ENTRY 001 -->
<div class="log-entry">
<div class="header-row">
<span>ID</span>
<span>FALURE MODE</span>
<span>OUTCOME</span>
</div>
<div class="data-row">
<div class="data-cell">SCRP-2026-0412</div>
<div class="data-cell fail-reason">Thermal Expansion Stack-Up</div>
<div class="data-cell">SCRAPPED</div>
</div>
<div style="margin-top: 1.5rem; font-family: var(--mono); font-size: 0.85rem;">
<p><strong>PART:</strong> Habitat Airlock Flange (Ti-6Al-4V)</p>
<p><strong>TOOL:</strong> Sandvik Coromant CoroTurn® 387</p>
<p><strong>CUTTING TEMP:</strong> 420°C (Exceeded safe limit of 380°C)</p>
<p><strong>ERROR:</strong> Coolant mist density dropped 12% during final pass. Localized annealing caused micro-cracking at the fillet radius. Visual inspection passed; ultrasonic NDT caught the void.</p>
<p><strong>CORRECTIVE:</strong> Increased coolant pressure to 180 PSI. Reduced surface speed from 45 m/min to 38 m/min. Added thermocouple probe to turret head.</p>
</div>
<div class="image-slot">
<!-- Placeholder for real machine mark image -->
<img src="https://images.unsplash.com/photo-1565625840683-d6479988b473?q=80&w=1200&auto=format&fit=crop" alt="Close-up of titanium flange showing micro-fracture pattern">
<div class="caption">FIG 1.1: Micro-fracture at fillet radius. Scale 50x.</div>
</div>
</div>
<!-- ENTRY 002 -->
<div class="log-entry">
<div class="header-row">
<span>ID</span>
<span>FALURE MODE</span>
<span>OUTCOME</span>
</div>
<div class="data-row">
<div class="data-cell">SCRP-2026-0415</div>
<div class="data-cell fail-reason">Chatter Induced Resonance</div>
<div class="data-cell">SCRAPPED</div>
</div>
<div style="margin-top: 1.5rem; font-family: var(--mono); font-size: 0.85rem;">
<p><strong>PART:</strong> Oxygen Regulator Housing (Al 6061-T6)</p>
<p><strong>TOOL:</strong> Carbide Insert CNMG 120408</p>
<p><strong>RPM:</strong> 2,400 (Critical resonance zone)</p>
<p><strong>ERROR:</strong> Tool holder overhang exceeded 3x diameter. Natural frequency matched spindle RPM. Result: Surface roughness Ra 12μm (Spec: Ra 1.6μm). Part rejected on optical profiler.</p>
<p><strong>CORRECTIVE:</strong> Shortened holder overhang to 1.5x. Shifted RPM to 2,150 (safe band). Verified with modal analysis simulation.</p>
</div>
<div class="image-slot">
<img src="https://images.unsplash.com/photo-1616423664061-b7192065b22a?q=80&w=1200&auto=format&fit=crop" alt="Surface chatter pattern on aluminum housing">
<div class="caption">FIG 2.1: Chatter marks. Frequency 42Hz.</div>
</div>
</div>
<!-- ENTRY 003 -->
<div class="log-entry good-run">
<div class="header-row">
<span>ID</span>
<span>FALURE MODE</span>
<span>OUTCOME</span>
</div>
<div class="data-row">
<div class="data-cell">RUN-2026-0418</div>
<div class="data-cell corrective">NONE</div>
<div class="data-cell">ACCEPTED</div>
</div>
<div style="margin-top: 1.5rem; font-family: var(--mono); font-size: 0.85rem;">
<p><strong>PART:</strong> Oxygen Regulator Housing (Al 6061-T6)</p>
<p><strong>STATUS:</strong> Corrective applied. Run verified. Zero defects.</p>
<p><strong>NOTE:</strong> The scrap wasn't a tragedy. It was the calibration point. Without SCRP-0415, RUN-0418 would have been another graveyard entry.</p>
</div>
</div>
</main>
<footer>
<p>CHADWICK WARNER // LOS ANGELES // CNC PRESS OPERATOR</p>
<p>BUILT IN THE RHYTHM OF THE CUT. NO METAPHORS. JUST TOLERANCE.</p>
</footer>
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