Whether through milling or turning, producing exceptionally large parts poses some unique challenges to the CNC machining process.
Of course, the first major hurdle is finding machines with large enough chucks/tables to fit your workpieces – many conventional mills and lathes will simply lack the needed size capacity. As part dimensions increase, typical machine weight limits can also easily be exceeded. However, even when you have the proper CNC machines for the job, there are some special considerations to keep in mind when manufacturing large parts and sub-assembly components.
In our last blog, we discussed the special considerations for milling complex small parts and miniature components. Superior Machining also specializes in custom CNC milling for large parts and full-sized industrial components. Our facility also integrates multiple large-turn capacity lathes with milling capability, accommodating large part diameters up to 30” with lengths up to 80”, and milled parts up to 72” in width x 120” in length.
Addressing the Challenges of Milling/Turning Large Parts and Sub-Assemblies:
Large Part Handling and Workholding
Handling large industrial parts often requires specialized lifting equipment for loading/unloading workpieces into the machine. Smaller machine shops that typically use manual loading methods for smaller parts may not even be able to handle the big, heavyweight workpieces.
Then comes the workholding, which often necessitates custom tooling and fixtures to maintain rigidity and stability throughout the machining process. The fixtures and workholding solutions only become more challenging as part dimensions increase and designs become more complex.
Large-Capacity CNC Mills and Lathes
Of course, the CNC machines themselves also must be large and robust enough to accommodate these parts, with sufficient weight capacity and axis travel limits. Thermal expansion is another critical issue, as large parts can experience significant dimensional changes due to heat. Effective management of heat through coolant systems and environmental control is essential to maintain quality and precision.
Optimized Tooling and CAM Programming
Milling and turning parts with large diameters and lengths often requires lengthy cutting tools for proper reach, which are prone to deflection and wear. That means it’s absolutely crucial for us to optimize the tool path to minimize deflection while constantly monitoring the tool condition.
Efficient Project Planning and Logistics
The lengthy cycle times for machining large parts necessitate efficient process planning to minimize downtime and ensure each stage is performed accurately. Logistically, moving large parts between machining centers and providing adequate storage space are significant concerns. At Superior Machining, our lean American manufacturing processes help us efficiently plan out your project while streamlining the overall process of shipping and logistics.
Superior American CNC Machining Services Since 1995
Superior Machining is backed by more than 25 years of superior results in the manufacturing of large parts and industrial components. Our facility integrates 100+ CNC workcenters to deliver the greatest range of flexibility possible to our customers’ large machining projects. Our commitment to quality has established our company as one of the leading CNC milling and turning service providers for the Muenster, Texas region and beyond.
