CNC machines, particularly in the realm of large CNC machining, are an impressive tool for fabricating a diverse array of products, but they come with their own unique size constraints. The average machine shop or hobbyist is less likely to possess a significantly large machine, as such equipment can be impractical in many situations.
This leads to the question: how can large parts be machined?
Specifically, what is the process for CNC machining parts that are too large to fit the device? While this task is completely achievable, it does demand a higher level of machining expertise and additional planning.
This article aims to clarify what large CNC machining entails, as well as provide an overview of the best practices and potential pitfalls of machining large parts.
What is Large CNC Machining?
Large CNC machining is a manufacturing process of CNC machining that creates parts and components that are bigger in size and scale. A large CNC machining center can handle workpieces that range from a few inches to several feet in size and are used across a variety of industries, including aerospace, automotive, and construction.
Large CNC machines can provide the same level of accuracy and precision as their smaller counterparts and can create complex geometries and features on a larger scale. These machines often require specialized equipment and expertise to operate
Considerations for Large Part Machining
When machining parts that are too large for your standard machine, there are some planning issues that one should consider.
Multiple setups and runs
The first of these is that you need to properly think through how the part is going to be processed in multiple different setups and runs. Large parts need to be machined in multiple setups where each setup gives access to a portion of the part and processes a different segment.
While lining up each setup, the machine tools and the part need to conform in such a way that the accuracy of features machined in different setups relative to one another match up in quality.
Overall part size
The other major limitation that comes with such a task is overall size. If it is too large for your enclosure, it needs to be done in sections. Similarly, many machines have a weight limit, which includes the part and all the fixturing and height can be a make or break factor. If the part is heavy or too tall to get under the machine, it may not be worth doing at all.
Limited types of large machining tools
Another problem can often be that there are very limited machine tools dedicated to the development of large parts. As most machines are dedicated for smaller lot sizes, many manufacturers have played into this market at the expense of any tools that specialize in large parts.
Even with large machines this can be the case, with a lot of machine shops requiring operator attendance to finish up the part manually (which can be slow and laborious).
Accuracy
There are also accuracy issues that can arise when doing things in multiple setups. This will require a lot of diligence and attention to detail. Large parts also create another problem where they produce intense amounts of heat. Users may have to compensate for this heat in their pre-calculations.
Design-phase considerations
Sometimes machining a large part can be simplified immensely by just breaking it into smaller segments that can be assembled later. If your customer allows for this, it is highly recommended. Needless to say, this does away with a lot of the headaches being discussed in this article, and can even result in some novel parts.
It’s also wise to pick the right machine and the right type of model for your work. If you’ve only been considering a lathe, keep in mind that some parts are better off with a mill, for example. 4-axis mills can produce some surprisingly lathe-like work with a different angle and setup that offer different possibilities.
This can be cumbersome to decide on, however certain CAD software can run the numbers and decide which would be best to use in what given scenario. It’s all about planning.
Preparations
There are a few things you need to get out of the way beforehand (both literal and figurative ones. It may be best to open the windows on your enclosure sides so the parts can protrude or even remove the enclosure to machine large parts. In some cases, you might even have to remove the tool, changing it to give your machine a little bit more room for a marginal part to fit.
Collisions, as always, are going to be a major issue and they only get worse with larger parts. Check very carefully that no collisions will occur before letting the program do its job. It may also help having a full solid model of your machine and enclosure interior to facilitate checking collision possibilities via CAD.
Since bigger parts also usually bring a higher level of weight to the mix, it’s best to deal with this. This usually requires the need for weight supports. Make sure any of part weight that’s not on the table is well supported with outrigger stands of some kind. In certain cases, you may require some kind of rollers so the machine can travel freely too. Lastly, make sure you have proper equipment to help load and unload parts too heavyto carry manually.
You can also prep the part with a different machine. CNC Routers have large work envelopes, allowing them to handle much larger parts than the mill may be capable of. However, they aren’t ideal for processing the entire part as they have a variety of issues. Routers can also provide some novel solutions that improve the accuracy for your machines. Putting in counter-bores that can act as reference for your mill is one great example.
Consider the Part Geometries
While lining up the part in a straight manner is standard practice, machining large parts takes a bit more ingenuity. On any rectangle, the diagonal between two corners is longer than any edge, so it may be best to try putting the part at an angle that doesn’t line up the straight edges while getting the part’s features lined up right with your machine’s travel path.
It can, thus, fit better in the available space and economize the work envelope.
Rectangular parts
It may be better to slide rectangular parts in certain cases such as when holes need to made along their entire length. One way to streamline this process is to use a couple of round pins installed on your table’s T-slots as stops for the work to slide against. Put them in parallel to the machine’s X-axis, making sure the part has a true edge along its entire length. This will help to maintain the squareness.
Round parts
Round parts, on the other hand, should be spun rather than slid. This allows the machine to access every feature into the machine’s work envelope. Each time the part is spun, there should be some overlap with the prior setup so features can be indicated to orient the machine to the part. You should mount some round stops on the table that will form a tangent to the circle. You can mount them on the inside or outside, whichever is more convenient. They’ll ensure that as the round part spins, the center stays put.
You can also extend your Y and X-axes by sliding and spinning the part to compensate. You can cut the various corners one at a time and then rotate the part to another side. This can be made much easier with the use of locating pins that go right into the T-slot.
Tool Tips
Certain tools like right-angle heads can turn parts around to an orientation that saves the day. Similarly, big fly cutters can extend your mill’s reach, particularly to get those harder to reach edges. It may not extend it by a lot, but when you’re machining a large part, every little bit of reach helps.
Bottom Line
In conclusion, large CNC machining refers to creating parts and components bigger in size and scale. Machining large parts requires a lot of planning and consideration for multiple setups, overall part size, limited machine tools, accuracy, design-phase, and preparations.
Choosing the right machine and type of model for the work can help simplify the process. Machining large parts can be accomplished with the right machining savvy and additional planning, and CNC machines can provide the same level of accuracy and precision as their smaller counterparts while creating complex geometries and features on a larger scale.
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