Process Zones

Large-Part Machining

Large-Part Machining is here defined as the challenge of machining any part that is too heavy or bulky for a single human being to move the part to another location quickly, or too large to fit within the work zone of the most commonly available CNC machine tools. Parts such as these could apply to almost any industry, though aircraft, construction, power generation, and oil drilling are ready examples of industries that commonly have a need for very large machined parts. In large-part machining, much of the challenge has to do with performing as much of the work as possible in a single setup. Five-axis or 3+2 machining is often required to let a machining center reach many of the features of the part in a single setup.

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Large-Part Additive Manufacturing

These articles sample possibilities for additive manufacturing of large metal parts.

Building on the Right Foundations

One of the largest vertical turning and milling centers in the country will be installed in this Cincinnati-area job shop. Although installing the foundation for this huge machine was a massive undertaking, the company is building on other “foundations” as well.

repeating parts at WSI

Delivering Value in Program Production

A contract manufacturer specializing in ongoing production programs describes the investments involved in winning this work.

Minimizing Turnaround Times for Big Parts

The key to success (and the primary challenge) for any job shop is minimizing turnaround time for non-repeating work. This Indiana shop shares some of its strategies for reducing lead times for the various large-scale jobs it encounters.

horizontal machining center

Systematic Success

By: Matthew Jaster
A more efficient manufacturing process has enabled this manufacturer to ramp up production of its devices for the oil and gas industry.

Big Multifunction Machines for Big Castings

By: Derek Korn
Turn-mill technology enables this company to minimize lead times and handling for its large machined castings.

Going Live on a Vertical Lathe

By: Russ Willcutt
For this company, investing in live tooling and a high-pressure coolant system on a pair of new CNC vertical lathes eliminated setups, increased throughput and led to safer material handling on the shop floor.

Bloodhound Fin Support Machined with Vortex

By: Peter Zelinski
Machining strategy contributes to 40 percent cycle time saving on large five-axis aluminum part.

Large Machines and Large Capacity in Renovated Pfronten Facility

By: Matthew Jaster
DMG MORI hosted its 20th open house earlier this month in Pfronten, Germany. The event featured 76 machine tool exhibits, including four world premieres, and nearly 8,800 attendees had the opportunity to tour the recently renovated and expanded facility to see its latest machine tool technologies. Here are some observations from the event:

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