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. On-machine probing is another important resource, because the machine is often required to precisely locate the part prior to machining and may even inspect the part after machining is done.

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Featured Zone Content

May 2012

Large-Part Additive Manufacturing


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

March 2012

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.

October 2011
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.

June 2011

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.



April 2013

“CNC Retrofit” Often Means More

By: Matt Danford
This video testimonial provides an inside look at the myriad benefits Major Tool & Machine has realized from a new CNC platform—but like other, similar projects, implementing that platform required a complete motion system overhaul.

January 2013

Scaling Up 3D Printing

By: Peter Zelinski
One of the most inhibiting limitations of additive manufacturing is build size, but that is currently being overcome.

January 2013

Vertical Turning Adds a Horizontal Ram

By: Mark Albert
For American Vulkan, having both a vertical and a horizontal ram on a large VTL is a critical advantage. The added flexibility enables the company to finish some of its biggest coupling components in one setup to a level of precision and surface quality not attainable otherwise.

August 2012

90 Cubic Inches Per Minute in Titanium

By: Peter Zelinski
Mag says its XTi super profiler is designed to remove metal at impressive rates. Its first two machines are are being used for aerospace applications.

August 2012

Inserts Withstand Heavy, High-Feed Cuts

By: Modern Machine Shop
Swapping standard button inserts for a new grade from Ingersoll helped this manufacturer of downhole oil-drilling equipment double throughput on a troublesome arbor milling job in hardened steel.


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