How Is Large Part Machining Different
The machining of large parts presents some unique challenges and often requires a higher level of planning compared to small part machining. Due to their large and heavy nature, additional steps and considerations are required in order to effectively and safely handle and machine large parts. If your project requires large part machining, it is important to work with an experienced team, like ABS, who have the necessary facilities and proven know-how for heavy machining. Below are several key factors that make large-part machining different.
- Safety: due to their size and weight, large part machining and handling involves additional risks that are not present in the machining of smaller parts. Heavy machining requires additional planning to ensure the job can be performed safely. For this reason, it is crucial that OEMs discuss safety practices upfront with potential machining contractors to ensure safety protocols are thorough and personnel safety is considered in every step of the process. Some examples of safety measures for large part machining include robust in-house operator training programs as well as various inspections including safety walk-throughs prior to initiating a job as well as inspections of cranes, lifting devices, and other critical equipment.
- Setup and Mobility: mobility is often an issue for large parts due to their size and weight. Transport of these pieces throughout the shop requires cranes and special equipment as well as experienced and skilled personnel to properly handle the part. Since large parts are not easily relocated, a simple and well-organized set-up and plan are crucial. For example, processing steps such as cutting, welding, and painting often come to the large part to minimize transport of the structure. It can also be challenging to position large pieces in the machine, thus, repositioning of the part should be minimized - this also helps ensure more precise machining and tighter tolerances are achieved.
- Potential for Stress: the potential for various stresses is typically higher in large part machining compared to smaller parts. These stresses can build in the part resulting in distortion and issues with the part shape after machining is completed, which may lead to difficulties meeting tolerances. Frequent and thorough inspections of the large part during processing as well as cautious machining practices allow operators to identify part stress early on and minimize its impact.
- Temperature Concerns: whether you are machining small or large parts, heat is generated during the process. Heat generation is amplified during large part machining and may require preventative steps to avoid potential issues. For example, large parts may be allowed to cool down in between machining steps. While this approach takes additional time, it increases the accuracy of machining operations and preserves the integrity of the large part.
- Multi-Pass Machining: the risks associated with heavy machining are generally higher. If a final part does not meet specifications, the part may need to be modified or scrapped resulting in significant schedule delays and additional cost. To minimize these risks, large part machining may involve multiple passes on a given machine with inspections often occurring in between passes to confirm dimensions. This approach increases the likelihood that the part will be machined correctly the first time and can be consistently reproduced in the future – overall saving time and money.
- Advanced Equipment: equipment used for large parts must have a bigger work space and reach and need to be more advanced than traditional machines. One technology that makes large part machining possible is 5-axis machines, such as ABS’ 5-axis boring mills. Traditional machines require multiple setups to rotate the part orientation to perform the necessary machining steps. These part adjustments can lead to misalignments and errors each time the part is removed and reinserted into a new position – not to mention the additional time it takes to reposition a large part with cranes and other equipment. 5-axis machines require a single setup since it uses all 5 axes to work on every surface of the part simultaneously - significantly increasing operations efficiency, reducing the opportunity for error, and minimizing repositioning of the large part. Other examples of specialized equipment for large part machining include large milling, deep hole drilling, and contour boring machines.
ABS’ Large Part Machining Expertise
Established in 1971, ABS Machining has grown to become the recognized global leader in large machining, fabrication, and assembly for OEMs. The key to our success has been exceptional people, unparalleled facilities, and an unwavering commitment to quality. Our people are experts in their given field. Their expertise is matched only by their passion for serving our clients. We continue to invest in our people with education programs, cross training and in our internal accredited apprenticeship center.
ABS set out on a path over 4 decades ago to become a global leader in large machining, with the most advance and versatile fleet of equipment. By achieving this goal, ABS has grown to be recognized as one of the largest and most advanced contract manufacturing companies in North America. ABS’ fleet of CNC Boring Mills, Vertical Turning Lathes, and Table Type Boring Mills are supposed across six facilities and serviced with cranes lifting capacities up to 160 tons. Backed by a dedicated staff of professionals in each discipline of manufacturing, ABS truly offers a single source for the most challenging programs of today and for the future. Successfully achieving this goal organically required the following commitments:
- Continuous investment regardless of economic cycles.
- Acquisition of the most advanced technologies in the Large Machining industry.
- Continuous improvements and upgrades of existing capital to ensure all assets are leading edge in the industry.
- Advancing internal capabilities for maintenance programs.
- Building a Government recognized Training Facility to ensure continuity, and that future skilled trades are available.
- Investing and expansion in all support staff roles such as Safety, Quality, Engineering, and Production Control.
Contact us today to see how we can help with your machining project, or give us a call at 1-844-227-6224.
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