Large Workpiece Machining
Large Workpiece Machining
(OP)
We have some components for our machine that in the past have always been cast iron. We recently tried starting with a solid chunk of P20 steel, and machined everything. We are very plesed with the results, and the component life is at least double the cast version.
Since we start with a solid chuck, there is a ton of machining spindle time required to manufacture these. The initial block is ~36" x 36" x 18" thick. We literally machine away probably 1/3 of the material. There is a large pocket in the center ~24" x 24" x 6-8" deep. Some times the entire face of the part gets machined down 4" except for maybe a 10" x 10" area.
My question is...how can we reduce the machining spinde time? Is there a laser (or other) cutting process that can go through 18" of material? Or some type of band saw? Or is there a manufacturer out there that can supply us the raw material closer to the final dimensional size? Or ???
Thanks,
Ken
Since we start with a solid chuck, there is a ton of machining spindle time required to manufacture these. The initial block is ~36" x 36" x 18" thick. We literally machine away probably 1/3 of the material. There is a large pocket in the center ~24" x 24" x 6-8" deep. Some times the entire face of the part gets machined down 4" except for maybe a 10" x 10" area.
My question is...how can we reduce the machining spinde time? Is there a laser (or other) cutting process that can go through 18" of material? Or some type of band saw? Or is there a manufacturer out there that can supply us the raw material closer to the final dimensional size? Or ???
Thanks,
Ken





RE: Large Workpiece Machining
Software For Metalworking
http://closetolerancesoftware.com
RE: Large Workpiece Machining
RE: Large Workpiece Machining
I have not failed. I've just found 10,000 ways that won't work." — Thomas Edison
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RE: Large Workpiece Machining
Have you tried casting the part from the improved material like ajack & arunmrao mention.
Else my first response was the same as mrainey though this is a pretty big piece.
Some suppliers will supply pre-cut material - for a fee, you may want to shop around.
KENAT,
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RE: Large Workpiece Machining
"Wildfires are dangerous, hard to control, and economically catastrophic."
Ben Loosli
RE: Large Workpiece Machining
We've used this process in the past to save considerable machine time (although I haven't specifically done P20, we have done some decent size blocks, 50x50x13" thick).
--Jay
RE: Large Workpiece Machining
RE: Large Workpiece Machining
RE: Large Workpiece Machining
It is very quick and economical,disadvantage can't make multiple castings.
I have not failed. I've just found 10,000 ways that won't work." — Thomas Edison
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RE: Large Workpiece Machining
I know that poring this casting can be done. Another question is where bregine is located?
RE: Large Workpiece Machining
If you're not using CNC machines to do this work, that would be a good place to start. A medium size horizontal machining center with a strong spindle and chip conveyor should be able to do a part like that overnight, maybe unattended once you get the process stable.
Whether CNC or not, most machinists tend to baby their cutting tools so as to maximize edge life.. at the expense of machining time, for which they get paid by the hour, so you can see the incentive.
The thing to do is go through each part cut by cut with your cutting tool supplier and maximize the metal removal rate. You can probably cut the machining time in half, and maybe go beyond that.
If chips aren't hitting the ceiling, you're not pushing hard enough...
Mike Halloran
Pembroke Pines, FL, USA
RE: Large Workpiece Machining
Hope this helps.
Vic
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Mech Rulz
RE: Large Workpiece Machining
RE: Large Workpiece Machining
RE: Large Workpiece Machining
Everyone is mentioning forging, but you said it used to be cast iron? Why not cast steel? There are many heavy equipment parts that are made of cast steel and hold up very well.