Milling of large parts requires the use of specialized equipment capable of providing high accuracy when working with massive workpieces. Such products are used in heavy industry, energy, shipbuilding, mechanical engineering and defense industries. Their weight can reach several tons, note specialists from the metalworking production company Intech, and their dimensions can reach tens of meters, which places special demands on equipment, tools and processing methods.
Features of processing large-sized products
The main difficulty when working with large parts is the need to combine high precision with a large workpiece mass. Even a minimal deviation of tens of microns when processing a product several meters long can lead to defects.
Therefore, when milling, turning or drilling, machines with a reinforced frame, increased rigidity and a vibration damping system are used. In addition, modern CNC systems are used, which make it possible to process complex surfaces along three-, four- and five-axis trajectories.
There is equipment capable of performing not only standard operations, but also combined machining — milling-boring, turning-milling and drilling-milling. This allows all processing steps to be performed without additional repositioning of the workpiece, which increases accuracy and reduces cycle time, — Intech explains.
Milling machines for large parts
Milling is a key step in creating large metal structures. For such tasks, portal milling machines, bridge machining centers and machines with a movable stand are used.
Gantry machines have a massive frame and a wide working field, which allows processing parts up to 10–20 meters in length. They are ideal for machining machine bodies, plates, frames, mold elements and frames.
Computer numerical control (CNC) machines are used, providing accuracy up to 0.01 mm. This is especially important in the production of base surfaces and flanges, where perfect geometry matching is required, — the Intech company announces the algorithm for working in such areas.
Lathes and rotary lathes
If it is necessary to process cylindrical and annular surfaces, lathes for heavy parts are used. They allow processing workpieces with a diameter of up to several meters and a weight of tens of tons.
Vertical lathes are ideal for large housings and flanges. Their vertical faceplate design ensures even distribution of workpiece weight and minimizes deformation during rotation.
When turning parts such as axles, bushings, drums, rings and flywheels, according to Intech specialists, both horizontal and vertical CNC turning complexes are used.
Boring and jig boring machines
When it is necessary to machine holes, seats or internal surfaces in massive parts, horizontal boring machines are used. They provide high precision when drilling and boring even in workpieces more than 1 meter thick.
Modern equipment is used with the ability to position the tool in several coordinates, which allows processing complex parts without reinstallation. Jig boring machines are used for machining gearbox housings, frames and blocks, where strict alignment of holes and planes is required.
Drilling and drilling-milling complexes
Deep-drilling and radial drilling machines are used to pre-process holes and install fasteners. Their design allows you to work with large-area parts, including massive metal plates and beams.
Drilling and milling centers allow you to combine several operations in one installation, which shortens production cycles. Such machines are used for processing frames, plates and welded structures, where it is necessary to make hundreds of holes and chamfers with minimal deviations.
CNC Machining Centers
Modern CNC machining centers allow you to perform many operations in one setup — milling, drilling, boring, threading and geometry control.
The latest generation machining centers are used, equipped with real-time measurement systems and automatic error compensation. This is especially important in the manufacture of complex metal structures, where high precision surface mating is required,” states the Intech company.
Accuracy control and processing quality
Processing large parts requires not only powerful equipment, but also strict quality control. At all stages, measurements are carried out using coordinate measuring machines (CMMs), laser trackers and 3D scanners.
This approach allows us to guarantee the accuracy of dimensions, geometry and alignment, even when processing products several meters long.
Conclusion
Milling of large parts is a complex technological process that requires the use of powerful machines and precise control systems. Modern milling, turning-boring, boring and machining centers allow you to perform operations with high accuracy and minimal loss of time.
Use of a complex of equipment designed to process parts of any size and complexity. Plus, the professionalism of engineers and modern technologies ensures a high level of quality and accuracy in the manufacture of products for mechanical engineering, energy, metallurgy and other industries, — Intech emphasizes.
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