We received an RFQ from a very steady customer to make a 'heavy duty' version of an assembly we have been making for them for many years. For the most part it the same thing we've always made, just bigger. But, there is one feature of one part that has me thinking twice about the approach.
We need to machine a 2.25" radius 'half moon' into the side of a 1"x3" piece of CRS 1" deep into the flat side and all the way through the short side. On a 'standard duty' version of this part the feature is a .75" radius so we use a 1.5" diameter indexable mill and plunge mill to the required .375" depth - no problem. That same technique on this HD part would require a 4.5" mill. Again, no problem, except that our shop is 100% manual with R8 spindles. I'm concerned I'm going to beat our mill(s) to death trying to cut that feature plunging a 4.5" mill. A rotary table is out of the question because this part is 175" long. So far, it's just one part for one assembly, so maybe I can get away with it. However,in the event it shows up again I would like to have a reliable solution.
I would love to hear some ideas if anyone has any. Of course it could be subbed out or I could rent some time on a buddy's CNC (6 hour round trip with a 14' long piece of steel) but I would like to avoid that if possible.
We need to machine a 2.25" radius 'half moon' into the side of a 1"x3" piece of CRS 1" deep into the flat side and all the way through the short side. On a 'standard duty' version of this part the feature is a .75" radius so we use a 1.5" diameter indexable mill and plunge mill to the required .375" depth - no problem. That same technique on this HD part would require a 4.5" mill. Again, no problem, except that our shop is 100% manual with R8 spindles. I'm concerned I'm going to beat our mill(s) to death trying to cut that feature plunging a 4.5" mill. A rotary table is out of the question because this part is 175" long. So far, it's just one part for one assembly, so maybe I can get away with it. However,in the event it shows up again I would like to have a reliable solution.
I would love to hear some ideas if anyone has any. Of course it could be subbed out or I could rent some time on a buddy's CNC (6 hour round trip with a 14' long piece of steel) but I would like to avoid that if possible.