Machining a job that is outside a milling machine’s table travel using Fusion 360

Introduction

This write up is not for the purists with years of experience but is an explanation of how I thought through how to machine something over size that would not fit into my Tormach PCNC440 milling footprint as a single operation.  Hopefully it might help others to grasp the process.

The challenge began when a local turret clock expert came to me and asked if I could machine a new Hour and Minute Hand for a clock he was working on.   The Hour Hand was around 14” long and the Minute Hand some 18” long.   

Here is the Fusion 360 view of the minute Hand.

clock minute hand milled in three steps

Clearly these lengths were way outside the 440 table X movement (10”) so a plan was needed.  There then followed a lot of staring into the distance at mealtimes and also at bedtime accompanied by vocal “hmmm”s as I tried to mentally visualise what was needed.  This idiosyncrasy is something my wife has come to terms with over the years…..

My conclusion from this mental preparation was that I needed to be able to accurately step the stock across the tooling table and then take two or three bites at the profile machining.  

What follows would almost certainly benefit from a video but sadly I am not set up for this. 

Click the link below to download the PDF document.

Milling an oversize object

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