by John Ayer
Here is one of the tricks I have used over the years to stretch machine capacity when I am doing long thin parts such as automation line rails. The rails might be up to 16 feet long and my machine only has a table 4 feet long.
I place the part on the machine with the first end at the maximum machine travel and the other end supported past the opposite end of the machine travel. The work is positioned against a rail or some stops that are clamped to the table to tram it in.
Next, I do the work that fits in the machine travel and then drill and ream a pilot hole at the overhang end. Note the location of this hole relative to the other work. With a little planning, this hole often can be positioned in an area that will be machined away.
Now, put a dowel pin that is the same size as your pilot hole into the spindle. Bring the pin down into the hole and lock the spindle. Loosen the hold down clamps and use the table to move the part to the first end. You can continually pull the workpiece along as you work while keeping the spindle and the work set at a known point.
This can be done with a CNC or a Bridgeport-style knee mill. You just have to calculate the motions from the new zero or reset the work offset using something like a TRANS function.
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