The real challenge of extra‑large part turning
Turning a three‑meter bearing ring or a 2.5‑meter pipeline flange is not simply a matter of scale. These parts are heavy – often 10–20 tons – and their dimensions push even large machine tools to their limits. The challenges are vibration during interrupted cuts, maintaining concentricity across large diameters, achieving consistent surface finishes on sealing faces, and completing the job in a reasonable timeframe.
The CK5235 addresses each of these challenges directly: the double‑column frame provides the rigidity to resist cutting forces, the hydrostatic table absorbs vibration, the precision spindle bearings maintain concentricity, and the two‑tool‑post design cuts cycle time.
Application 1: Wind turbine bearing rings
Wind turbine bearing rings, particularly for yaw and pitch systems, are among the most demanding turning applications. These rings are large – often 2–3 meters in diameter – and require high concentricity between outer and inner diameters, tight roundness tolerances, and excellent surface finish on the raceways. Any deviation affects bearing life and turbine reliability.
On the CK5235, the workpiece is clamped once on the 3,150 mm hydrostatic worktable. The double‑column rigid frame ensures that the cutting force does not deflect the crossrail or columns, even during heavy roughing. The ±30° swiveling tool post allows raceway tapers to be machined accurately without special form tools. The hydrostatic table provides a vibration‑free platform for finishing passes, so raceway surface finishes are consistent across the entire circumference. For a typical 2.2‑meter bearing ring, roundness can be held within 0.015 mm, and surface finish within Ra 1.6–2.0 µm – good enough for most bearing applications without additional grinding.
Application 2: Extra‑large flanges for pipelines and wind towers
Flanges for oil, gas, and water pipelines, as well as wind tower sections, can reach diameters of 2.5–3.5 meters. A large flange requires face turning on both sealing surfaces (often with a gasket groove), outer diameter turning, inner diameter boring, and chamfering. On a smaller lathe, these operations might require multiple setups or struggle with vibration during facing cuts.
On the CK5235, all operations are completed in a single setup. The 55 kW spindle and 63–80 kN·m torque provide the power needed for deep roughing cuts, even on stainless steel flanges. For a 2.5‑meter carbon steel flange, total machining time on the CK5235 is typically 30–40% shorter than on a single‑column machine of similar capacity, thanks in large part to the two‑tool‑post design that allows roughing and finishing to proceed in parallel.
Application 3: Large valve bodies and pump housings
Valve bodies for oil and gas pipelines, power plants, and water treatment facilities, as well as large pump casings, are often complex castings with multiple flange faces, internal bores, and sealing surfaces. These parts are heavy and often have irregular shapes, which can cause unbalanced loading on the worktable.
The CK5235's double‑column frame handles unbalanced loads effectively. The symmetric structure distributes forces evenly, so the crossrail remains level even when the workpiece is not perfectly centered. The ±30° swiveling tool posts allow the operator to machine tapered valve seating surfaces without special tooling. For a large globe valve body weighing 12 tons, the CK5235 can complete facing, boring, and thread machining in a single setup – eliminating the need to move the part to another machine for secondary operations.
Application 4: Heavy gear blanks for mining and cement equipment
Gear blanks for mining mills, cement kilns, and heavy industrial gearboxes are large forgings or castings that require heavy material removal. The primary machining requirement is to produce a turned blank that is concentric, dimensionally accurate, and properly faced for subsequent gear cutting.
The CK5235's 55 kW main motor provides ample power for deep roughing cuts, removing material quickly from heavy forgings. The 16‑step gearbox allows the operator to select the optimal speed for roughing versus finishing. The two‑tool‑post design means that while the left tool post is roughing the outer diameter, the right tool post can be finishing the end face or boring the inner diameter. For a 2‑meter gear blank weighing 18 tons, total cycle time on the CK5235 is often 25–35% shorter than on a single‑tool‑post machine.
How the double‑column design improves your daily work
The difference between a single‑column and a double‑column vertical lathe is not something you see on a specification sheet – it is something you feel on the shop floor. When you are taking a 10 mm depth of cut on a 2.5‑meter flange, a single‑column machine may start to chatter. The crossrail deflects slightly, and the surface finish suffers. On the CK5235, the double‑column frame keeps everything rigid. The cut is stable, the finish is consistent, and the job gets done faster.
For parts with off‑center weight – a valve body with a heavy boss on one side, a bearing ring that is not perfectly balanced – the double‑column design is especially valuable. The symmetrical structure distributes forces evenly, preventing the crossrail from tilting and maintaining tool alignment across the entire part.
Single‑setup machining – the hidden productivity gain
Every time you move a 10‑ton part from one machine to another, you lose time, you risk handling damage, and you introduce alignment errors. The CK5235 is designed to minimise these hidden costs. With a worktable large enough to accommodate parts up to 3.5 metres in diameter, most extra‑large components can be fully machined in a single setup. This means fewer transfers, less handling, and more time actually cutting metal.
For a shop processing 8–10 large flanges per week, moving from a two‑setup process to a single‑setup process on the CK5235 can free up 15–20 hours of machine time per week. Over a year, that adds up to hundreds of additional hours of productive cutting.
How the CK5235 compares to premium brands
The CK5235 is priced roughly 40–50% lower than a similarly equipped European or Japanese double‑column vertical lathe. Yet the specification – double‑column rigid frame, hydrostatic worktable, precision spindle bearings, 55 kW main drive, Siemens CNC, and two tool posts – matches or exceeds many mid‑range offerings. The cost saving comes from smart engineering: proven structural designs, regional castings with proper stress relief, established linear guide and ball screw suppliers, and standard Siemens CNC platforms. There are no exotic materials or over‑engineered features that add cost but bring little real‑world benefit.
Practical preparation for buyers
Before the CK5235 is delivered, users should prepare a reinforced concrete foundation capable of supporting the machine's 32–40 ton weight, provide a suitable overhead crane for unloading and positioning (20‑ton capacity recommended), and ensure a stable power supply (380V, 50Hz, three‑phase, approximately 80–100 KVA). Standard delivery includes on‑site installation, operator training, and complete documentation – operation manuals, maintenance guides, electrical diagrams, and quality certificate.
➡️ To discuss how the CK5235 fits your specific parts – bearing rings, large flanges, valve bodies, pump housings, or gear blanks – or to request a trial cut or quotation, click here to speak with our application engineering team.