The real challenge of complex large‑part machining
For many job shops and production lines, complex large‑diameter components such as flanges with bolt circles, bearing rings with locating features, and valve bodies with multiple faces require both turning and milling operations. The traditional solution – turn on a vertical lathe, then transfer to a machining center for milling and drilling – introduces several costly problems: alignment errors between features, additional fixturing time, increased work‑in‑progress, and the risk of handling damage to heavy parts.
The HAIDI VL1600 addresses all of these challenges by combining both turning and milling capabilities in a single machine. The workpiece is clamped once on the 1,400–1,600 mm worktable, and all operations – rough turning, finish turning, face milling, bolt‑hole drilling, tapping, and grooving – are completed without repositioning.
Application 1: Large flanges with bolt hole circles
A typical large pipeline flange requires face turning of sealing surfaces, outer diameter turning, inner diameter boring, and drilling of a bolt hole circle with precise angular spacing. On a traditional two‑machine process, the flange is turned first, then transferred to a machining center for drilling. The transfer introduces alignment errors – the bolt circle may not be perfectly concentric with the turned diameter.
On the VL1600, the flange is turned and drilled in one setup. The C‑axis indexes the worktable to each bolt‑hole position with 0.001° resolution, and the live tool drills each hole to precise depth and location. The result is a bolt circle that is perfectly concentric with the turned features – no alignment errors, no rework.
Application 2: Wind turbine bearing rings
Bearing rings for wind turbine yaw and pitch systems require turning of outer and inner diameters, milling of locating slots, and drilling of mounting holes at specific angular positions. The tolerances are tight – any positional error affects assembly and bearing performance.
On the VL1600, the 5–8 ton workpiece capacity handles the weight of large bearing rings with ease. The 12‑station ATC turret holds turning tools, milling cutters, drills, and taps simultaneously. The C‑axis provides the angular positioning required for slots and mounting holes. All operations run automatically from a single program, eliminating the handling and repositioning errors that would otherwise occur.
Application 3: Valve bodies and pump housings
Large valve bodies and pump housings often require machining of flanges on multiple faces, boring of internal passages, and drilling of threaded ports. These parts are complex and often have irregular shapes that make handling difficult.
The VL1600's vertical orientation simplifies loading of heavy, irregular castings. The C‑axis allows the worktable to rotate the part to present each face to the spindle. The live‑tool turret performs turning, boring, milling, drilling, and tapping in sequence. The result is a complete part – no transfers, no second operations, no lost time.
How single‑setup machining improves your bottom line
The productivity gains from single‑setup machining are substantial. For a typical flange or bearing ring, the total processing time on the VL1600 is often 30–50% shorter than on separate turning and milling equipment. The reasons are straightforward:
No transfer time – The part stays on the same machine from start to finish.
No realignment – The C‑axis maintains the part's orientation, so all features are referenced to the same datum.
No handling damage – Heavy parts are moved once, not twice or three times.
Reduced work‑in‑progress – Parts move from raw material to finished component in one operation.
For a shop processing 100 large flanges per month, moving from a two‑machine process to a single‑setup process on the VL1600 can free up 20–30 hours of machine time per week – capacity that can be used for additional jobs.
What makes the VL1600 cost‑effective
The VL1600 is priced significantly below comparable European or Japanese turn‑mill vertical lathes of similar capacity. Yet its specification – cast iron box‑type construction, C‑axis with 0.001° resolution, 12‑station ATC live‑tool turret, and Siemens/Fanuc CNC – matches or exceeds many mid‑range offerings.
When you compare a new HAIDI VL1600 against a used machine of similar capability, the price difference is often smaller than you think – especially after you factor in the inevitable repairs, worn components, and downtime that a used machine will require.
New VL1600 offers:
Full warranty and factory support
No hidden wear – every component is new
Modern CNC control (Siemens or Fanuc)
Factory‑set geometry and accuracy
Complete documentation from day one
Used alternatives often require:
Immediate repairs – spindle bearings, guideways, hydraulics
Control system updates or retrofits
Recalibration and re‑alignment
Unplanned downtime during repairs
No warranty or support
What VL1600 customers can expect
The VL1600 combines the capabilities of a vertical lathe and a machining center in a single, compact platform. For shops that currently use separate machines for turning and milling of large parts, the VL1600 represents a significant step forward in productivity, accuracy, and cost control.
The machine's rigid construction – box‑type cast iron structure, precision cross‑roller bearings, and full‑gear transmission – ensures consistent performance even under heavy cutting conditions. The C‑axis and live‑tool turret provide the versatility needed for complex parts. And HAIDI's responsive support and spare parts availability keep the machine running when you need it most.
➡️ To discuss how the VL1600 fits your specific parts – flanges, bearing rings, valve bodies, or gear blanks – or to request a trial cut or quotation, click here to speak with our application engineering team.