Turning Large Cylindrical Parts into a Multi-tasking Opportunity
As manufacturers look to produce increasingly complex large-diameter components in fewer set ups, the ability to combine turning and milling operations on a single platform is becoming increasingly desirable. However, conventional mill-turn approaches can present certain compromises in the production of heavy cylindrical parts. Fives High Precision Machines (Fives HPM), through its Giddings & Lewis brand, is addressing the challenge from a different direction: by adding five-axis contouring capability to a platform specifically engineered for large-part vertical turning.
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Big-diameter components for sectors such as aerospace and maritime are particularly challenging. They can combine substantial weight and tight tolerances with demanding machining and material-removal requirements. The choice of machine platform, therefore, can have a significant influence on key metrics like productivity and accuracy, as well as overall manufacturing efficiency.
The Giddings & Lewis VTC Series from Fives HPM adopts a fundamentally different starting point. Designed specifically for parts of this nature, these advanced vertical turning centers provide robust turning capabilities with powerful milling. Moreover, they blend high stiffness and substantial table capacity with multifunctional machining capabilities that, depending on model configuration, potentially include turning, milling, drilling, tapping, and grinding. The introduction of the Giddings & Lewis all-in-one B/C contouring attachment extends that capability further, bringing five-axis contouring to the VTC platform.
A Different Approach
Combining operations in a single set up proves advantageous, avoiding the non-value-added task of moving a component between stand-alone turning and milling machines. Separate operations can also compromise accuracy due to the need for workpiece refixturing.
Most multi-tasking solutions address this challenge by using a milling machine as the primary platform and adding turning capability. While practical for light-duty metal removal applications and prismatic parts, the mill-turn strategy is less suited to the specific requirements of large, heavy cylindrical components.
In complete contrast, a Giddings & Lewis vertical turning center sees enhancement through the addition of advanced milling capability. This distinction matters. The VTC Series is purpose-built around the requirements of big-diameter part turning, with the ability to accommodate workpieces up to 5 m in diameter and 60,000 kg in weight.
The robust 250 mm (9.8 in) square ram with wear-free hydrostatic pads and symmetrical carriage offer excellent stiffness and damping characteristics to prevent torsion and vibration during heavy cutting. The long 1750 mm (68.9 in) ram travel can access deep bores with a minimum size of 324 mm (12.8 in) potentially reducing tool length and improving rigidity.
Five-Axis Contouring
Forming part of the material removal product offerings of Fives HPM, the new Giddings & Lewis all-in-one B/C contouring attachment is designed to build on these inherent advantages. Mounted to the headstock of VTC Series machines, the two-axis programmable attachment provides B- and C-axis movement. Specifically, the C axis rotates the attachment to facilitate contouring in the virtual Y-axis plane, while the B-axis controls the angle of the tool to provide contoured features, or drilled or tapped off-angled holes.
The attachment incorporates a 2,200 rpm spindle producing up to 33 kW (44.25 hp) in S6-40% operation, with 22 kW (29.5 hp) available continuously. Maximum spindle torque is 916 Nm (670 ft-lb), while the B/C axes provide up to 855 Nm (625 ft-lb), depending on tooling geometry and cutting forces. Coolant-through-the-spindle, flood coolant and an automatic tool changer further extend machining capability.
For many manufacturers, however, the most important specification of the new attachment will likely be size.
Small Design, Big Possibilities
At around 700 mm (27.6 in) in length, the attachment is unusually compact for its capabilities, supporting fitment across a much wider range of VTC Series machines. In fact, the all-in-one B/C contouring attachment is suitable for use on machines with table diameters from 4.5 m down to 1.25 m (from VTC 4500 to VTC 1250 models).
The differentiating features of the all-in-one B/C contouring attachment are the fact that customers maintain the same compact footprint of a vertical turning center with lower foundation requirements compare to other machines with similar functionality.
Built for Precision at Scale
The VTC Series has been engineered from the outset to provide the stiffness and stability necessary for machining large cylindrical components.
A signature table bearing design minimizes deflection and delivers precision table runout of just 0.005 mm (0.0002 in) TIR, both radially and axially. The design also helps prevent tipping on tall or unbalanced components, while hydrostatic rams provide high stiffness and damping characteristics.
This combination of structural rigidity, capacity and multifunctionality reflects what Fives HPM calls ‘precision at scale’: the ability to transfer high levels of machining accuracy and process control to components at the upper end of the manufacturing scale.
One Platform, More Opportunity
The objective of developing the all-in-one B/C contouring attachment is not simply to add features, but to allow manufacturers to bring more operations on to a single platform. Fewer set ups mean less handling, improved throughput and improved part quality. For aerospace and maritime manufacturers working with hardmetals, these benefits can be particularly significant.
Notably, the attachment is manufactured at the Giddings & Lewis facility in Fond du Lac, Wisconsin, reinforcing the brand's long-standing U.S. manufacturing heritage dating back to 1859. Customers have access to comprehensive technical support, including integration, automation, services, spare parts, and training through the U.S. headquarters.
As part of the newly unified Fives HPM portfolio, Giddings & Lewis combines established engineering prowess with the group’s wider expertise and resources. For manufacturers tackling increasingly demanding large-diameter component applications, this combination provides more than machine capability alone: it unites applications knowledge, engineered solutions, and lifecycle support under a single brand umbrella.
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