Concept

Process consolidation integrates turning, milling, drilling, tapping, boring, chamfering, gear hobbing and grinding operations—originally performed on multiple machines—into a single turn-mill center. With one clamping, one program and one machining cycle, the part is fully finished.

Core Mechanisms
• Multi-axis linkage: main/sub spindles, B/C axes, Y axis and driven tool turret enable machining from any angle.
• Simultaneous machining: dual tool posts can cut both spindles at once, eliminating idle time.

• In-process compensation: laser or probe measures → CNC auto-compensates → closed-loop dimensional control.

Key Benefits
• Higher accuracy: removing re-clamping errors improves positional and concentricity tolerances by over 50 %.
• Cycle-time halved: processes that once required 3–4 machines are compressed into one, cutting part-to-part time by 40–60 %.
• Lower costs: fewer fixtures, less tool changing, reduced labor and smaller floor space.

• Greater flexibility: modular tooling and program libraries allow new parts to be launched at the push of a button, ideal for high-mix, low-volume production.

Application Example

Electric-vehicle motor housing: OD turning → keyway milling → oil-seal hole drilling → thread tapping → internal chamfering, all in one setup, achieving ≤ 0.005 mm roundness within a 90-second cycle.

Implementation Essentials
Process planning: break down operations → match tool positions → simulate collisions → generate consolidated program.
Tool management: standardize on HSK or Capto interfaces to reduce tool-arm payload.

Maintenance strategy: periodic laser calibration plus spindle thermal compensation ensure long-term accuracy.

In one sentence
Process consolidation turns a turn-mill center into “a whole production line in one machine,” delivering the best balance of precision, efficiency, cost and flexibility—today’s key enabler for cost-effective precision manufacturing.