NEWS

A detailed look at a high-efficiency batch processing solution: completing drilling and end-face milling in a single setup.

We recently successfully delivered a batch order of 5,000 precision parts. This order stemmed from an initial run of a few hundred prototypes; the original process involved turning on a lathe followed by milling and drilling on a separate milling machine. While this multi-stage approach met the precision requirements for the prototypes, it created a clear efficiency bottleneck for mass production. The client was highly satisfied with the prototype quality and immediately placed an order for 5,000 units—a task with a tight deadline and a heavy workload.

Faced with this volume, sticking to the traditional "turn-then-mill" sequence would have required each part to undergo two separate setups, two machine transfers, and multiple manual loading/unloading steps. This would not only extend total processing time but also significantly reduce overall productivity due to the waiting periods and handling between operations. To overcome this bottleneck, our engineering team redesigned the process. The core strategy was to consolidate all subsequent drilling and end-face milling operations onto a single 4-axis CNC machining center, utilizing a custom-designed fixture.

4-Axis CNC Machining Center: Integrating Drilling and End-Face Milling. The pain point of multi-stage processing is that after the external profile is turned on a lathe, the part must be transferred to a milling machine for drilling and end-face milling. Each machine transfer requires re-alignment, calibration, and re-clamping, which consumes extra man-hours and risks introducing cumulative positioning errors. In the new solution, we leverage the rotary axis capabilities of the 4-axis CNC machining center to integrate the two core operations—drilling and end-face milling—onto a single machine. By optimizing the toolpath and machining sequence, the machine automatically performs a series of actions—such as end-face milling and drilling at various angles—after a single setup, eliminating the need to remove or reposition the workpiece mid-process. Compared to traditional 3-axis machine tools, a 4-axis CNC machining center adds a rotary axis, enabling milling and drilling operations at various angles; this makes it ideal for parts requiring machining on multiple faces or hole patterns on end faces. The parts in this order required machining on both end faces as well as multiple side holes. 4-axis simultaneous machining allowed all features to be processed in a single setup, effectively eliminating tool-setting errors and efficiency losses associated with re-clamping.

Specialized Fixtures: The Key to Unlocking Mass Production Capacity

Equipment alone is not enough; in mass production, clamping efficiency directly determines equipment utilization and the time required per unit. General-purpose fixtures typically hold only one or two workpieces at a time, and manual clamping and alignment consume significant non-productive time. To match the high-speed cycle times of the 4-axis CNC machining center, our engineering team designed a custom fixture.

This specialized fixture features a rapid positioning and clamping mechanism capable of holding six workpieces simultaneously while maintaining stable positioning accuracy. The design accounts for potential interference during 4-axis rotation and the direction of cutting forces, ensuring rigidity during high-speed milling and drilling. Actual testing showed that using the specialized fixture reduced average non-productive time per unit by over 60% and significantly increased the spindle uptime.

Efficiency Data:

Delivered 15 Days Ahead of Schedule. The new process combination—integrating end-face drilling and milling on a 4-axis CNC machining center with a specialized fixture—delivered outstanding results for a 5,000-unit production run. While the original process estimated a 35-day production cycle, the actual work was completed in just 20 days, beating the customer's deadline by 15 days. Furthermore, the reduction in clamping operations improved dimensional consistency and positional accuracy rates compared to the prototyping stage.

This achievement not only validates the role of process integration in driving efficient production but also demonstrates that, for mass production orders, the right equipment and custom fixtures offer greater advantages in cost and delivery time than simply increasing the number of machine tools. We have now incorporated this process into our standard operating procedures, enabling us to provide faster, more cost-effective mass production services for parts with similar configurations.