Holds the rotor body and its bearing
EMI shielding and cooling of the batteries
Hybrid or fully electric cars move to the beat of their heart – the electric motor, which has become the key element in the powertrain, thanks, in part, to its enormous torque.
Of particular interest to machine operators is the electric motor housing made of a wide range of aluminium alloys. Given that annual quantities have now reached high volume production levels, unit costs are becoming increasingly important. The stator bore in particular is the most cost-intensive part, placing high demands on the tool and cutting edge. In the case of bore diameters of 200 mm and above, reducing the weight of the tools plays an essential role in preventing the tilting moment and torque of the machining centre from being maxed out.
We have the perfect solution to hand for these challenges too.
The MaxiMill SEC12 (1) and the HPC PCD milling cutter (2) are used for milling the e-motor housing.
The solid carbide drill WTX-AL (1) and the PCD drill (2) are used for drilling the e-motor housing.
Standard Thread machining
Threads down to the bottom of the core hole
100-300m/min | M8: fz 0,07-0,12
Time saving thanks to operation combination
100-400m/min | M8: fz 0,03-0,12
Stronger threads thanks to forming
The following tools are used for drilling the stator of the e-motor housing: fine boring tool (1), 3D-printed composite boring bar (2, top left & right), conventional boring bar (2, bottom left & right), special U-axis (3, top), U-axis with front tool (3, bottom) actuating tool (4).
The batteries for electric and hybrid vehicles must be carefully protected to ensure safety and a long service life. Thin-walled battery trays made of high-strength aluminium alloys are the container of choice as they add little to the overall weight. To keep the cost at a reasonable level, durable and innovative tool systems which can carry out several cutting operations in one go, for example, are used for the array of holes and threads. Speed is also essential when it comes to the long seating surfaces for the battery tray lid.
Our HSC and HPC-tested milling tools break all speed limits.
Milling of the module support surfaces
Size: 10 - 32mm
Depth: 2,5xD; 4xD
Ap: max. 3mm
Vc: 400-1500 m/min
Fz: 0,06-0,2 mm
Drilling of the clamping holes of the battery tray
Drilling, threading and chamfering the screw thread in a single operation
Size: 4-16 mm
Type: metric / inch / UNC
Vc: 100-400 m/min
Fz: 0,03-0,0,07 mm
Face milling of the long sealing surfaces
Type: Eco, Performance and HPC
Ap: max. 3 mm
Vc: 1000-4000 m/min
Fz: 0,04-0,15 mm