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Machining electric motor housing and battery trays

Holds the rotor body and its bearing

EMI shielding and cooling of the batteries

1. Machine electric motor housing: stator drilling

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.

Milling the e-motor housing

The MaxiMill SEC12 (1) and the HPC PCD milling cutter (2) are used for milling the e-motor housing.

Drilling the e-motor housing

The solid carbide drill WTX-AL (1) and the PCD drill (2) are used for drilling the e-motor housing.

Threading the e-motor housing

1. Cutting tap

Standard Thread machining
25-80m/min

2. Thread milling cutter

Threads down to the bottom of the core hole
100-300m/min | M8: fz 0,07-0,12

3. Drill thread milling cutter

Time saving thanks to operation combination
100-400m/min | M8: fz 0,03-0,12

4. Cold forming tap

Stronger threads thanks to forming
20-60m/min

Stator bore e-motor housing

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).

2. Milling and drilling operations on battery trays

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.

1. PCD endmill

Milling of the module support surfaces

  • Flatness as well as burr-free edges are the main requirements of this operation
  • High number of teeth
  • Carbide shank for a rigid tool and reduced vibration
  • 3D printed head to achieve special geometries

Technical data
Size: 10 - 32mm
Type: HPC
Depth: 2,5xD; 4xD
Ap: max. 3mm
Vc: 400-1500 m/min
Fz: 0,06-0,2 mm

2. Semi-Standard step drills with countersinking

Drilling of the clamping holes of the battery tray 

  • Step drills equipped with indexable inserts
  • Configurable semi-standard product portfolio
  • Indexable insert portfolio for aluminium machining

Our service:

  • Shortest delivery time under 3 weeks
  • High-Tech Tools for the highest productivity
  • Fixed prices at the Standard-tool pricing level

3. Drill thread milling cutter

Drilling, threading and chamfering the screw thread in a single operation 

  • Three tools in one
  • Extremely efficient on large quantities of threads
  • Precise thread depths with accurate repeatability
  • Over 50% reduction in the primary processing time, thanks to high cutting speed and feed
  • No chip residue in the thread
  • High-speed cutting (HSC) can be performed
  • Free TPT app for creating CNC programs and for use as a tool finder

Technical data
Size: 4-16 mm
Type: metric / inch / UNC
Vc: 100-400 m/min
Fz: 0,03-0,0,07 mm

4. HPC PCD milling cutter

Face milling of the long sealing surfaces 

  • Significant reduction in the primary processing time by up to 72%
  • 3D-printed milling ring for maximum number of cutting edges and perfect coolant supply
  • Maximum cutting data values and service life for efficient production
  • Reduced burr formation and quieter running than conventional PCD milling cutters
  • PCD cutting edges can be re-lasered
  • Available as face mills, screw-in cutters or monobloc milling cutters from stock (dia. 10 – 100 mm)

Technical data
Size: 10-100mm
Type: Eco, Performance and HPC
Ap: max. 3 mm
Vc: 1000-4000 m/min
Fz: 0,04-0,15 mm