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

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 breakdown torque and torque of the machining centre used from being maxed out. 
We have the perfect solution to hand for these challenges too.

Milling the electric motor housing

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

Electric motor housing machining

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. Taps

Standard Thread machining

2. Thread milling cutters

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

3. Circular thread milling cutter

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

4. Thread formers

Stronger threads thanks to forming

Stator bore of the electric 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 end mill

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 – 32 mm
Type: HPC
Depth: 2.5xD; 4xD
Ap: max. 3 mm
Vc: 400 – 1500 m/min; Fz: 0.06 – 0.2 mm

2. Semi-Standard step drills with countersinking

Milling of the module support surfaces 

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

Our service:

  • Shortest delivery time within 3 weeks
  • High-tech tool for maximum productivity
  • Fixed prices at a standard price level

3. Circular thread milling cutter

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

  • Three tools in one
  • Extremely efficient when large quantities of threads are to be produced
  • 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
Dimensions: 4 – 16 mm
Type: metric / imperial / UNC
Vc: 100 – 400 m/min
Fz: 0.03 – 0.007 mm

4. HPC PCD milling cutters

Face milling the long seating surfaces 

Flatness and surface quality are the main requirements for machining

  • Significant reduction in the primary processing time of up to 72%
  • 3D-printed milling ring for maximum number of cutting edges and perfect coolant supply
  • Maximum cutting speeds 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 monoblock milling cutters from stock (dia. 10 – 100 mm)

Technical data
Dimensions: 10 – 100 mm
Type: Eco, Performance and HPC
Ap: max. 3 mm
Vc: 1,000 – 4,000 m/min
Fz: 0.04 – 0.15 mm