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Machining electric motor housing and battery trays

1. Electric motor housing

Holds the rotor body and its bearing

2. Battery tray

EMI shielding and cooling of the batteries

         

1. Electric motor housing machining
The home of torque

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.

The CERATIZIT Group has the perfect solutions to hand for these challenges too.

1. PCD rough milling cutter

Roughing the stator housing and face milling

  • Roughing the stator bore
  • Maximum productivity thanks to five tool cutting edges
  • Universal tool that can also be used for face milling the stator housing

2. PCD ­porcupine cutter

Machining flat surfaces and difficult-to-access areas

  • Standard PCD ­porcupine cutter
  • Can be used for a variety of stator machining applications
  • Maximum productivity thanks to three cutting edges
  • Burr-free machining due to very sharp cutting edge

3. PCD stator tool

Finishing the highly precise stator bore

  • Adjustable short clamping holder for highest level of accuracy
  • Lightweight construction with aluminium base body
  • PCD inserts: different standard grades available
  • Different standard shapes available
  • DAH for perfect runout

         

2. Battery tray machining
Take charge: efficient volume production of the battery box

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.

HSC and HPC-tested milling tools from the CERATIZIT Group fly in the face of all speed limits.

1. Drill 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

2. HPC PCD milling cutter

Face milling the long seating surfaces

  • 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)
To product

3. Stepped drill with countersink

Drilling the clamping holes

  • Drilling the holes for clamping the battery tray to the chassis
  • Indexable insert stepped drill with countersink
  • Configurable semi-standard product portfolio
  • Indexable insert range for aluminium machining
  • Short delivery times > under 3 weeks
  • High-tech tools for maximum productivity
  • Fixed prices at the level of standard tool prices
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