https://cdn.mtdcnc.global/cnc/wp-content/uploads/2021/03/23171508/Main-Diameter-Reaming-640x360.jpg
    Tooling

    ISCAR drives EV charge

    • By MTDCNC
    • March 23, 2021
    • 4 minute read

    Public awareness of global warming, together with a pressing concern to create and maintain a clean environment, has led to a series of legislations worldwide that are forcing automotive manufacturers to decrease CO2 emissions. Apart from improving fuel consumption, downsizing engines and making vehicles lighter, manufacturers must turn to new technologies to reduce emissions. A rapid increase in battery electric vehicle (BEV) development shows that electric vehicles are not only the future but are, in fact, the present. The automotive industry is on the brink of colossal change, and soon, our perception of cars and transportation may alter forever.

    As a company, ISCAR is now developing innovative metal cutting tools that offer cutting-edge solutions for the evolving BEV industry. As a leader in cost-effective machining solutions, ISCAR has identified several common component machining processes in the BEV industry where it is breaking new ground.

    Stator housing machining

    One of the most notable trends of the electric vehicle powertrain is its simplicity, as it has fewer moving parts than traditional internal combustion engines (ICE). This makes manufacturing time and costs drop dramatically when producing BEV’s. 

    One of the main components of an EV is the aluminium motor (stator) housing. The partially hollow form represents a challenge and maintaining low cutting forces is essential for roughness and cylindricity requirements. ISCAR’s solution for this machining process has facilitated the transformation from the standard costly lathe-based process to an economical machining centre whilst reducing scrapped parts and reaching an optimal CPK ratio. 

    Main Diameter Reaming

    The most challenging operation in machining the aluminium stator housing is the main diameter boring and reaming. Considering the trend to use low power machines, the tool’s large diameter and long overhang require creative thinking to minimise weight and spindle load while maintaining rigidity. ISCAR uses titanium and carbon fibre for the tool body, as well as the welded frame design. 

    The use of Finite Element Methods (FEM) help resolve obstacles associated with this challenging application by considering parameters such as cutting forces, displacement field during machining, natural frequency and maximum deformation.

    Bearing Seat Reaming

    The electric motor generates its maximum torque from a standing start, this means it does not require a complex transmission system. A simple reduction gear is enough for the average EV and this sits between the stator housing and the gear cover. 

    To maintain concentricity between stator and gear cover bearing seats, the reaming operation must be performed in the same machining sequence.

    For operation, ISCAR provides a special ‘push and pull’ reaming type tool with adjustable PCD blades that retain geometrical tolerances in different inner diameters.

    Rotor Turning

    The rotor consists of many electric steel stacked plates. Lamination sheets are used instead of a solid body to reduce current loss, so the surface must be completely clean of chips, oil, dust or dirt; so dry cutting is a must. This is a challenge as heat is generated when cutting and fragmented chips stick to the surface, which also demands quality finishes throughout the interrupted turning operation.

    ISCAR has overcome this by developing a combined tool with cooling holes on the top and bottom of the cutting edge to cool and blow away swarf. The two-round inserts are positioned for semi-finish and finishing operations, generating an excellent surface finish.

    Battery Case Drilling

    As batteries replace fuel as an energy source, the battery case is integral to car design. Large lightweight requirements make aluminium a natural choice for this part. When dealing with high-end supercars or sports cars, every unit of weight counts and this is why some automakers are turning to CFRP, which offers lightweight with a lower thermal conductivity than aluminium. 

    ISCAR has a wide choice of tools for machining aluminium and CFRP, such as the SUMOCHAM indexable head drilling line that offers a variety of geometries suited for specific materials. For drilling aluminium, ICN heads are designed with a sharp cutting edge and polished rake face. ICG heads feature a chip splitter for better chip removal when working with a long overhang. For drilling CFRP, a special ICF geometry is available with a diamond coating to overcome machining failures such as delamination. 

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2021/03/23171508/Main-Diameter-Reaming-640x360.jpg

    ISCAR drives EV charge

    Public awareness of global warming, together with a pressing concern to create and maintain a clean environment, has led to a series of legislations worldwide that are forcing automotive manufacturers to decrease CO2 emissions. Apart from improving fuel consumption, downsizing engines and making vehicles lighter, manufacturers must turn to new technologies to reduce emissions. A rapid increase in battery electric vehicle (BEV) development shows that electric vehicles are not only the future but are, in fact, the present. The automotive industry is on the brink of colossal change, and soon, our perception of cars and transportation may alter forever.

    As a company, ISCAR is now developing innovative metal cutting tools that offer cutting-edge solutions for the evolving BEV industry. As a leader in cost-effective machining solutions, ISCAR has identified several common component machining processes in the BEV industry where it is breaking new ground.

    Stator housing machining

    One of the most notable trends of the electric vehicle powertrain is its simplicity, as it has fewer moving parts than traditional internal combustion engines (ICE). This makes manufacturing time and costs drop dramatically when producing BEV’s. 

    One of the main components of an EV is the aluminium motor (stator) housing. The partially hollow form represents a challenge and maintaining low cutting forces is essential for roughness and cylindricity requirements. ISCAR’s solution for this machining process has facilitated the transformation from the standard costly lathe-based process to an economical machining centre whilst reducing scrapped parts and reaching an optimal CPK ratio. 

    Main Diameter Reaming

    The most challenging operation in machining the aluminium stator housing is the main diameter boring and reaming. Considering the trend to use low power machines, the tool’s large diameter and long overhang require creative thinking to minimise weight and spindle load while maintaining rigidity. ISCAR uses titanium and carbon fibre for the tool body, as well as the welded frame design. 

    The use of Finite Element Methods (FEM) help resolve obstacles associated with this challenging application by considering parameters such as cutting forces, displacement field during machining, natural frequency and maximum deformation.

    Bearing Seat Reaming

    The electric motor generates its maximum torque from a standing start, this means it does not require a complex transmission system. A simple reduction gear is enough for the average EV and this sits between the stator housing and the gear cover. 

    To maintain concentricity between stator and gear cover bearing seats, the reaming operation must be performed in the same machining sequence.

    For operation, ISCAR provides a special ‘push and pull’ reaming type tool with adjustable PCD blades that retain geometrical tolerances in different inner diameters.

    Rotor Turning

    The rotor consists of many electric steel stacked plates. Lamination sheets are used instead of a solid body to reduce current loss, so the surface must be completely clean of chips, oil, dust or dirt; so dry cutting is a must. This is a challenge as heat is generated when cutting and fragmented chips stick to the surface, which also demands quality finishes throughout the interrupted turning operation.

    ISCAR has overcome this by developing a combined tool with cooling holes on the top and bottom of the cutting edge to cool and blow away swarf. The two-round inserts are positioned for semi-finish and finishing operations, generating an excellent surface finish.

    Battery Case Drilling

    As batteries replace fuel as an energy source, the battery case is integral to car design. Large lightweight requirements make aluminium a natural choice for this part. When dealing with high-end supercars or sports cars, every unit of weight counts and this is why some automakers are turning to CFRP, which offers lightweight with a lower thermal conductivity than aluminium. 

    ISCAR has a wide choice of tools for machining aluminium and CFRP, such as the SUMOCHAM indexable head drilling line that offers a variety of geometries suited for specific materials. For drilling aluminium, ICN heads are designed with a sharp cutting edge and polished rake face. ICG heads feature a chip splitter for better chip removal when working with a long overhang. For drilling CFRP, a special ICF geometry is available with a diamond coating to overcome machining failures such as delamination.