How to efficiently process the motor shaft of new energy vehicles? Check out this solution

Date：2023-02-28　　　Author：XINDA MOTOR

Electric vehicle motor shaft

Motor shaft

Electric vehicle drive motors are required to have output characteristics capable of exhibiting high performance throughout the entire range of rotation from low speed to high speed, and lightweight shafts with good dynamic balance have been developed in recent years.

the problem we are facing

In order to reduce the weight, the interior of the shaft is hollow. In the current shaft processing, deep hole drilling is required.

Automobile axles are manufactured from mild steel and there are many chip control issues in production.

The shaft also requires post-hardening machining, so how to use CBN inserts efficiently and economically is also an important factor.

Main Processes of Tungaloy Solutions

Tungaloy's unique technology provides a comprehensive solution for deep hole drilling, improved chip control and efficient use of CBN inserts.

Process analysis

Process 1: car outer circle

Outer circle_T9200+TungTurnJet

The TungTurn-Jet internal coolant tool holder series directly supplies coolant through the tool holder to the tool tip. The optimized two coolant jets improve cutting control and maximize production efficiency .
Thanks to the latest improved surface coating treatment technology, T9200 series CVD coated grades provide excellent wear and fracture resistance.
TungTurnJet improves the cooling effect of the tool tip combined with the latest T9200 grade series to greatly extend the tool life.

Process 2: External thread processing

External thread_TungThread+TungTurnJet

Even in thread turning with poor chip control, TungTurnJet improves the cooling effect at the tool tip by directly delivering coolant to the tool tip, reduces wear on the insert, and can still greatly improve chip control and help ensure thread shape during machining .
TungThread high-precision ground inserts ensure thread accuracy, and M-grade thread inserts with chipbreakers improve chip control and cost-effectiveness.

Process 3: Combined drilling and chamfering (pre-hole processing for deep hole drilling)

Drilling + chamfering_DrillMeister

With DrillMeister drill point and chamfer combination drill, drilling and chamfering can be done at the same time to save processing time.
The smooth sharpening of the DMP drill tip achieves low cutting forces.
The latest AH9130 grade is used for low carbon steel processing to extend tool life.

Process 4: Deep hole drilling

Deep hole drilling_DeepTriDrill

Gun drilling is a drilling method to obtain the highest hole straightness, and the gun drilling processing method is used to meet the high dynamic balance requirements of the shaft.
DeepTriDrill indexable blade gun drill has higher production efficiency than traditional brazed gun drill. DeepTriDrill gun drills eliminate the need for regrinding and simplify tool inventory management.
The chip splitting edge design on the insert can divide the chips into small pieces and produce fine chips. Even with normal coolant pressure on common mills and lathes, fine chips are easily ejected from the bore.
The insert has a large rake angle design to reduce cutting force and achieve higher feed rate.

Process 5: Milling groove

Slot milling_TungMeister

The VEH milling cutter head adopts anti-vibration technology , and its variable helix angle and variable tooth pitch design can prevent vibration of the cutter during slot milling and maximize efficiency.
TungMeister's rich tool head and tool holder lineup can be combined flexibly, and the tool combination scheme can choose the most rigid tool length.
The latest AH715 grade extends tool life in mild steel machining.

Process 6: Hard turning

Hard Turning_TungTurnJet+CBN

WavyJoint inserts with a large brazing area can effectively dissipate the heat generated by the tip during machining, which can reduce the temperature of the tip and help reduce the occurrence of crater wear, even in interrupted machining applications . reliability .
By using the cooling effect of the TungTurnJet toolholder to further reduce the tip temperature, the combination of the insert and the toolholder can greatly extend the tool life.
BXA10 grade is the first choice for hardened steel from continuous to heavy intermittent turning.

How to efficiently process the motor shaft of new energy vehicles? Check out this solution

-End-

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