Customized Product Tour Exhibition · High-Precision Machining of New Energy Vehicle Motor Casing

May 16,2024

Customized Product Tour Exhibition
Focus on developing applicable solutions

High-Precision Machining of New energy Vehicle Motor Casings

• Customer background and needs

QX Die Casting in Foshan, China is a well-known company specializing in the field of new energy. The aluminum alloy shells it produces for new energy vehicles are hot-selling products on the market. However, as market competition intensifies, the parts are processed through multiple devices and multiple processes, resulting in high costs and shrinking corporate profits. Therefore, reducing the number of processes, improving efficiency, and ensuring accuracy at the same time are technical difficulties that need to be overcome. The machine model has been tried many times without success. JOINT took on this problem, spent more than a year on technical research, and completed a complete solution of equipment + fixture + process. 

• Technical difficulties and challenges

1. Merge multiple processes to greatly improve efficiency

The turning and milling compound machine is used to optimize the cutting tools and processes, merge multiple processes, and complete the turning and milling processing in one clamping, nearly doubling the processing efficiency.

2.Precision control of eccentric workpiece processing

The eccentric structure of the workpiece: it will lead to greater inertia, resulting in a large roundness deviation of the processing inner cavity (generally 0.03-0.05mm).
The material is soft and prone to tool vibration: The workpiece material is soft and the tool vibration is prone to occur during processing, which affects the surface roughness and processing accuracy.

In response to the above problems, the main spindle box, spindle, and body structure of the CNC lathe were designed and modified, which greatly improved the cutting rigidity and the stability of the entire machine during large inertia rotation.

3. Thin-wall variant and eccentric inertia fixture design

Through point clamping, eccentric balancing and other methods, the fixture design problems of thin-wall clamping and eccentric clamping are solved. The accuracy of deep cavity processing is stable within 0.02mm, and the end hole is within 0.009).

4. Better finish for deep cavity processing

Thin-walled deep cavity machining: During deep cavity machining, the tool is easily affected by cutting forces, which affects the machining accuracy and poor finish.

Select tools suitable for deep cavity machining, and determine the optimal cutting parameters through multiple experiments to reduce the stress on the tools and improve the stability and smoothness of the machining. 

 

• User effectiveness and social benefits

The above solutions have greatly improved the processing quality of new energy casings for users, and also brought more orders and development opportunities to users.
This solution has also been applied to other processing areas such as valve body parts.