11.05.2023

-Strategy- バッテリーフレーム

部品の完全な機械加工は、加工工程を検討し調整を行う必要があります。これが、コスト効率・信頼性の高い製造を実現し、完璧な結果を得る方法です。このような高度な加工工程をお客様に提供するために、マパールは電気自動車に重点を置くコンポーネントを定義し、最適な加工工程を提供出来るように策定しました。バッテリー フレームはこれらのコンポーネントの 1 つです。

＃製品 ＃産業 ＃自動車 #電気自動車 ＃フライス加工
  • 1/5

    The solid carbide milling cutter OptiMill-SPM-Finish finishes large pockets in a single pass. ©MAPAL 

  • 2/5

    The generic component presents the challenges involved in machining a battery frame. ©MAPAL 

  • 3/5

    The specially designed PCD milling cutter machines both bores with different diameters. ©MAPAL 

  • 4/5

    Took an in-depth look at battery frames at MAPAL and their optimal machining strategy (from left to right): Andreas Wolf (Test Engineer), Florian Hofmeier (Component Manager Driveline) and Michael Kucher (Component Manager E-Mobility). ©MAPAL 

  • 5/5

    In total, seven tools are employed by the generic process to machine the battery frame. ©MAPAL 

バッテリーフレームはあらゆる電気自動車にとって重要な部品です。 通常、事前加工後に溶接されるフレームのパーツで構成され、バッテリーフレームとして機能します。 マパールのeモビリティの専門家は、さまざまなお客様でのデーターに基づいて、バッテリー フレームの主要な機械加工を網羅する汎用コンポーネントをまとめました。 「この部品では、機械加工に伴う特別な課題に焦点を当てます。」と MAPAL の eモビリティ   マネージャーの Michael Kucher 氏は述べています。

部品の機械加工中に直面する課題には、段付き穴、複数層の異なる穴、さまざまな寸法のフライス加工されたポケット・ショルダーへの要求の高い表面仕上げなどが求められます。
 

The generic component presents the challenges involved in machining a battery frame.   ©MAPAL
“We master these challenges above all with the optimally designed milling cutters”, says Kucher. Milling is even used for most bores on the frame part. Depending on diameter and machining depth, the experts decide in each case whether to drill or mill. “While the cycle time during the milling of bores is somewhat longer, milling offers decisive advantages in this case, which more than make up for the lost time.” In the past, long chips which occurred while drilling aluminium parts often proved very problematic to customers. “Removing long chips from inside the frame part presented a risk for the process”, says Kucher. The short milling chips are easy to remove. There is also a lot less burr formation during milling than drilling. And there is no need for tools changes. Multiple bores with different diameters can easily be machined with a single milling cutter.

This advantage is brought to bear particularly when a bore has a larger diameter in one of the lower layers than the bore entrance at the top layer. “This can be done effectively with a reverse cutting edge on the milling cutter”, says Kucher. The alternative would be reclamping the workpiece in order to machine the bore from the bottom with a drill. A specially designed PCD milling cutter from MAPAL machines the bore at a spindle speed of 16,000 rpm, a cutting speed of 650 m/min and a feed of 0.063 mm.
 
In total, seven tools are employed by the generic process to machine the battery frame  ©MAPAL

Optimal surfaces with the OptiMill-SPM-Finish

MAPAL recommends the OptiMill-SPM-Finish for roughing shoulders, pockets and slots as well as finishing pockets. “It achieves an optimal surface finish and works stably even in corners with large wrapping and high loads”, Kucher says of the tool. Because the chip spaces are polished, chip removal functions perfectly. The special feature of this tool is that the user can finish large depths in a single pass. This saves time, making it particularly cost-effective. When finishing the battery frame, a surface finish of up to Rz = 1 µm is achieved. During roughing, it operates at a spindle speed of 10,981 rpm, a cutting speed of 414 m/min and feed rates between 0.12 and 0.22 mm. The same spindle and cutting speeds are achieved during finishing with a feed of 0.075 mm. 

The specially designed PCD milling cutter machines both bores with different diameters.   ©MAPAL

In total, seven tools are used during the generic process, including six milling cutters: besides the OptiMill-SPM-Finish, amongst others the recently introduced FaceMill-Diamond-ES. In order to attain a perfectly harmonised system, all of the tools with cylindrical shanks are clamped in the new UNIQ chucks in the generic process.


“We can now offer our clients an all-round package to meet the challenges of machining battery frames, which includes PCD and solid carbide tools, chucks, and the corresponding process. For this we adapt the generic process for our customers based on their concrete situation”, Kucher explains.  

MAPAL solutions for electrified mobility
Kathrin Rehor, PR Project Manager at MAPAL

Contact

Kathrin Rehor Public Relations Kathrin.Rehor@mapal.com Phone: +49 7361 585 3342

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