Electrified drives

Machining requirements and features of different housing types

Highly integrated housing

Highly integrated electric motor housing

Description: Highly integrated, complex housing with stator mount, transmission mount and connection for the power electronics. High functional integration saves assembly costs. Compact design. Complex cast housing as a result.

FEATURES

• Stator incorporated directly in the housing or via a stator carrier / cooling jacket
• Stator bore with stages and flat surfaces as functional surfaces
• A bearing bore of the rotor is integrated coaxially with the stator bore in the housing
• Positioning of the second bearing cover via dowel pins or fitting surfaces; second bearing bore must be coaxial
• Bearing bores of transmission stages integrated in the housing; high concentricity and positional accuracy are required
• Cooling channels partially integrated in the housing
• Complex cast aluminium housing

MACHINING REQUIREMENTS

• Elaborate contour trains with several diameter levels ( high cutting forces and large machining volume)
• Mixed processing (-> chip separation / removal)
• Interrupted cuts (-> contacting, cooling circuit)
• 15°-30° flat lead-in chamfers (-> flow chip formation and high radial forces)

Pot-shaped housing

Pot-shaped electric motor housing

Description: To reduce the complexity, in particular to implement a simpler construction of the cooling jacket, pot-shaped or bell-shaped housings or stator supports are used.

FEATURES

• As an intermediate housing for integration in the overall system
• Stator bore with stages and flat surfaces as functional surfaces
• A bearing bore of the rotor is integrated coaxially with the stator bore in the housing
• Positioning via fitting surfaces on the outer surface
• Cooling channels as ribs on the outside
• Thin-walled, susceptible to vibration
• Tension problematic

MACHINING REQUIREMENTS

• Extremely thin-walled parts (-> ap corresponds to wall strength)
• Outer cooling ribs must be machined
• Pot or bell shape (-> promotes vibrations, special clamping concepts and vibration dampers)
• 15°-30° flat lead-in chamfers (-> flow chip formation and high radial forces)

Tubular housing

Tubular electric motor housing

Description: The simplest design of motor housings is tubular. The length of the housing and thus the electrical machine can be varied comparatively easily for different powers. As a result, the installation effort increases due to the low level of functional integration.

FEATURES

• No rotor bearing bores integrated in the housing
• Two bearing covers to hold the rotor
• Positioning of the two bearing covers over fitting surfaces for coaxiality of the bearing points
• Minimal complexity
• Practically rotationally symmetrical
• Thin-walled, susceptible to vibration
• Tension problematic

MACHINING REQUIREMENTS

• More stable components usually with an internal cooling structure
• Extruded profiles also possible (AlSi1 -> flow chips)
• Without clamping straps (-> special clamping concepts)
• Partly with fits on both sides in IT6 tolerance

Hybrid housing

Hybrid transmission housing and hybrid module/intermediate housing

Description: Integration of the electrical machine into the existing transmission architecture using disk-shaped hybrid modules or intermediate housing. Space neutral structures are also implemented with partially pot-shaped housings as slide-in parts.

FEATURES

Hybrid module/intermediate housing

• Mainly incorporation of the stator
• No rotor bearing with disc shape
• Rotor bearing integrated with pot shape

Hybrid transmission housing

• Extreme length-diameter ratios
• Thin-walled, susceptible to vibration
• Elaborate contour trains
• Interrupted cut

MACHINING REQUIREMENTS

Hybrid transmission housing

• IT6 tolerance
• High demands on coaxiality and stage dimensions
• Restricted maximum weight and moment of tilt

Pre-machining

Pre-machining

The use of an ISO boring tool is particularly suitable for pre-machining. This method allows high cutting speeds and feed rates to remove material quickly and economically. Under specific conditions, for example with precisely pre-cast parts and corresponding machine conditions, the first roughing operation can be omitted.

Semi-finishing

Semifinitura di corpi motore per azionamenti elettrici

Durante la semifinitura, viene preparato il complesso contorno del corpo del motore elettrico. In questo modo, il contorno completo con smussi e passaggi radiali può essere prodotto nella qualità voluta durante la lavorazione di precisione finale. Questa fase consente di dare una forma ottimale al corpo. A seconda della potenza del mandrino e del sovrametallo, potrebbe essere necessario dividere la semifinitura in due fasi. 

Lavorazione di precisione

Finitura di corpi motore per azionamenti elettrici

Nell’ultima fase viene eseguita la lavorazione di precisione relativa alla foratura dello statore, per mezzo di un bareno dotato di inserti di taglio finemente regolabili e pattini di guida.

Lavorazione esterna del corpo statore

La lavorazione esterna dei corpi statore per i motori elettrici è un compito molto impegnativo. Questi corpi, spesso di forma tubolare o a campana, sono fondamentali per l’efficienza del motore elettrico. Durante il processo si devono superare diverse sfide. I corpi in alluminio a parete sottile con alette integrate per il circuito di raffreddamento richiedono la massima precisione in termini di accuratezza del diametro, tolleranze di forma e di posizione. È molto importante la concentricità tra i diversi diametri. 

Soluzioni di asportazione truciolo per…

Basic

Soluzione prototipo con utensili standard

• Elevata flessibilità
• Sistema per la prelavorazione e la finitura
• Struttura modulare
• Assortimento standard a partire da Ø 87 – 1000 mm
• Portamorsetti regolabile di barenatura nel range di µm
• Utilizzo facile

Prelavorazione

• Frese elicoidali

  with ISO indexable inserts

  • Coated ISO indexable inserts made of carbide or PCD-tipped indexable inserts
  • Reduced cutting forces
  • Standard product
  • HSK extension for different machining depths

• ModulBore

  Boring head with bridge module

  • Pre- and finish machining system
  • Modular construction
  • ISO cartridges

Finish machining

• ModulBore

  high level of flexibility during boring and fine boring

  • Pre- and finish machining system
  • Modular construction
  • Standard range from ø 87 mm – 1000 mm
  • Fine boring cartridge adjustable in the µm range
  • Easy to handle

Performance

Series solution with HSK-63 / HSK-100

Process-safe solution with adapted performance and requirement spectrum

• Three-stage process (pre-, semi-finish and finish machining)
• Particularly light tools
• Large components on compact machines
• Optimal solution for small and medium quantities

Pre-machining

• Helix milling cutter

  with ISO indexable inserts

  • Coated ISO indexable inserts made of carbide or PCD-tipped indexable inserts
  • Reduced cutting forces
  • Standard product
  • HSK extension for different machining depths

• PCD form cutter

  contour machining the bottom of the bore

  • Brazed cutting edge
  • Special contours possible
  • Can optionally be used with HSK extensions

Semi-finish-machining

• Precision boring tool

  with ISO indexable inserts

  • Tool shape adapted to magazine changer
  • Coated ISO indexable inserts made of carbide or PCD-tipped indexable inserts

• Precision boring tool

  single-stage or multi-stage

  • ISO cartridges
  • PCD-tipped ISO indexable inserts
  • Tool body made of aluminium

• Precision boring tool

  single-stage or multi-stage

  • ISO cartridges
  • PCD-tipped ISO indexable inserts
  • Tool body made of aluminium

Finish machining

• 精镗刀具

  带有导向板 

  • 镶嵌PCD的切削刀片 
  • 可精细调节 
  • 导向条由聚晶金刚石PCD制成 
  • 刀具形状适宜于刀库的要求 

• 精镗刀具

  采用钢制轻型结构 

  • 镶嵌PCD的切削刀片 
  • 金属陶瓷刀片，用于加工钢质轴承衬套 
  • 可以精细调节并且具有极高热稳定性 
  • 带EA系统的导向板技术 

Expert

具有HSK100刀柄的批量解决方案

针对大直径加工提供极高生产率

• 分为三个阶段的加工流程（预加工、半-精加工和精加工）
• 较大的加工直径 > 220 mm
• 最高的性能和精度
• 对于大批量、短节拍加工任务的最理想加工工艺

预加工

• ISO标准镗刀

  铝结构 

  • 镶嵌PCD的切削刀片 
  • ISO标准短刀杆 
  • 分一级的或者多级结构执行

Semi-finish-machining

• Precision boring tool

  Aluminium construction

  • PCD-tipped indexable inserts 
  • Design as welded construction or with tool body made of aluminium

Finish machining

• Fine boring tool

  in lightweight construction

  • PCD-tipped indexable inserts
  • Cermet indexable inserts for machining of steel bearing bushes
  • Finely adjustable and temperature stable
  • Guide pad technology

• Actuating tool

  for u-axis-systems

  • Suitable for machining of housing variants
  • To compensate for insert wear