Electrified drives

Automobile manufacturers and suppliers are facing new challenges when it comes to components for electric motors. The example of the housing of an electric motor shows how big these challenges are: Compared to a transmission housing, this has to be manufactured within significantly tighter tolerances, since the accuracy has a decisive influence on the efficiency of the motor.

In addition, due to the special structure, such as integrated cooling channels, the electric motor housing is usually significantly thinner than a transmission housing. In addition, bearing bushes made of steel materials are pressed into some of these housings. Special protection shields in the tool ensure that steel chips do not come into contact with the aluminium surfaces during processing and damage them.

Machining requirements and features of different housing types

Basic procedure for machining of stator housings

The machining process as well as the tools are designed individually depending on the
measurement situation, machine park and clamping setup. In this way, the cutting forces
applied to the component are kept as low as possible. The machining of the stator bore is divided into 3 steps: Pre-machining, Semi-finish machining and Finish machining.
Basic procedure for machining of stator housings
Stator housing external machining

External Machining stator housing

External machining of stator housings for electric motors is a demanding task. These housings, which often come in tubular or pot-shaped designs, are crucial for the efficiency of the electric motor. Several challenges have to be overcome during the process. The thin-walled aluminium housings with integrated ribs for the cooling circuit require the highest precision in terms of diameter accuracy, shape and position tolerances. The concentricity between different diameters is of huge importance.

Pre-machining
  • Helixfräser mit ISO-Wendeschneidplatten

    Fraise hélicoïdale avec plaquettes amovibles ISO

    Pré-usinage de diamètre extérieur et de surface

    • Plaquettes de découpage amovibles ISO avec revêtement carbure ou plaquettes de coupe à insert en PCD
    • Réduction des forces de coupe
    • Produit standard
    • Extension HSK pour différentes profondeurs d'usinage

  • ISO BORING TOOL Roughing of outer diameter

    Outil d'alésage ISO

    Pré-usinage de diamètre extérieur

    • Outil cloche étagé pour
    • Usinage extérieur
    • Plaquettes de coupe ISO

  • MILLING CUTTER WITH ISO INDEXABLE INSERTS

    Fraise avec plaquettes amovibles ISO

    Ébauche de rainure de joint

    • Plaquettes amovibles ISO en carbure revêtues
    • Amortisseur de vibrations en option
    • Ébauche efficace des rainures de joint

Usinage final
  • PCD MILLING CUTTER WITH SPECIAL CONTOUR

    Fraise PCD à profil spécial

    Finition de rainure de joint

    • Détourage PCD
    • Géométrie parfaite des différents contours de rainure
    • Amortisseur de vibrations en option
    • Usinage final de toutes les rainures en une seule coupe

  • PCD MILLING CUTTER WITH SPECIAL CONTOUR Finishing the sealing groove

    Outil d'alésage de précision en construction légère

    Finition de diamètre extérieur

    • Arêtes de coupe PCD réglables
    • Corps d'outil en construction légère
    • Diamètre d'usinage jusqu'à 260 mm

Solutions d'usinage pour…

MAPAL Basic, Performance, Expert Line

Altre soluzioni di lavorazione

  • Topfförmiges Elektromotorengehäuse in CAD Darstellung

    Fori cuscinetto e di posizionamento

    Con la massima concentricità e rotondità

    Scopri di più
  • Außenreibahle mit EA-System

    Alesatore esterno con sistema EA

    • Lavorazione esterna del foro cuscinetto

  • Planfräser mit PKD-Fräseinsätzen

    Fresa a spianare con inserti in PCD

    • Generazione di profili di superficie definiti per le superfici di tenuta e di contatto (ad es. strutture a taglio trasversale)
    • Finitura di superficie Rz < 1

Other electrified components