The three-electric system of new energy vehicles (EV/HEV)—battery, motor, and electronic control—is the core processing scenario.
The battery tray and housing are typically made of aluminum alloy extrusions, requiring extensive end-face milling and drilling operations. Although aluminum alloy has high thermal conductivity, it tends to cause tool adhesion. It is recommended to use uncoated carbide milling cutters with large rake angles and high chip flute designs, combined with minimal quantity lubrication (MQL) technology, to significantly extend tool life and ensure surface finish quality.
The motor housing and rotor shaft are commonly made of ductile iron or tempered steel, with extremely high precision requirements for the internal bore. CBN (cubic boron nitride) tools and coated carbide reamers are the preferred choices for precision boring and reaming, capable of consistently achieving IT6-IT7 tolerance levels.
The thin-walled machining of heat dissipation fins in electronic control housings is highly challenging, requiring high-speed milling strategies with high spindle speeds and small cutting depths, along with ultra-fine grain carbide end mills to prevent machining deformation.
Additionally, the lightweighting of the chassis leads to an increased use of high-strength steel and aluminum alloy components, imposing higher demands on the wear resistance and chip-breaking performance of turning inserts. PVD-coated carbide turning inserts excel in this scenario.