The automotive industry encompasses a wide variety of essential components, each influencing vehicle performance and operational efficiency in distinct ways. Ensuring optimal performance requires meticulous attention to the coordination and integration of these parts throughout the design and manufacturing stages. Tailored machining solutions are necessary for different materials, placing increased demands on cutting tools.

This article provides a detailed overview of various machining solutions for automotive components, featuring case studies and product innovations for professionals and manufacturers to consider and discuss.

Aukete Turbocharger Housing Machining Innovations

As electric vehicles gain traction, particularly plug-in hybrids and range-extended models, turbocharged engines are becoming increasingly prevalent. Aukete provides integrated machining solutions for this critical component.

Flange Face Machining

Tool Solution: AFM45-XN07/09 Series

Features: The XN07/09 series includes tools with a 45° cutting angle and blades featuring 14 cutting edges on each side, designed with a high-positive rake angle. Tool diameters range from D40 to D200 mm, with options including MM3, MM4, and MR6 grooves, offering excellent cost-performance across various conditions.

Boss Surface Machining

Tool Solution: ASM90-LN13 Series

Features: The ASM90-LN13 series boasts a 90° cutting angle, with inserts that provide four cutting edges and a positive rake angle. Tool diameters range from D40 to D315 mm, with the MR2 groove type available in six blade variants, optimizing both surface finish and machining efficiency.

V-Hole Machining

Tool Solution: Custom Composite Tool

Features: This non-standard tool incorporates standard inserts and allows for various sizes with three tools to complete hole machining. It includes a precision finishing tool with an adjustable unit for on-site size calibration, ensuring both convenience and accuracy.

V-Belt Back Turning

Tool Solution: Custom Turning Tool

Features: This tool features dual internal cooling holes to address cooling needs on both the front and back cutting surfaces. The double-ended blade design and dual locking mechanisms provide exceptional rigidity.

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Tae-Kollo Gear Transmission Machining Innovations

Gear manufacturing, particularly with materials like low-carbon steel, often results in long, continuous chips that can complicate machining processes. Tae-Kollo recommends a suite of solutions including AddMultiTurn, AddForceCut, and TungMeister for efficient gear transmission machining.

Operation 1: Outer Diameter and End Face Turning

During roughing, back turning tools are used, while finishing employs front turning tools. High-feed back turning tools achieve processing efficiency, outperforming traditional ISO tools by approximately 200%. The Y-PRISM insert locking system ensures superior rigidity, facilitating stable multi-directional machining and increased efficiency.

Operation 2: End Face Grooving

Locking screws secure inserts, ensuring high rigidity and stability during end-face milling and transverse feeding. High-rigidity tool holders and increased insert back thickness provide safety for deep grooving, with effective coolant supply promoting chip removal and process stability.

Operation 3: Groove Milling Finishing

Roughing tools with wavy cutting edges, smaller than finishing blades, deliver comparable surface finishes to square end mills while maintaining high productivity. Interchangeable tool heads significantly reduce machine downtime, with double-sided locking for consistent precision.

Operation 4: Chamfering Finishing

The VCW tool head enables simultaneous front and back processing, integrating tool functions. Interchangeable heads minimize machine downtime, with double-sided locking ensuring high repeatability and precision.

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Wald Clutch Component Machining Innovations

The hard materials used in clutch master hubs demand cutting tools with high strength, impact resistance, and durability. Wald presents an advanced PCBN cutting insert solution to address these needs.

Tool Features: The solution incorporates a radius-edged design for improved impact and wear resistance, extending tool lifespan. The PNH2018 ultra-fine-grain PCBN material provides consistent cutting performance and reduces edge chipping during the processing of hardened steel. Additionally, the PCBN inserts are coated with C2 technology, enhancing wear and corrosion resistance. This coating protects the tool from cutting heat and forces, improving surface quality and reducing roughness.

Compared to previous tooling solutions, Wald’s approach increases machining efficiency by 5% and reduces tool costs by 25%, resulting in significant cost savings and enhanced economic benefits.

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Zhengzuan Electric Drive Housing Machining Innovations

Electric vehicle motor housings, especially coil mounting holes, present challenges due to the significant tool and spindle weight, which can cause vibration and deformation.

Tool Solution: Zhengzuan offers a lightweight boring tool with a coaxiality of 0.01 mm and precision of 0.005 mm, weighing under 15 kg. The tool features an adjustable insert structure for precise control and an unequal segment design to minimize vibration. It operates at S=2000 r/min and F=400 mm/min, with a tool life of 5000–8000 pieces and a fourfold increase in machining efficiency. This boring tool reduces machine load, stabilizes processing, and ensures excellent dimensional accuracy and surface finish while enabling higher processing parameters and enhanced efficiency.

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Iscar Automotive Component Machining Innovations

The evolving demands for lightweight structures, electrification of drive systems, and increased efficiency have intensified the challenges in automotive RD. Iscar offers solutions designed to assist automotive parts manufacturers in adopting more sustainable and environmentally friendly practices.

ISO TURN Tool Series

Iscar provides a comprehensive range of ISO standard tools, including new geometries for compact, economical inserts. The YNMG 1604 series is suitable for standard positioning grooves and features a 25º cutting edge angle for precise V-groove turning.

SUMO CHAM Chameleon Drill Series

The SUMOCHAM series features replaceable head drills that streamline machining cycles. The drill rod includes high-wear-resistant positioning grooves and a spiral internal coolant channel for efficient chip removal. Crafted from premium tool steel, it offers superior hardness and wear resistance.

HELIDO S890 FSN Milling Cutter Series

The HELIDO S890 FSN is a right-hand indexable face milling cutter with an 88º cutting edge angle. The tool features screw clamping and a cutting depth of up to 9 mm (0.35”), suitable for steel and cast iron. It is designed for roughing and semi-finishing with eight reinforced cutting edges.

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Kyocera Universal Joint Machining Innovations

With the growth of the automotive market, the demand for universal joints has surged. Kyocera leverages its precision ceramic technology to provide advanced solutions for universal joint production.

End Roughing

The MFPN milling cutter, with a 45° design and a double-sided ten-edge cutting configuration, enhances stability and reduces chip thickness for consistent cutting.

Outer Diameter and End Face Roughing

The GT GS groove type offers low resistance, making it ideal for outer hard and inner soft materials, minimizing coating layer damage.

Semi-Finishing of Outer Diameters

Kyocera’s PP and PQ chip-breaking grooves improve chip handling and reduce resistance during high feed rates, enhancing surface finish and extending insert lifespan.

Post-Heat Treatment Outer Diameter Turning

The Kyocera CBN series, featuring MEGA coating, addresses various materials and conditions, while the aluminum oxide ceramic series provides high hardness and strength for hard material machining.

Post-Heat Treatment Internal Hole Interrupted Turning

The latest MEGACOAT coating, with high-wear-resistant KBN05M material, enhances chip control, extends tool life, and maintains precision.