Tool solutions for the mobility of tomorrow from CERATIZIT
The automotive industry is facing one of the biggest changes in its history. Aspects such as lightweight construction, electrification of drive systems or new concepts for increasing efficiency make vehicle development more challenging than ever.
For this reason, the ability to rely on a strong partner who has the right tools and strategies for every single vehicle component is of great importance. Team Cutting Tools from the CERATIZIT Group is ready to face the mobility challenges of tomorrow with maximum innovation, expertise and by working closely with its customers.
CERATIZIT unveils powerful tools for electric motor production
The position of the automotive industry is clear. Over the next ten years, practically every carmaker will be building electric cars by the million – with clean electric motors and as plug-in hybrids. However, the question remains: are the right tools available for the largescale production of electric motors?
CERATIZIT has an extremely effective tool programme that provides the perfect technical and commercial solution for every machining task encountered in the production of electric motors. Its two newly developed fine boring tools for the high-performance high-volume production of electric motor housings are simply outstanding.
Additively manufactured high-end solution
With its new fine boring tool, which is additively manufactured (AM) throughout, CERATIZIT has developed a special tool for stator bores that satisfies all the stipulated requirements and leaves nothing to be desired in terms of machining speed and precision.
The totally new design makes it rigid enough to satisfy IT6 tolerance requirements and the corresponding roundness criteria.
Despite its large diameter (in excess of 200mm) and considerable length, the developers have kept the weight of the fine boring tool below 17kg and designed it to accommodate the tilting movement of machining centres.
That such a lightweight tool can be manufactured at all comes down to the experience in 3D printing gained over the years by CERATIZIT. The delicate, optimally braced structure of the base body is only achievable when produced by an AM process.
Experienced AM designers, who are not only aware of the potential offered by generative manufacturing but are also familiar with the requirements of 3D printing, have used FEM calculations to investigate the effective forces and optimise the topology of the structure.
The result is a fine boring tool whose design can be scaled almost at will to meet a customer’s needs. With four cutting edges per step and up to five steps per tool, even challenging boring tasks can be completed at high feed rates in a single operation. Effective plug-and-play solution The PCD cutting edges are soldered into cartridges that are also additively manufactured. This eliminates any heat input into the base body and prevents the associated deformation. Once the loaded cartridges have been fitted into the designated fixtures in the base body,
CERATIZIT grinds the tool to precisely the required size – with micrometre precision. Customers obtain a plug & play solution that will enable them to achieve process-secure machining results that are always within specification. By using 3D printing, CERATIZIT was able to take advantage of other strengths of the additive manufacturing process.
The coolant holes in both the base body and the cartridges are designed so that every cutting edge receives exactly the amount of coolant it needs while at the same time flushing the chips out of the bore. Scratched surfaces are avoided, which contributes greatly to increased process security and a reduction in waste.
Contact Team Cutting Tools
An unconditional service promise, wideranging expertise – in smart factory concepts, for example – and a firm focus on special-purpose, customer specific solutions make the Team Cutting Tools from the CERATIZIT Group the ideal project partner for automobile manufacturers worldwide.
