{"id":18392,"date":"2021-09-24T08:07:49","date_gmt":"2021-09-24T06:07:49","guid":{"rendered":"https:\/\/niles-simmons.de\/efficient-machining-of-stator-housings-for-e-mobility\/"},"modified":"2024-01-17T07:21:51","modified_gmt":"2024-01-17T06:21:51","slug":"efficient-machining-of-stator-housings-for-e-mobility_article","status":"publish","type":"page","link":"https:\/\/niles-simmons.de\/en\/efficient-machining-of-stator-housings-for-e-mobility_article\/","title":{"rendered":"Efficient Machining of Stator Housings for E\u2011Mobility"},"content":{"rendered":"
[vc_row][vc_column][vc_column_text]\n

Spotlight on cost-per-part in machining stator housings<\/h4>\n

When a machine tool manufacturer and a tool manufacturer known for boring and fine boring tools get together for a joint project, extraordinary results are guaranteed. NILES-SIMMONS and MAPAL have come together to develop a process that dramatically reduces the machining time of stator housings (or inner housing, cooling jacket, coolin sleeve, motor housing) for electric motors in the e\u2011mobility sector and also features innovative details.<\/h4>\n

<\/p>\n

Machi\u00adning the sta\u00adtor housing includes inter\u00adnal machi\u00adning with various sec\u00adtions, machi\u00adning the smal\u00adler centre bore and machi\u00adning the out\u00adside with its coo\u00adling ribs.<\/em><\/span><\/p>\n

 <\/p>\n

The tran\u00adsi\u00adtion from con\u00adven\u00adtio\u00adnal com\u00adbus\u00adtion engi\u00adnes to elec\u00adtric dri\u00adves in the auto\u00admo\u00adtive indus\u00adtry is beco\u00adming incre\u00adasingly clear. NILES-SIMMONS is facing up to this change and tar\u00adge\u00adting machi\u00adning equip\u00adment for parts pro\u00adduc\u00adtion for the e\u2011mobility sec\u00adtor with highly effi\u00adci\u00adent manu\u00adfac\u00adtu\u00adring pro\u00adces\u00adses \u2013 with the aim of seam\u00adlessly fol\u00adlo\u00adwing on from the suc\u00adcessful times of cranks\u00adhaft manufacture.<\/p>\n

The majo\u00adrity of machi\u00adnes built by NILES-SIMMONS in Chem\u00adnitz are used for the machi\u00adning of rota\u00adtio\u00adnally sym\u00adme\u00adtri\u00adcal work\u00adpie\u00adces. While tur\u00adning plays a key role here, MAPAL as a tool manu\u00adfac\u00adtu\u00adrer focu\u00adses pri\u00adma\u00adrily on cubic parts which are dril\u00adled, rea\u00admed and mil\u00adled. In light of this, it\u2019s little sur\u00adprise that there had been few points of cont\u00adact bet\u00adween the two com\u00adpa\u00adnies in the past. That chan\u00adged at the EMO 2019 trade show. At MAPAL\u2019s stand, NILES-SIMMONS dis\u00adco\u00advered an exhi\u00adbit iden\u00adti\u00adfied as a tur\u00adning work\u00adpiece: a sta\u00adtor or motor housing for elec\u00adtric motors. By then, MAPAL had estab\u00adlished fine bor\u00ading tools for machi\u00adning parts on mil\u00adling cen\u00adtres as a highly effi\u00adci\u00adent and ultra-pre\u00adcise pro\u00adcess in the industry.<\/p>\n

 <\/p>\n

A BENEFICIAL BLEND OF TURNING AND BORING OR FINE BORING<\/p>\n

Soon, both sides had the impres\u00adsion that a com\u00adbi\u00adna\u00adtion of tur\u00adning, bor\u00ading and fine bor\u00ading could take machi\u00adning this key com\u00adpo\u00adnent for e\u2011mobility to a new level. Fol\u00adlo\u00adwing the trade show, they set up a joint deve\u00adlo\u00adp\u00adment pro\u00adject. NILES-SIMMONS rebuilt a machine for the pro\u00adject and MAPAL sup\u00adplied tools for pre\u2011, semi- and fine machining.<\/p>\n

Pot-shaped parts like sta\u00adtor housings are a fre\u00adquently used design for elec\u00adtric motors in the auto\u00admo\u00adtive indus\u00adtry. The thin-wal\u00adled alu\u00admi\u00adnium housing fea\u00adtures ribs on the out\u00adside for the coo\u00adling cir\u00adcuit and is instal\u00adled in  the lar\u00adger motor housing. \u201cHere, we have a rota\u00adtio\u00adnal work\u00adpiece  with a rear-side imba\u00adlance that can be tur\u00adned, but, due to the high level of dia\u00adme\u00adter accu\u00adracy and the shape and posi\u00adtion tole\u00adrance requi\u00adred by the mar\u00adket, must be bored and fine bored,\u201d says MAPAL\u2019s Area Sales Mana\u00adger Andr\u00e9 Ranke, describ\u00ading the start\u00ading point for the part\u00adner\u00adship. A cus\u00adto\u00admer work\u00adpiece was not used for the tests car\u00adried out at NILES-SIMMONS with MAPAL tech\u00adni\u00adci\u00adans as part of the pro\u00adject. Ins\u00adtead, MAPAL desi\u00adgned a dummy that fea\u00adtured all pro\u00adduc\u00adtion-ready requi\u00adre\u00adments. The inner dia\u00adme\u00adters vary bet\u00adween 220 mm and 231 mm, and the outer diameters
\nbet\u00adween 250 mm and 260 mm. Inner and outer fit tole\u00adran\u00adces in the IT6 range and cylind\u00adri\u00adcal forms bet\u00adween 20 and 30 \u03bcm are requi\u00adred. The con\u00adcen\u00adtri\u00adcity bet\u00adween the dif\u00adfe\u00adrent dia\u00adme\u00adters is limi\u00adted in some cases to 0.05 mm.<\/p>\n

 <\/p>\n

<\/p>\n

Pro\u00adject\u00adteam (v.l.): Sales Mana\u00adger Tho\u00admas L\u00f6tzsch, Deve\u00adlo\u00adp\u00adment Engi\u00adneer Tech\u00adno\u00adlo\u00adgie Chris\u00adtian Wink\u00adler, Pro\u00adject Mana\u00adger Daniel Pilz (all NILES-SIMMONS), Area Sales Mana\u00adger Andr\u00e9 Ranke, Tech\u00adni\u00adcal Advi\u00adsor Axel Schwarze und Appli\u00adca\u00adtion Engi\u00adneer Heiko S\u00fc\u00df (all MAPAL). In the fore\u00adground, the MAPAL inter\u00adnal machi\u00adning tools for (from left) pre-roug\u00adhing, roug\u00adhing, machi\u00adning the cen\u00adter bore and finis\u00adhing, as well as the workpiece.
\n<\/em><\/span><\/p>\n

 <\/p>\n

ALL OF THE TOOLS ARE ALREADY IN THE MACHINE<\/p>\n

For the deve\u00adlo\u00adp\u00adment pro\u00adject, NILES-SIMMONS sel\u00adec\u00adted a DZS 315-type pick-up lathe from NSH sub\u00adsi\u00addiary RASOMA, also based in Sax\u00adony. The machine has a modu\u00adlar design and can the\u00adr\u00ade\u00adfore be con\u00adfi\u00adgu\u00adred pre\u00adcis\u00adely to suit the rele\u00advant machi\u00adning pro\u00adcess. The test set-up fea\u00adtured a ver\u00adti\u00adcal work\u00adpiece spindle at the top, a work\u00adpiece spindle under\u00adneath, a tool con\u00adsole and a tool revol\u00adver. Gene\u00adrally spea\u00adking, addi\u00adtio\u00adnal machining
\nunits can be built into the machine, mea\u00adning all neces\u00adsary tools can be housed in the machine, redu\u00adcing set-up and non-pro\u00adduc\u00adtive time. The upper spindle picks up the work\u00adpiece and moves it to the sta\u00adti\u00adons one after ano\u00adther in a sin\u00adgle clam\u00adping setup with the lathe slide.<\/p>\n

There are advan\u00adta\u00adges to ver\u00adti\u00adcal machi\u00adning. One of these is the space-saving inter\u00adlin\u00adked setup of indi\u00advi\u00addual machi\u00adning units, opti\u00admum trans\u00adport of chips and pro\u00adces\u00adsing agents, and a com\u00adpact design with a small instal\u00adla\u00adtion area, inclu\u00adding a pick-up system.<\/p>\n

\u201c<\/span>The pick-up is a stan\u00addard solu\u00adtion for tur\u00adning, as it is alre\u00adady widely used today for com\u00adpa\u00adra\u00adble parts. This loa\u00adding solu\u00adtion is per\u00adfectly desi\u00adgned for auto\u00adma\u00adted mass pro\u00adduc\u00adtion of sta\u00adtor housings,\u201d says Tho\u00admas L\u00f6tzsch, Sales Mana\u00adger at NILES-SIMMONS.<\/p>\n

The key bene\u00adfit of the newly deve\u00adlo\u00adped pro\u00adcess is the poten\u00adtial boost in pro\u00adduc\u00adti\u00advity. From the out\u00adset, part pro\u00adduc\u00adtion time has alre\u00adady been cut by 50 per\u00adcent in the com\u00adbi\u00adned tur\u00adning and bor\u00ading pro\u00adcess com\u00adpared to the con\u00adven\u00adtio\u00adnal tur\u00adning pro\u00adcess. Daniel Pilz, who mana\u00adged the pro\u00adject at NILES-SIMMONS, descri\u00adbes how time is saved in each indi\u00advi\u00addual step, which, as the case may be, may involve the tur\u00adning of the work\u00adpiece, of the tool or of both.<\/p>\n

 <\/p>\n

<\/em><\/span><\/p>\n

left + cen\u00adter: The work\u00adpiece is clam\u00adped to the upper pindle and moved to the machi\u00adning sta\u00adti\u00adons one after ano\u00adther in one clam\u00adping setup.; <\/em><\/span>right: The first step is roug\u00adhing the inside of the housing.<\/em><\/span><\/p>\n

 <\/p>\n

NEW WAYS TO USE TRIED-AND-TESTED TOOLS<\/p>\n

The first sta\u00adtion turns the pro\u00adcess pre\u00adviously used by MAPAL on its head. Ins\u00adtead of roug\u00adhing the part with a rota\u00adting tool, the tool sits still in the machine, and it\u2019s the work\u00adpiece coming from above that turns. As MAPAL\u2019s tool is equip\u00adped with four blades, unlike a con\u00adven\u00adtio\u00adnal tur\u00adning tool, only around a quar\u00adter of the time is nee\u00added to com\u00adple\u00adtely pre-rough the various inner dia\u00adme\u00adters on the part.<\/p>\n

In the second machi\u00adning step, a bell-shaped tool deve\u00adlo\u00adped by NILES-SIMMONS is used for the outer con\u00adtour, while a MAPAL ISO bor\u00ading tool is used for semi-finis\u00adhing the inner dia\u00adme\u00adter. The inside and out\u00adside of the work\u00adpiece are machi\u00adned at the same time. \u201cWhat\u2019s spe\u00adcial is that a sta\u00adtio\u00adnary, ver\u00adti\u00adcal exter\u00adnal machi\u00adning tool is pla\u00adced to the spindle housing. The spindle dri\u00adves the inter\u00adnal machi\u00adning tool,\u201d says Daniel Pilz, describ\u00ading the setup. The work\u00adpiece dips into the annu\u00adlar gap for\u00admed by these two tools. All dia\u00adme\u00adters are pro\u00addu\u00adced with one sin\u00adgle feed move\u00adment \u2013 for this spe\u00adci\u00adfic part, this amounts to three inner and three outer dia\u00adme\u00adters. Four blades are used for each dia\u00adme\u00adter. \u201cAs well as being able to machine the inside and out\u00adside simul\u00adta\u00adneously, altog\u00ade\u00adther we take just an eighth of the time we would need for con\u00adven\u00adtio\u00adnal tur\u00adning,\u201d says Pilz. Other bene\u00adfits include the following:<\/p>\n

\u2022 Due to the coun\u00adter\u00adac\u00adting cut\u00adting forces of the inter\u00adnal and exter\u00adnal machi\u00adning, a lower tor\u00adque must be main\u00adtai\u00adned on the work\u00adpiece clam\u00adping device<\/p>\n

\u2022 Vibra\u00adti\u00adons in the thin-wal\u00adled part during machi\u00adning are absor\u00adbed by the simul\u00adta\u00adneous cut\u00adting action of the inserts on the inside and outside.<\/p>\n

In this test, simul\u00adta\u00adneous inter\u00adnal and exter\u00adnal machi\u00adning took place with a cut\u00adting speed of 700 m\/min. Machi\u00adning using the sand\u00adwich method with the work\u00adpiece in the middle ensu\u00adres that the part is sta\u00adbi\u00adli\u00adsed during machi\u00adning, as the inserts are cut\u00adting on both sides at the same time and thus gui\u00adding the part. Com\u00adplex clam\u00adping tech\u00adno\u00adlogy with vibra\u00adtion dam\u00adpe\u00adning is not requi\u00adred, which has a noti\u00adceable impact on costs. While indus\u00adtry alre\u00adady uses MAPAL\u2019s tool on hori\u00adzon\u00adtal machi\u00adning cen\u00adtres for the inter\u00adnal machi\u00adning of sta\u00adtor housings, the bell-shaped exter\u00adnal tool from NILES-SIMMONS was newly deve\u00adlo\u00adped and a patent was filed for the inno\u00adva\u00adtive process.<\/p>\n

The sub\u00adse\u00adquent fine machi\u00adning pro\u00adcess uses an alre\u00adady tried-and-tes\u00adted MAPAL fine bor\u00ading tool with guide pads, which is ulti\u00adm\u00adately used to fully finish the centre bore for the sta\u00adtor bea\u00adring, inclu\u00adding all stages. MAPAL pro\u00addu\u00adces the fine bor\u00ading tool used in various designs. A wel\u00added design with blades and guide pads made from PCD was used for the tests in Chem\u00adnitz. The dia\u00adme\u00adter can be adjus\u00adted in the \u03bcm range.<\/p>\n

 <\/p>\n

<\/p>\n

left: The semi-finis\u00adhing tool for inner machi\u00adning is clam\u00adped in the lower spindle. It is sur\u00adroun\u00added by the bell-shaped outer tool, which is secu\u00adrely moun\u00adted; c<\/span><\/em>enter: In simul\u00adta\u00adneous machi\u00adning, the work\u00adpiece is moved into the annu\u00adlar gap bet\u00adween the outer tool and the inner tool from above. Ple\u00adnty of coo\u00adling lubri\u00adcant is used for machi\u00adning.; right: Fine machi\u00adning of all inner dia\u00adme\u00adters is done with a fine bor\u00ading tool.<\/span>
\n<\/em><\/p>\n

 <\/p>\n

STATOR HOUSING ARE THE NEW CRANKSHAFTS<\/p>\n

NILES-SIMMONS expects the manu\u00adfac\u00adtu\u00adring of sta\u00adtor housings or coo\u00adling jackets to become as important to elec\u00adtric mobi\u00adlity as cranks\u00adhafts were to com\u00adbus\u00adtion engi\u00adnes in the past. The expec\u00adted quan\u00adti\u00adties, cycle times and costs are in a com\u00adpa\u00adra\u00adble range. \u201cEnqui\u00adries for these parts amount to 250,000 parts per year,\u201d says COO Klaus Kr\u00e4\u00adher. By 2030, there may be demand for as many as 20 to 50 mil\u00adlion parts world\u00adwide. \u201cA 50 per\u00adcent time saving is a
\nhuge state\u00adment, espe\u00adci\u00adally as there is defi\u00adni\u00adtely more poten\u00adtial in our new pro\u00adcess,\u201d says Kr\u00e4her.<\/p>\n

In addi\u00adtion to the suc\u00adcessfully imple\u00admen\u00adted ver\u00adti\u00adcal con\u00adcept, NILES-SIMMONS is also inves\u00adti\u00adga\u00adting the pos\u00adsi\u00adbi\u00adlity of refit\u00adting exis\u00adting hori\u00adzon\u00adtal machi\u00adnes. The Chem\u00adnitz-based com\u00adpany has over 300 turn-broa\u00adching and cranks\u00adhaft mil\u00adling machi\u00adnes curr\u00adently in use in car manu\u00adfac\u00adtu\u00adr\u00aders\u2019 cranks\u00adhaft pro\u00adduc\u00adtion lines world\u00adwide. Both the inno\u00adva\u00adtive pro\u00adcess and MAPAL\u2019s tools can also be inte\u00adgra\u00adted into a hori\u00adzon\u00adtal ver\u00adsion of the concept.
\nMAPAL also offers the pos\u00adsi\u00adbi\u00adlity of using addi\u00adtively-manu\u00adfac\u00adtu\u00adred tools in which weight savings are not the sole focus and coo\u00adlant out\u00adlets can be geared even more spe\u00adci\u00adfi\u00adcally towards the cut\u00adting edge.<\/p>\n

Apart from the machi\u00adning of sta\u00adtor housings, the pro\u00adcess can also be used for other work\u00adpie\u00adces from a wide range of sec\u00adtors, such as coo\u00adling ele\u00adments for hybrid engi\u00adnes, pipe and flange cou\u00adplings for the oil and gas indus\u00adtry, bea\u00adring and housing com\u00adpon\u00adents for gene\u00adral machi\u00adning, and work\u00adpie\u00adces for the pla\u00ads\u00adtics indus\u00adtry. This makes this pro\u00adcess rele\u00advant for a very wide range of dif\u00adfe\u00adrent work\u00adpie\u00adces with tube- and pot-shaped
\ngeo\u00adme\u00adtry requi\u00adring tole\u00adran\u00adces less than or equal to IT6 and with ultra-pre\u00adcise shape and posi\u00adtion tolerance.[\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column][vc_empty_space height=\u00bb50px\u00ab][vc_cta h2=\u00bbDon\u2019t hesi\u00adtate to cont\u00adact us\u00ab] <\/p>

Contact<\/h1>\n
Sales Depart\u00adment
\n+ 49 371 802 \u2013 333
\nsales.nsi@nshgroup.com<\/div>\n[\/vc_cta][\/vc_column][\/vc_row]\n<\/div>","protected":false},"excerpt":{"rendered":"

[vc_row][vc_column][vc_column_text] Spot\u00adlight on cost-per-part in machi\u00adning sta\u00adtor housings When a machine tool manu\u00adfac\u00adtu\u00adrer and a tool manu\u00adfac\u00adtu\u00adrer known for bor\u00ading and fine bor\u00ading tools get tog\u00ade\u00adther for a joint pro\u00adject, extra\u00ador\u00addi\u00adnary results are gua\u00adran\u00adteed. NILES-SIMMONS and MAPAL have come tog\u00ade\u00adther to deve\u00adlop a pro\u00adcess that dra\u00adma\u00adti\u00adcally redu\u00adces the machi\u00adning time of sta\u00adtor housings (or inner\u2026<\/p>\n","protected":false},"author":3,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"inline_featured_image":false,"wp_typography_post_enhancements_disabled":false,"footnotes":""},"class_list":["post-18392","page","type-page","status-publish","hentry","entry","no-media"],"_links":{"self":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages\/18392","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/comments?post=18392"}],"version-history":[{"count":7,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages\/18392\/revisions"}],"predecessor-version":[{"id":20624,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages\/18392\/revisions\/20624"}],"wp:attachment":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/media?parent=18392"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}