hp tooling 2020 #1

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materials & tools Creating stator bores in a single operation Powerful tools for electric motor production The position of the automotive industry is clear. Over the next ten years practically every car maker 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 large-scale production of electric motors? At EMO 2019, CERATIZIT demon strated an extremely effective tool programme that provides the perfect technical and commercial solution for every ma chining task encountered in the production of electric motors. The two newly developed fine boring tools for the highperformance high volume production of electric motor housings are simply outstanding. Present situation The machining demands represented by the housing of a car’s electric motor are no different from those of an internal combustion engine, apart from the stator bore of the thin-walled electric motor housing. Depending on the size and type of the motor, the stator bore will vary between approximately Ø 200 mm and 300 mm, extend to a depth of more than 300 mm and must satisfy extremely tight accuracy requirements; for example, tolerances conforming to IT6 and roundness criteria as low as 2/100 mm. These are huge challenges for a finishing tool designed to produce the complete bore in a single operation in high volume production. However, they have to be met if electric motors are to be produced in a timely and economic manner in quantities in excess of 100,000. Solid steel tools are ill-equipped for these tasks, as they are far too heavy for most machine spindles. The solution is to be found in lightweight bodies that reduce the tool weight to somewhere below 20 kg, which today’s standard CNC machining centres are able to accommodate. Available in multi-step designs for complete machining applications, they feature several cutting edges per step and in some cases guide rails as well. Despite their light weight, fine boring tools like these must possess a high degree of rigidity to successfully transmit the power to the cutting edges and hence achieve the required tolerance results Additively manufactured high-end solution With its new fine boring tool, which is additively manufactured 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 200 mm) and considerable length, the developers have managed to keep the weight of the fine boring tool below 17 kg and designed it to accommodate the tilting moment of machining centres. That such a lightweight tool can be manufactured at all is down to the experience in 3D printing gained over the years by CERATIZIT. The delicate, optimally braced structure of the base body can only be produced by an additive manufacturing (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 Produce stator bores at unbelievable levels of efficiency; with the new special tool from CERATIZIT that will soon be possible 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 & 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 - 10 no. 1, 2020, March
materials & tools 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 such 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. it’s no less innovative. It is more affordable and of a modular design that makes it easier to manufacture. Lightweight construction and the AM expertise at CERATIZIT were also to the fore in this new development. The CERATIZIT branch in Stuttgart-Vaihingen is responsible for the individual design of the fine boring tool with regard to tool size, guide rails and the required number of steps. It is also where the tools are manufactured on an ultra-modern machine. The advantages at a glance: ➤ complete finish machining of the stator bore in a single operation ➤ up to five steps, each with four PCD cutting edges, offers high-performance capability ➤ extremely precise machining results (tolerance class IT6) ➤ topology-optimised, additively manufactured lightweight body ➤ additively manufactured tool cartridges with soldered PCD cutting edges ➤ optimised coolant hole configuration for cooling each cutting edge and flushing chips out of the bore ➤ customer-specific design Plastic step boring bar for the stator bore CERATIZIT has developed another fine boring tool for the electric motor housing. Its design is somewhat simpler, but Thanks to its incredibly innovative design, the weight of the tool is reduced to well below what the market has come to expect and is consequently exactly what anyone involved in the machining of stator bores in a single operation on machining centres has been waiting for KREBS & RIEDEL Schleifscheibenfabrik GmbH & Co. KG • CBN and Diamond Wheels in Vitrified Bond • Grinding Wheels in Vitrified Bond • Grinding Wheels in Resinoid Bond • Fiber-reinforced Cut-off and Rough Grinding Wheels Innovative Grinding Technology since 1895! Visit us: Hall 2 Stand 2031 18 - 21 March 2020 Augsburg Grinding Perfection for every Process! KREBS & RIEDEL Schleifscheibenfabrik GmbH & Co. KG Bremer Str. 44 • 34385 Bad Karlshafen Phone: +49 5672 184-0 E-Mail: mail@krebs-riedel.de Web: www.krebs-riedel.de hv02di20
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