3D printed stator bore tool for the machining of aluminum e-motor housings.

This version of the tool features a newly designed arm structure, a larger center tube made of carbon fiber, and weighs a total of 7.3kg.

The complex tool is capable of machining three large diameters in just one operation, saving set-up time and machining time for automotive component manufacturers and delivering the highest accuracy and surface qualities.

Machining three diameters in one operation, the stator bore tool ensures the alignment and concentricity of the machined surfaces whilst reducing the cycle time significantly.

The lightweight 3D printed combination tool enables a faster tool change and spin-up even on less powerful machines.

  

  

Design Evolution

First-generation design (9.5kg) on the left, and latest tool design variants (less than 8kg) on the right for hassle free tool changing.

  

Process Simulation

  

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Workpiece Material
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  • P Steel (4)
    • P0
      Low-Carbon Steels, Long Chipping C < .25%; <125 HB; <530 N/mm^2 UTS (4)
    • P1
      Low-Carbon Steels, Short Chipping C < .25%; <125 HB; <530 N/mm^2 UTS (4)
    • P2
      Medium and High Carbon Steels C < .25%; <220 HB; <25 HRC; >530 N/mm^2 UTS (4)
    • P3
      Alloy Steels & Tool Steels C > .25%; <330 HB; <35 HRC; 600-850 N/mm^2 UTS (4)
    • P4
      Alloy Steels & Tool Steels C > .25%; 350-420 HB; 35-43 HRC; 850-1400 N/mm^2 UTS (4)
    • P5
      Ferritic, Martensitic, and PH Stainless Steels <330 HB; <35 HRC; 600-900 N/mm^2 UTS (4)
    • P6
      High Strength Ferritic, Martensitic, and PH Stainless Steels 350-450 HB; 35-43 HRC; 900-2400 N/mm^2 UTS (4)
  • M Stainless Steel (4)
    • M1
      Austenitic Stainless Steel 130-200 HB; <600 N/mm^2 UTS (4)
    • M2
      High Strength Austenitic Stainless and Cast Stainless Steels 150-230 HB; <25 HRC; >600 N/mm^2 UTS (4)
    • M3
      Duplex Stainless Steel 135-275 HB; <30 HRC; 500-1200 N/mm^2 UTS (4)
  • K Cast Iron (4)
    • K1
      Gray Cast Iron 120-290 HB; <32 HRC; 125-500 N/mm^2 UTS (4)
    • K2
      Low and Medium Strength CGI and Ductile Irons 130-260 HB; <28 HRC; <600 N/mm^2 UTS (4)
    • K3
      High Strength Ductile and Austempered Ductile Iron 180-350 HB; <43 HRC; >600 N/mm^2 UTS (4)
  • S High-Temp Alloys (3)
    • S1
      Iron-Based, Heat-Resistant Alloys 160-260 HB; 25-48 HRC; 500-1200 N/mm^2 UTS (3)
    • S2
      Cobalt-Based, Heat-Resistant Alloys 250-450 HB; 25-48 HRC; 1000-1450 N/mm^2 UTS (3)
    • S3
      Nickel-Based, Heat Resistant Alloys 160-450 HB; <48 HRC; 600-1700 N/mm^2 UTS (3)
    • S4
      Titanium and Titanium Alloys 300-400 HB; 33-43 HRC; 900-1600 N/mm^2 UTS (3)
Cutting Edges Per Insert
Cutting Edges Per Insert
  • 2.0 (4)
  • 4.0 (65)
Cutting Edges Per Insert Min to Cutting Edges Per Insert Max
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Corner Radius
Corner Radius
  • 0.008 in (1)
  • 0.016 in (3)
  • 0.02 in (2)
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Corner Radius
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  • 0.4 mm (3)
  • 0.5 mm (2)
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Corner Chamfer
Corner Chamfer
  • 0.0 mm (69)
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Corner Chamfer
Corner Chamfer
  • 0.0 in (69)
Corner Chamfer Min to Corner Chamfer Max
application
Grade Of Cutting Tool
Grade Of Cutting Tool
  • KB1610 (2)
  • KBHK10 (5)
  • KBHK15 (5)
  • KC6005 (18)
  • KC6105 (17)
  • KC6305 (16)
  • KD1415 (3)
  • KT6225 (1)
  • KT6315 (2)
Wiper Insert
Wiper Insert
  • N (69)
frontEnd
Insert Shape
Insert Shape
  • L-RECTANGLE 90 (4)
  • S-SQUARE 90 (65)
insertGeometry
Shape
Shape
  • L-RECTANGLE 90 (4)
  • S-SQUARE 90 (65)
Insert IC Size
Insert IC Size
  • 6.0 mm (30)
  • 6.5 mm (2)
  • 7.0 mm (2)
  • 8.0 mm (2)
  • 9.0 mm (29)
Insert IC Size Min to Insert IC Size Max
Insert IC Size
Insert IC Size
  • 0.237 in (30)
  • 0.256 in (2)
  • 0.276 in (2)
  • 0.315 in (2)
  • 0.354 in (29)
Insert IC Size Min to Insert IC Size Max
Cutting Edge Length
Cutting Edge Length
  • 6.0 mm (5)
  • 6.5 mm (2)
  • 7.0 mm (2)
  • 8.0 mm (2)
  • 9.0 mm (4)
  • 9.05 mm (1)
  • 14.476 mm (1)
  • 18.0 mm (1)
  • 27.0 mm (1)
  • 45.0 mm (1)
Cutting Edge Length Min to Cutting Edge Length Max
Cutting Edge Length
Cutting Edge Length
  • 0.237 in (5)
  • 0.256 in (2)
  • 0.276 in (2)
  • 0.315 in (2)
  • 0.354 in (4)
  • 0.356 in (1)
  • 0.571 in (1)
  • 0.709 in (1)
  • 1.063 in (1)
  • 1.772 in (1)
Cutting Edge Length Min to Cutting Edge Length Max
Chip Breaker CBMD
Chip Breaker CBMD
  • FB (1)
  • FT (2)
  • S (10)
Cutting Tool Material
Cutting Tool Material
  • B H (12)
  • D P (3)
  • H T (3)
  • H W (51)
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