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Housings and covers in EVs use aluminum alloys. The most complex machining challenges in these components come from thin walls, large diameter requirements and geometric tolerances such as concentricity between the main bore and bearing bore.

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Battery housings are typically machined from aluminum casting alloys or aluminum extrusion profiles. Aluminum with low silicon content typically produces long chips and is more susceptible to built-up edges on tooling, thin walls and delamination in composite materials.

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Structural components are often made of aluminum extrusion profiles and castings. Machining challenges for these components come from thin walls and fixturing difficulties that cause unstable machining conditions.

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Gears are made of steel with a combination of hard and soft turning using primarily standard tooling solutions.

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Rotors and shafts are often machined using primarily standard tooling solutions for various types of steel with high surface hardness and good core toughness such as case-hardened steel, forged steel and heat-treatable steel.

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CFRP components experience surface quality issues including delamination, fiber pull out, uncut fibers and breakout, causing rapid flank wear on turning inserts due to the composite's abrasive nature.

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At the heart of every EV is the battery and each vehicle typically needs hundreds to thousands of battery cells to operate. The production of these cells involves the handling of abrasive minerals that wears and corrodes processing equipment.

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