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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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SAP Material Number ISO Catalog Number ANSI Catalog Number Grade [L10] Insert Cutting Edge Length [L10] Insert Cutting Edge Length [S] Insert Thickness [S] Insert Thickness [W] Insert Width [W] Insert Width [Clearance Angle Major Clearance Angle Major Second [GAA] Insert Rake Angle
3856827 RIRT4C4512 RIRT4C4512 KC6005 45.0000 1.772 3.1500 .1240 5.5600 .2190 8.000 18.000 12.000
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    SAP Material Number ISO Catalog Number ANSI Catalog Number Grade [L10] Insert Cutting Edge Length [L10] Insert Cutting Edge Length [S] Insert Thickness [S] Insert Thickness [W] Insert Width [W] Insert Width [Clearance Angle Major Clearance Angle Major Second
    3858727 RIR01EGU00 RIR01EGU00 KC6105 14.4750 .5699 1.5500 .0610 2.8000 .1102 8.000 18.000
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      3856793 RIR04E1312 RIR04E1312 KC6005 27.0000 1.063 3.1300 .1230 5.5600 .2190 8.000 18.000 12.000
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        5159761 RIQ06R0500FT RIQ06R0500FT KT6315 6.0000 .2362 2.6000 .1024 0.5000 .0196 8.000 18.000 0.000
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          5826310 RIQ09R0506FT RIQ09R0506FT KT6315 9.0000 .3543 3.1500 .1240 0.5000 .0196 14.000 24.000 6.000
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            5676787 RIQ06EDR00 RIQ06EDR00 KC6005 6.0000 .2362 2.6000 .1024 8.000 18.000 0.000
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              5676786 RIQ06EDR00 RIQ06EDR00 KC6305 6.0000 .2362 2.6000 .1024 8.000 18.000 0.000
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                5676790 RIQ06EDR06 RIQ06EDR06 KC6105 6.0000 .2362 2.6000 .1024 14.000 24.000 6.000
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                  5676791 RIQ06EDR06 RIQ06EDR06 KC6305 6.0000 .2362 2.6000 .1024 14.000 24.000 6.000
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                    5676795 RIQ06EDR12 RIQ06EDR12 KC6305 6.0000 .2362 2.6000 .1024 20.000 30.000 12.000
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                      5676792 RIQ06EDR12 RIQ06EDR12 KC6005 6.0000 .2362 2.6000 .1024 20.000 30.000 12.000
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                        5676761 RIQ06E1300 RIQ06E1300 KC6105 6.0000 .2362 2.6000 .1024 8.000 18.000 0.000
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                          5676728 RIQ06E1306 RIQ06E1306 KC6105 6.0000 .2362 2.6000 .1024 14.000 24.000 6.000
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                            5676763 RIQ06E1312 RIQ06E1312 KC6105 6.0000 .2362 2.6000 .1024 20.000 30.000 12.000
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                              5676765 RIQ09E1306 RIQ09E1306 KC6105 9.0000 .3543 3.1500 .1240 14.000 24.000 6.000
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                                5676767 RIQ09E1312 RIQ09E1312 KC6105 9.0000 .3543 3.1500 .1240 20.000 30.000 12.000
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                                  5676766 RIQ09E1312 RIQ09E1312 KC6005 9.0000 .3543 3.1500 .1240 20.000 30.000 12.000
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                                    5127885 RIQ06R0400S RIQ06R0400S KB1610 6.0000 .2362 2.6000 .1024 0.4000 .0160 8.000 18.000 0.000
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                                      4181068 RIQ09R0400S RIQ09R0400S KB1610 9.0000 .3540 3.1500 .1240 0.4000 .0160 8.000 18.000 0.000
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                                        4003518 RIQ06R0200 RIQ06R0200 KD1415 6.0000 .2362 2.6000 .1024 0.2000 .0079 8.000 18.000 0.000
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                                          5676770 RIQ06EGR00 RIQ06EGR00 KC6005 6.0000 .2362 2.6000 .1020 8.000 18.000 0.000
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                                            5676768 RIQ06EGR00 RIQ06EGR00 KC6105 6.0000 .2362 2.6000 .1020 8.000 18.000 0.000
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                                              5676771 RIQ06EGR06 RIQ06EGR06 KC6005 6.0000 .2362 2.6000 .1020 14.000 24.000 6.000
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                                                5676778 RIQ09EGR00 RIQ09EGR00 KC6005 9.0000 .3543 3.1500 .1240 8.000 18.000 0.000
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                                                  5676781 RIQ09EGR06 RIQ09EGR06 KC6305 9.0000 .3543 3.1500 .1240 14.000 24.000 6.000
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                                                    5676780 RIQ09EGR06 RIQ09EGR06 KC6105 9.0000 .3543 3.1500 .1240 14.000 24.000 6.000
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                                                      5004291 RIQ09R0400FB RIQ09R0400FB KT6225 9.0000 .3543 3.1500 .1240 0.4000 .0156 3.000 18.000 12.000
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                                                        6183831 RIQ07C4500S RIQ07C4500S KBHK10 7.0000 .2756 3.1500 .1240 8.000 18.000
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                                                          6183837 RIQ07C4500S RIQ07C4500S KBHK15 7.0000 .2756 3.1500 .1240 8.000 18.000
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                                                            6183839 RIQ09C4500S RIQ09C4500S KBHK15 9.0000 .3540 3.1500 .1240 8.000 18.000
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                                                              6183833 RIQ09C4500S RIQ09C4500S KBHK10 9.0000 .3540 3.1500 .1240 8.000 18.000
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                                                                6183834 RIQB6C4500S RIQB6C4500S KBHK15 6.0000 .2362 2.6000 .1024 8.000 18.000
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                                                                  6183780 RIQB7C4500S RIQB7C4500S KBHK10 6.5000 .2559 2.6000 .1024 8.000 18.000
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                                                                    SAP Material Number ISO Catalog Number ANSI Catalog Number [H2] Overall Height [H2] Overall Height [L] Overall Length [L] Overall Length [LU] Usable Length [LU] Usable Length [W1] Unit Base Width [W1] Unit Base Width
                                                                    5025597 SF300M1LA1RA SF300M1LA1RA 118.0000 4.645 450.0000 17.716 300.0000 11.811 195.0000 7.677
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                                                                      5025599 SF300M1RS SF300M1RS 118.0000 4.645 450.0000 17.716 300.0000 11.811 195.0000 7.677
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                                                                        5025598 SF750M1LA1RA SF750M1LA1RA 118.0000 4.645 900.0000 35.443 750.0000 29.527 195.0000 7.677
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                                                                          5025683 SFSLSS SFSLSS
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                                                                            5025679 SFCR20S SFCR20S
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                                                                              5025677 SFCRHSK3263 SFCRHSK3263
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                                                                                5025678 SFCRHSK63100 SFCRHSK63100
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                                                                                  5025680 SFVB SFVB
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