CAT.EVBROCHURE.3/23
EV T OOLING S OLUTIONS
Ready to Create New Standards
H
Tooling Solutions for EV
Stator Housing
Aluminum Alloy
.00047” / .012mm ø.0019" / .05 mm ø.0003 / .008 mm ø.0019" / .05 mm
ø.0051" / .13 mm ø.0008" / .02 mm ø.0019" / .05 mm
For Stator Housing/Bearing Mounting Hole Drilling Special Composite Boring Tool
Machined Portion · Composite tool features excellent machining accuracy and dramatically reduced cycle time. · Optimization of tool weight and rigidity based on advanced stress analysis and performance data.
Drilling
Milling
Non-Ferrous Drilling
PCD Face Milling
Indexable Endmills
NHGS Series ¢ DLC Coated Solid Carbide Drills
¢ ALNEX - PCD Milling
¢ 90° Shoulder Milling
Series
Series
Diameter: ø.0625” to .6250” (ø3.0 to 16.0mm) L/D: 3, 5: ø.0625” to .6250” (ø3.0 to 16mm) 10: ø.0625” to .5118” (ø3.0 to 13mm)
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Tooling Solutions for EV
Reducer Case Bearing Mounting Pre-Cast Hole Drilling
Aluminum Alloy
Conventional machining process
(4)
(3)
(6)
(1)
(5)
(2)
Machined Portion
(1) Internal (Small Diameter) (2)Bottom Surface (3) Internal (Large Diameter)
Roughing
.00047” / .012mm ø.0019" / .05 mm ø.0003 / .008 mm ø.0019" / .05 mm
(4) Chamfer Edge (5)Internal (Small Diameter) (6) Internal (Large Diameter) + Necking
Finishing
Conventionally: Different tools required for roughing and finishing
For Bearing Mounting Hole Drilling One-Pass Roughing and Finishing Tool
(1) (5) Internal (Small Diameter) Roughing/Finishing (2) Bottom Surface (3) (6) Internal (Large Diameter) Roughing/Finishing + Necking (4) Chamfer Edge
■ Capable of machining in 1 pass! ■ Total tool count reduced ■ Contributes to reduced cycle time
Drilling Process
Cartridge Style
Brazed Style
A.L.M.T.
Effective No. of Teeth: 6
Effective No. of Teeth: 3
Special Formed PCD Insert with Necking Edge
PCD Brazed Cutting Edge with Necking Edge
· The use of three formed inserts enables one-pass finishing even on pre-cast hole work with large variations in machining allowance. · The introduction of a parallel adjustment mechanism maintains high squareness accuracy even when diameter height is adjusted. · Light-weight aluminum alloy body enables usage on small machining center with weight limitations.
· By brazing the PCD cutting edges directly to the body, the number of effective cutting edges is increased from 3 to 6, thus achieving higher machining efficiency.
Indicates A.L.M.T. Corp. products.
A.L.M.T.
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Tooling Solutions for EV
Reducer Case Pre-Cast Hole Drilling
Aluminum Alloy
Regrindable PCD Reamer with Chipbreaker Function Machined Portion
DLC Coat Drill Machined Portion
Regrindable PCD Reamer with Chipbreaker Function A.L.M.T.
For Pre-Cast Hole Drilling DLC Coated Drill
Diameter: ø.197 to .472” (ø5.0 to 12.0mm)
Diameter: ø .197 - 3.150” ( ø5.0 to 80.0mm )
(large dia. max. ø.630” ( ø16.0mm) and below
Positioning accuracy for .0157" ( ø.4mm) and below is possible even at
feed rate of f= .039 IPR
1.0 mm/rev
1st Regrind 2nd Regrind
· Special chipbreaker shape improves chip control. · Newly regrinded chipbreakers are same quality as original. · Applicable feed rate range is f = .0079 to .0157 IPR ( .2 to .4 mm/rev ) (4 flutes)
· Special flute design achieves both drilling accuracy and high efficiency, even in pre-cast hole drilling when hole positions tend to be misaligned.
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Tooling Solutions for EV
Rotor Shafts and Gears
Special Steel
Ultra-hard Alloy Steel
For High-Efficiency Hardened Steel Machining Hard Skiving Tool
¢ 10x machining efficiency compared to conventional machining methods ¢ Surface roughness of Rz 2 μm and below is possible
¢ Our proprietary machining method achieves both machining accuracy and high efficiency while significantly reducing cycle time. ¢ Meets the strict machining accuracy required for high-speed rotating for EV rotor shafts.
Hardened Steel Turning Coated CBN BNC2115/BNC2125
Turning
Drilling
Pre-hardening Turning ¢ Coated Carbide Grades for Steel Turning AC8000P Series
MDW - GS / HGS GS ¢ Solid Carbide Drills Hard Drilling
Hollow Shaft Drilling
¢ Replaceable Tip Drilling
¢ Indexable Drilling
SMD Series
WDX Series
AC8015P AC8020P AC8025P AC8035P
HGS
Diameter: GS: ø.0391 - ø.7874” (ø1.0 - ø20.0mm) HGS: ø.0591 - ø.7874” (ø1.5 - ø20.0mm) L/D: GS: 2, 4 HGS: 3, 5, 8
Diameter: ø.4724” and above ( ø 12.0mm and above) L/D: 1.5, 3, 5, 8, 12
Diameter: ø.5118 to 2.677” ø13.0 to 68.0mm L/D: 2, 3, 4, 5
indicates A.L.M.T. Corp. products.
A.L.M.T.
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Tooling Solutions for EV
Differential Case
Ductile Cast Iron
SumiReamer SSR Series Machined Portion
High-efficiency Drills Machined Portion
SumiReamer SSR Series* *This is a special / custom item
For Ring Gear Mounting Hole Drilling High-Efficiency Drills
Diameter: ø.118 to .551” (ø3.0 to 14.0mm)
Diameter: ø.117 to .472” ( ø2.97 to 12.0mm)
2x conventional feed rate f = .0157 to .0197 IPR ( .4 to .5 mm/rev) is possible
1.8μm 2.3μm
R a 0.1
· A balanced design that combines sharpness and cutting edge strength, to achieve high feed rate of f= .0630 IPR ( 1.6mm/rev) .
· Our proprietary low-resistance cutting edge design achieves high-efficiency drilling. · High efficiency reduces power consumption by about 40%, contributing to energy savings toward SDGs.
Reaming Internal Diameter Finishing ¢ SumiReamer SR Series
Turning
Roughing ¢ Cast Iron Turning Grades AC4000K Series
Coated CBN - BNC500 ¢ For Ductile Cast Iron Turning Finishing
Diameter: ø.4685 to 5.5354” (ø11.9 to 140.6mm)
AC4010K AC4015K AC420K
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Tooling Solutions for EV
Spherical Cutters
Available sizes: Consult local Sumitomo Representative for more information
(actual sizes supported so far: ø1.3779 to 2.5197” (ø35 to 64mm)
Lay-flat Insert
· Ideal for small differential case machining.
Tangential Insert
· Tangential mounting increases insert rigidity, ideal for high-feed and high-efficiency machining.
Required tolerance range for spherical surface is 90 μm or below
Face Cutters
Available sizes: Consult Sumitomo Sales Representative for more information
(actual sizes supported so far: ø1.8898 to 3.9370” (ø48 to 100mm)
· Special cutter for dedicated machines ideal for outstanding mass production performance. · High-precision cutter body and ground insert support demanding machining accuracy. · Highly economical with indexable inserts.
.0019" / .05 mm
R a 3.2
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EV B rochure
Sumitomo Electric Carbide, Inc. Headquarters 1001 Business Center Drive Mount Prospect, IL 60056-2181
Phone: (847) 635-0044 Fax: (847) 635-7866 Website: www.sumicarbide.com
595 S. Emerson Avenue Suite 100 Greenwood, IN 46143 Indiana Branch - Greenwood
Sumitomo Electric Carbide, Inc. - Americas Tool Engineering Center
5637 S. Westridge Drive New Berlin, WI 53151
Michigan Branch 26800 Meadowbrook Suite 120 Novi, MI 48377
Sumitomo Carbide Canada, Inc. 150 Research Lane Unit 210 Guelph, Ontario N1G 4T2 Canada
Phone: (519) 265-6050 Phone: (844) 211-6050
www.sumicarbide.com
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