New energy vehicle composite material cutting process solution

In recent years, with the rapid development of new energy vehicles, energy saving, environmental protection, safety and lightweight will become the main development direction of new energy vehicles in the future. Composite materials with advantages such as high specific modulus, high specific strength, corrosion resistance and strong designability just conform to the trend of automobile development. Composite materials are widely used in the development and manufacturing of semi-structural parts such as automobile body panels and interior parts, mainly based on short-cut glass fiber reinforced composite materials such as SMC and GMT, including roof panels, trunk covers, engine hoods, trunk covers, spare tire compartments, bumpers, interior panels and front ends of vehicles.

Composite materials have become an indispensable part in the new energy vehicle industry. However, on the other hand, the high hardness components and multiphase structure of composite materials with different characteristics complicate machining operations, resulting in problems such as fiber delamination, burrs and excessive wear of the tool back face. Therefore, higher requirements are placed on processing machine tools, spindles and tools.

The high speed brought by the high-speed electric spindle is one of the necessary conditions for processing composite materials. The maximum speed of the German SycoTec high-speed electric spindle can reach 100,000rpm. It has the characteristics of small size, light weight, high power, high torque, high precision, and optional automatic tool change. It can not only improve the quality and efficiency of composite material machining, but also save costs and improve product competitiveness.

1. Spindle selection

The classic SycoTec 4025 and 4026 are both mini high-speed spindles with a speed range of 5,000-60,000 rpm, good heat dissipation performance, long service life and high cost performance.

SycoTec 4033 AC-ER8 has a maximum speed of 100,000 rpm, a maximum power of 500W, and a maximum torque of 8.4Ncm, but weighs only 0.5kg. It performs outstandingly in the cutting of composite materials for new energy vehicles.

The synchronous motor SycoTec 4036 DC-T has a speed range of 5,000 – 60,000 min-1, a maximum power of 900W, a maximum torque of 27 Ncm, a taper runout of typically 1 µm, strong cutting capacity and high processing efficiency.

2. Processing Case

SycoTec 4036DC-T Automotive ABS Milling