New energy auto parts and CNC processing

CNC machining plays a crucial role in the manufacturing of new energy vehicles.

Compared with traditional auto parts, new energy auto parts have some unique characteristics and requirements. For example, battery pack-related components require high-precision machining to ensure the safety and stability of the battery. The components of the electric drive system need to meet the requirements of high torque and high efficiency.

High precision manufacturing

• It can realize high-precision parts processing to ensure that the dimensional accuracy and form and position tolerances of key automotive components such as engine blocks, pistons, crankshafts, etc. meet strict standards. This helps to improve engine performance, reduce wear and noise, and extend service life. For example, CNC-machined engine blocks can ensure minimal cylinder roundness and cylindricity errors, thereby improving combustion efficiency and power output.

Complex shape machining

• Easily cope with the complex geometry and structure of auto parts. Such as automotive transmission gears, turbocharger impellers, etc., these parts have complex shapes and high precision requirements, and CNC machining can be accurately manufactured.

Consistency and reliability

• Ensure high consistency and reliability of mass-produced parts. In the mass production of cars, this is crucial to ensure the consistent performance and quality of each car.

Rapid prototyping

• In the research and development stage of the vehicle, CNC machining can quickly produce prototype parts, test and verify, shorten the research and development cycle, and reduce development costs.

Lightweight material processing

• With the development trend of automobile lightweight, more and more high-strength aluminum alloy and carbon fiber composite materials are applied. CNC machining enables efficient processing of these new materials to produce lightweight and high-performance parts.

Mold making

• The molds widely used in automobile production, such as stamping molds and injection molds, rely on CNC machining to ensure their accuracy and quality, so as to produce body coverings and interior trim parts that meet the requirements.

For example, some high-end automotive brands extensively adopt CNC machining technology when producing engine and chassis components for high-performance sports cars to achieve superior performance and quality.

High precision and high quality

• It is able to achieve micron level accuracy, ensuring that the size and shape of the auto parts are accurate. For example, for automotive brake system components, high-precision CNC machining can ensure the sensitivity and reliability of braking.
• The finished surface has a high finish, reducing the need for subsequent treatment and improving the durability of the parts.

Ability to process complex structures

• Components with complex internal structures and shapes can be manufactured. For example, the intake manifold of a car, its complex channels and shapes can be perfectly realized by CNC machining.

Improve production efficiency

• High degree of automation, can achieve continuous processing, greatly shorten the production cycle. In mass production, a large number of consistent parts are produced quickly.

Wide adaptability of materials

• Whether it is common metal materials, such as steel, aluminum, or new composite materials, CNC machining can cope with it. This gives automakers the flexibility to select materials based on performance and cost requirements.

Customized production

• To meet the needs of individual car customization, the production of unique parts for specific models or special requirements of customers.

Reduce scrap rate

• Precise control and stable processing significantly reduce the generation of waste products and save costs.

Good repeatability

• The same procedure can be used repeatedly to ensure the consistency of different batches of products.

Conducive to R&D and innovation

• Help automotive engineers quickly translate new design concepts into actual parts and accelerate product development process.

For example, in new energy vehicles, the shell and heat dissipation structure of the battery pack usually need to be CNC machining to ensure its good sealing and heat dissipation performance.

Battery module and battery box manufacturing

• The shell and bracket of the battery module are precisely machined to ensure the safe fixing and good heat dissipation of the battery. For example, battery boxes with specific shapes and sizes are machined through CNC to fit into the space of the vehicle chassis and provide adequate protection.
• Manufacturing battery connection components to ensure stable and reliable electrical connection between batteries.

Motor parts production

• Machining motor shell, stator and rotor and other core components. Precision machining of stators and rotors is crucial to the performance and efficiency of the motor, and CNC is able to ensure the accuracy of its size and shape.
• Make motor shaft, ensure its coaxiality and surface quality, reduce vibration and noise when the motor is running.

Drive system component

• For example, the gears, shafts and housings of the transmission require high-precision CNC machining to achieve good meshing and transmission performance.
• The parts of the differential are processed to ensure that the power distribution of the vehicle is even when turning.

Chassis and suspension

• The structure of the chassis is manufactured to ensure its strength and accuracy, and to improve the handling stability of the vehicle.
• The swing arm and pull rod of the suspension system are processed to ensure the motion accuracy and reliability of the suspension.

Interior and exterior trim

• Production of interior control panels, trim strips, etc., to achieve a refined appearance and good touch.
• Processing bumper, spoiler and other components of the exterior decoration to ensure the fit degree and aerodynamic performance of the body.

Electronic control system components

• For example, the shell of the circuit board, heat sink, etc., through CNC machining to ensure its size and installation accuracy.

In short, CNC machining plays an important role in the manufacturing of various key components of electric vehicles, providing a strong guarantee for the performance, safety and comfort of electric vehicles.

Numerical control turning

• Used for processing cylindrical or conical parts, such as shafts, hubs, etc. It can realize high precision machining of outer circle, inner circle, thread and other surfaces.
• For example, the processing of motor shafts of new energy vehicles usually uses CNC turning processes.

Numerical control milling

• Suitable for processing plane, surface, cavity and other complex shape parts. Can be used to manufacture battery case, motor housing, transmission housing, etc.
• For example, CNC milling is used when machining the mounting surface and heat sink of the battery case.

Electric discharge Machining (EDM)

• For materials with high hardness, complex shapes and difficult to process with traditional methods, such as die steel, EDM can effectively process high-precision cavities and small holes.
• Often used in the manufacture of molds, such as injection molds for the production of plastic parts.

Wire-cut machining

• It can accurately cut the two-dimensional outline of various shapes, especially for the processing of thin, special-shaped parts.
• It is often used in the manufacture of some precision stamping dies.

Laser cutting and welding

• Laser cutting can be used to cut sheets with the advantages of high precision, high speed and small heat-affected zone. It is often used for cutting body coverings, interior panels, etc.
• Laser welding can achieve high strength, high quality connection, suitable for battery pack welding, body frame splicing, etc.

Water jet cutting

• Cutting with high pressure water jet has no thermal effect on the material and is suitable for cutting various materials, including composite materials.
• It can be used to process interior trim parts and some special material parts.

3D printing

• For small batch, complex shape parts or prototype manufacturing, 3D printing can be rapid prototyping.
• For example, the manufacture of personalized interior parts or parts for special structures.

stamping

• Used for mass production of flat-panel components such as body coverings, chassis components, etc.

These processing processes have their own characteristics and advantages, in the processing of new energy auto parts, usually according to the parts of the material, shape, accuracy requirements and production batch and other factors, choose the appropriate processing process or a combination of processes to achieve the best processing effect.

Aluminium alloy

• It has light weight, high strength and good corrosion resistance. It is often used in body structure parts, battery housing, motor housing, etc., which helps to reduce vehicle weight and improve energy efficiency. For example, the body of the Tesla Model S is heavily made of aluminum.

High strength steel

• Provides excellent strength and impact resistance. It is widely used in chassis components, suspension systems and safety structures to ensure the stability and safety of vehicles.

Carbon fiber composite

• It has a very high strength-to-weight ratio, as well as good fatigue and corrosion resistance. Commonly found in high-end new energy vehicle body covering parts, drive shafts, etc., can significantly reduce weight. The BMW i3, for example, uses carbon fiber composites for its body.

Titanium alloy

• High strength, high temperature and corrosion resistance. Suitable for some high performance components, such as key components of brake systems.

Engineering plastics

• Such as polycarbonate (PC), nylon (PA), etc., has good insulation, chemical corrosion resistance and formability. Often used in interior parts, electronic parts of the shell.

Copper alloy

• Good electrical and thermal conductivity make it used in the windings, connectors and charging parts of motors.

Permanent magnet material

• Such as Ndfeb, used to manufacture motor permanent magnets, determines the performance and efficiency of the motor.

Heat-resisting alloy

• For engine components or components in high temperature environments, such as exhaust systems.

The choice of these materials depends on the specific functional and performance requirements of the parts, as well as the overall design and cost considerations of the vehicle.

At Honscn, we offer custom CNC machined green energy automotive parts. We are committed to producing high-quality, environmentally friendly automotive parts for our customers to meet their individual needs. In addition, we offer advanced CNC machining services that can precisely machinate a wide range of metal and plastic materials to ensure excellent product performance. In addition, we attach great importance to environmental protection and use energy saving and emission reduction processes in production. If you are interested in our products and services, please feel free to contact us or get a quote .