Machining industry 2019

Spotlight on e-mobility: there
is no future without a pastcycle times for maximum output quantities. Stator bores, forinstance, demand a high degreeof measuring precision. With adiameter of 235 mm, the appropriate 6-axis GÜHRING PCD
tool has a tilting moment of
22 Nm and weighs less than 20kilograms. This lightweight tool
is made from aluminium which,as well as reducing the spindle
load, guarantees maximum productivity.
Design of holistic tool and machine concepts
GROB and GÜHRING delivercustom-made turnkey solutions
tailored to the customer‘s speciHans-Peter Mögele (pictured right), Head of Tool Technology at GROB-WERKE GmbH & Co. KG,
fic needs: machines, processes,Achim Walker, Head of Original Equipment/OEM projects at Gühring KG.
devices, tools and automation
The automotive industry is changing: alternative drive conassure the user of a holistic machining and tool concept. As an excepts such as the electric motor are putting brand new machipert in all kinds of components, GROB works with the user to dening tasks on every supplier‘s agenda. Mechanical engineetermine the optimum machining process and finalises the design
ring firms and tool manufacturers have a duty to reliablyof the tools with GÜHRING. The machining experts at both commanufacture e-components. The production and automation
panies assure the user of the swift implementation of custom-masystems specialists at GROB-WERKE Mindelheim and toolde solutions of the highest quality. The client enjoys personal supmanufacturer GÜHRING are an experienced and well-oiled
port, from the planning of the individual machining operations
team.
right through to acceptance of series production. GROB is able
to illustrate every possible scenario, from the complete machiManufacturers of e-components must have the international, proning of the component in a single operation to fully automatedfessional expertise to overcome the special challenges inherent
machining in several clamping positions. Turning operations canin e-mobility. Maximum efficiency and profitability, along withalso be reliably manufactured, either by using milling and turning
process reliability in component manufacturing, are particularly
centres or by using a feed-out spindle. Wherever you are in theimportant in series production. One international automotive supworld, GROB and GÜHRING have their own production sites
plier has recognised this fact: GROB and GÜHRING were about
and service centres close at hand, particularly in areas with a highto start implementing the large-scale series production of electric
density of automotive companies and their suppliers – guaranmotor housings, complete with gearbox covers, for a renowned
teeing quick response times and maximum customer proximity.
car manufacturer. The challenges this presents are the reliable
manufacture of small diameter tolerances of up to IT6 and small
Wealth of experience goes into machininggeometric tolerances, such as concentricity of up to 40 µm with aGROB and GÜHRING are particularly skilled at tackling the inreference length of more than 400 mm which was laterally inverdividual requirements dictated by e-mobility. They draw on decated during machining. A perfect blend of machining centre anddes of experience in the automotive sector and the insights andprecision tools is essential for responding successfully to theseachievements of their own research and development departments.
challenges. For more than 90 years, GROB has been setting theGÜHRING, for example, boasts a huge amount of knowledge ofbar in the construction of highly innovative production and authe required precision tools. The Albstadt-based company has 40
tomation systems. The Mindelheim-based company in turn playears of experience in PCD (polycrystalline diamond), which it
ces its trust in GÜHRING as a longstanding partner for originalincorporates in the machining of e-motor housings, including
equipment and a leading manufacturer of rotating precision tools.
thin-walled and large diameters of up to 300 mm coupled with
It is a working relationship founded on tradition, expertise andsmall geometric tolerances, which are regularly encountered intrust. To offer even better support to GROB and its end customers
the manufacture of gearbox housings. It also integrates the latest
with the daily demands of machining, last year GÜHRING opeproduct innovations into e-machining. Preventive measures aimed
ned a new centre for original equipment in Mindelheim, right on
at maximising process reliability, such as the FEM calculation duGROB-WERKE‘s doorstep.
ring tool construction to reduce weight or rigidity and vibration
tests taking account of real operating speeds, are an establishedPartner for the series production of e-motor components
part of the routine. Innovative tool geometries, included for deGÜHRING is a longstanding supplier to the automotive industry
fined chip evacuation thanks to additive manufacturing, in coolant
and, like GROB, has outstanding production depth and an extduct connectors and cooling fins in the stator housing during milremely comprehensive product portfolio. GROB is a pioneer inling, boring and reaming are part of the product portfolio.
plant construction for the series manufacture of e-machines andGROB also boasts impressive, in-depth expertise in e-mobility:
electric motors. The customer is assured of cost-effective manuwith over 90 years’ experience in the system business, the comfacture, taking account of the costs per component and minimumpany recognised early on the evolution in automotive drivetrains

and diversified its product portfolio accordingly, adopting a longterm strategy. This development was given a further, major boostby the takeover of DMG meccanica, the leading machinery andplant manufacturer for the production of stators for electric motors
and generators in Italy and the construction of an ultra-moderndevelopment and applications centre. GROB is now able to offer
its customers comprehensive support, from the initial idea to large
series production of hybrid and electric drives.
All the components at a glance
Thanks to the strategic partnership formed by GROB andGÜHRING. Today reference customers are assured of the reliable
series production of tens of thousands of e-motor components.
In-house project groups and development teams at GROB andGÜHRING have been addressing the issue of e-mobility for manyyears. In constant dialogue with the automotive industry, a highdemand for production facilities for mass production in the automotive industry was quickly identified. At GROB, the focus is on
the core segments of electric motors and batteries. GROB alreadyoffers wave winding, hairpin, fan coil and inserting technology as
well as needle winding technology. Because of this, it covers theentire electric motor manufacturing process, which includes thevarious winding and shaping procedures for the wires, assemblyand also the contacts. GROB and GÜHRING are therefore able toprocess all of the components of an e-vehicle which require machining. In addition to e-motor housings and the related gearbox
covers, auxiliary units such as battery trays to accommodate theenergy storage system and compressor, which are used for thermal management in vehicles, are also machined. Due to their sizeof up to 2x1 m and their thin walls, battery trays are particularly
susceptible to vibration. This problem is overcome, chiefly during
milling, with the aid of geometric features such as very uneven
spacing when cutting and a rigid tool interface created by inputs
with optimised interference contours. Having already successfully completed more than 20 battery case projects, GÜHRING isconsidered a leader in this application. Machining with minimum
lubrication also guarantees the long-term sustainability of production. In this area too, both companies have a long track record ofsuccessful conventional drivetrain projects. Thermal management
presents another challenge in electric vehicles. In the past, conventional air conditioning systems have been powered by combustion
engines. For electric vehicles, in future electric compressors will
be used as heat and cold pumps. The compressor comprises twocoils, the opposing motion of which compresses gas. Small tolerances for the coils ensure that the most efficient compression
possible is achieved. For example, the requirements for geometrictolerance are an angularity of 20 µm and a line profile of 8 µm. The
smallest surface finish qualities below Rz 4 µm combined withthin-walled surfaces of less than 3 mm und cutting heights of up to25 mm are typical of this machining task. The solutions are milling
tools with minimum cutting pressures. Highly positive rake angles
and increased rigidity mean that tolerances are reliably met.
A clear grasp of the challenges for the future
GROB and GÜHRING are dedicated to ensuring that their customers can have all their e-mobility needs met from a single source,
anywhere in the world, and act as a professional partner to theworldwide automotive industry in the series production of electricdrives. With their strategy of a diversified product portfolio andtheir ability to offer and supply all the manufacturing processes
for electric motors, the partners are fully prepared for dynamic,
technological change in automotive drivetrains.

E-MOBILITYPIONEERING. SUSTAINABLE. MOBILE.

Sustainability, emission-free engines and less dependence on fossil fuels: the mobility of our future will change.
E-mobility is a central theme of the energy revolution and electric vehicles are a key component of the transport
revolution. E-motors are used in both hybrid vehicles and all-electric vehicles.
As a longstanding supplier to the automotive industry, Gühring has been addressing the challenges of e-mobility
since the industry first began switching to electricity. From original equipment and retooling to the reprocessingof tools and tool management, we are known as a single-source provider of professional solutions.

Griühll–ang

RETO

HEC

Nols

LF
ACIIE

VIC
RES
LDE

GME

NT&Our machining capabilities
also come into play here:

TOLIN

thitongs

GIN

AL

EQ

UIP

Gühring’s e-competence extends
far beyond mobility concepts.

ORI

Battery tray

Market penetration of e-mobility

100 % production depthElectrified mobility solutions are by no means confined to private mobility.
E-mobility is being embraced in the sport segment, goods transport andlocal public transport.

Gühring combines all the skills involved in tool manufacture under one roof.
Here, we help drive and implement trends in the metal industry.

Coatings
our own coating
systems and in-housecoating development
E-car

E-bikeE-scooter
E-motorbike

Publictransport

E-truck

Geometries
our own R&D fortool development

Cutting materials
our own carbide
manufacture

Plant and mechanicalengineering
our own mechanicalengineering and in-houseplant development

View of component
Gearbox side

E-MOTOR

Drive shaft bearing
Transmission bearing

AUTOMOTIVE

View of component
Stator side
Stator boreMotor shaft

Small diameter tolerances and geometrictolerances• cost-efficient and precise machining of small diameter

Eccentric reverse machining

tolerances up to IT6• machining of one side

• reliable tool solutions for particularly small geometric• process reliability with the aid of rigidity
Ø 0.04 A-B

A

tolerances, e.g. concentricity of up to 40 µm with areference length of over 400 mm• FEM calculation during tool construction to reduceweightGeometric tolerances of e-motor housing

Stator boreBØ 235 mmand vibration tests, taking account of realoperating speeds

400 mmMotor shaft
gearbox side

View of component
Stator side

REPR

OCE

Big diameter – light tools

SSI• small tilting moment• maximum rigidity with few materialsNG• minimised machine spindle load

Stator bore

Low-chip machining• defined chip evacuation away from component,

E-motor housing

by using special geometries

T• avoidance of chip ingress into the componentOwhen reaming, drilling and millingO• reduction of rinsing cycles, translating intoL

sustainable manufacture

MANAG

View of component
Cross-section ofstator boreEMENT

Connecting
bores forcoolant duct

Compressor

Gühring – your worldwide partnerMarket trend of e-mobility

Gühring is nearby, everywhere all over the world. This means we canguarantee first-class support and quick response times.
You can be sure that we are never far away.

Market share of the different drive systems as percentage of global sales

8,000

Employees worldwide

48

National companies

70Production sites

100 %Conventionally powered vehicle

90 %
80 %

Fuel-efficient conventionally
powered vehicle

70 %Fuel cell vehicle

60 %Battery electric vehicle50 %Extended range electric vehicle

40 %Plug-in hybrid electric vehicle

30 %
20 %

Full hybrid

10 %Mild hybrid

0%
2013

2019

2025

From: STRUKTURSTUDIE BWe mobil, Elektromobilität in Baden-Württemberg

2030

Original equipment & retoolingPowerful partner for new processes

200

No matter what challenges customers may face when machining their components, Gühring is thereto help as a dependable partner with many years of experience and expert know-how. We offer acomprehensive service that is optimally tailored to individual requirements that is designed toaccompany users when making an initial selection of tools. We also assume responsibility for thedesign of individual tool concepts and support the planning and optimisation of production – all basedon your particular requirements.
Original equipment
With around 200 employees worldwide and over 20 years of experience, Gühring implements around
600 original equipment projects every year. Our team of experts consisting of engineers, technicians, designers and sales staff support machine manufacturers and users from a wide range of industries worldwide in
the design of new tool concepts. As an experienced project partner, we support you from the planning stage
through to commissioning and series production.
Retooling
If customers need support with tooling or retooling new or existing machines for a new process, experts from
our Retooling department can handle all aspects of project management, ensuring problem-free execution.
We design and optimise tools and clamping fixtures and support project partners from the planning stage
through to commissioning of their machine. We remain in close contact with planners and machine manufacturers to ensure that all components are perfectly matched to one another.
Users receive a customised package of services – tailored to suit their precise needs. Starting from analysis
and scheduling, as well as process configuration, we design and optimise tools and clamping fixtures for thecomponents involved.
We guarantee absolute process reliability for our customers by conducting collision tests – both in simulations and in the machine room. At the final stage, we perform competent NC programming and machining toachieve a successful final acceptance of the machines. Gühring takes care of project management from theplanning stage through to commissioning – ensuring that deadlines and individual customer requirements
are met.
Contact our original equipment specialists direct:
T +49 75 71 108-0 | F +49 75 71 108-22 225
Winterlinger Strasse 12 | 72488 Sigmaringen-Laizemployees

20 yearsmorethanof OEM experience

600

more
thanprojects per yearGÜHRING KG l T +49 74 31 17-0 l F +49 74 31 17-21 279
Herderstrasse 50 - 54l 72458 Albstadt l Germany l info@guehring.de l www.guehring.com

183 067/19064-VII-22 | Printed in Germany | 2019

T H E M A C H I N I N G O F T O M O R R O W.