ISCAR'S MACHINING SOLUTIONS FOR

ELECTRIC VEHICLES

w w w. i s c a r. c o mElectric Motors

ISCAR drives you tothe next generation
Public awareness of global warming, together with a pressing
concern to create and maintain a clean environment, has led toa series of legislations worldwide that is forcing automakers todecrease CO2 emissions. Many countries have already declareda ban on sales of internal combustion vehicles in the near future.
Apart from improving fuel consumption, downsizing engines
and making lighter vehicles, automakers must turn to newtechnologies in order to cope with these emission limitations.
A rapid increase in battery electric vehicle development,manufacture and implementation, shows that electric vehicles are
not only the future but are, in fact, the present. The automotive
industry is on the brink of colossal changes and soon our
perception of cars and transportation may alter completely.

ISCAR, a company with many years of experience in the productionof metal cutting tools, offers unique solutions for the new generation.
As a leader in providing productive and cost effective machining
solutions, we strive to be up to date with all the new trends andtechnologies and be a part of a brighter, greener future.

2ISCARINDUSTREALIZEWE BSITE

3

Electric Motor Housing

Motor Housing Complete
Machining Solution
One of the main components of an electric motor is the motor
housing (stator housing), which is made from aluminum.
A special approach needs to be taken to achieve the critical
key characteristics of this part's lightweight, durability,ductility, surface finish and precision, including geometricaltolerances.
The partially hollow form represents an additional challenge
and maintaining low cutting forces is essential for roughness
and cylindricity requirements.

Brazed PCD toolfor external contouring

ISCAR's PCD line comprises top performance tools with highmachining parameters, minimum weight and long tool life.
Equipped with adjustable PCD blades or brazed tips and guiding
pads, these tools can hold the most demanding tolerances andgeometrical requirements. Combined tools with various profiles
decrease the number of tools required to make the part, which
reduces cycle time.
Combined tool for external reaming with an adjustable
PCD blade and guiding pads and an interchangeable
head for milling with PCD brazed cartridges.

4ISCARReamer with adjustable PCD
blades and guiding pads

Combined PCD brazed tool for internaland external reaming and interchangeable
head for grooving

Combined tool with PCD brazed
tips for spot facing and grooving

Combined tool with brazed PCD tips
for milling and boring

5

Electric Motor Housing

Face Milling

A wide variety of PCD/CBN face mills is available
to provide optimal solutions for surface finish,machining time, stability and price.

Adjustable PCD cartridges withextra rigid clamping

Adjustable PCD insertswith variety of edge types

Brazed PCD tips forhigh productivity

6ISCAR

Main Diameter Reaming

For a large tool diameter, creative engineering design wasapplied to minimize tool weight and spindle load while
guaranteeing tool rigidity for the application.
Exotic materials such as titanium and carbon fiber
are used for the tool body, as well as a welded frame design.

Welded frame
roughing tool

Welded frame
finishing tool

FEM Analysis

Finite Element Method (FEM) analysis enables theconsideration of many parameters, such as cutting forces,
displacement field during machining, natural frequency, andmaximum deformation.
Our designers utilize FEM analysis to resolve the obstacles
associated with this challenging application.

7

Electric Motor Housing

Bearing Seat Reaming
After Assembly

To maintain concentricity between bearing seats of the statorand transmission housing, the reaming operation must beperformed in the same machining sequence.

Tool positioned inside the partwithout rotation

8ISCAR

Push – Reaming of bearing seatand both shaft diameters

The complex push and pull type tool withadjustable PCD blades manages to retain thegeometrical tolerances required on the part.

Pull – Back reaming of thegear cover bearing seat9RotorTurning
The rotor consists of many stacked plates of electric steel.
Lamination sheets are used instead of a solid body to reduce
current loss. The surface must be completely clean of chips,
oil, water, dust or dirt, and coolant fluid cannot be used,
only air. This is a challenge as a lot of heat is generated
on the cutting area and the fragmented chips stickto the surface. Surface finish requirements for thisinterrupted turning operation remain strict.

ISCAR has overcome these challenges by developing a
combined tool with coolant holes both on top and bottomof the cutting edge to cool and blow away the chips. The
two round inserts are positioned for semi-finish and finish
operations, generating an Ra 1.9. surface quality.

10ISCARDry coolant holes directed
at the cutting area

Finish insert

Semi-finish insert
Dry coolant holes toblow away the chips

11

Bearing

Bearing Grooving
The PENTA 20 mm (.787") width blank insert enables grindingof complex profiles while maintaining the advantage of 5 cutting
corners. In the application of grooving the internal bearing ring,
ISCAR replaced single edge inserts with this 5-edge solution anddoubled the tool life per edge.

High pressure coolant inlet

12ISCARMultiple coolant holes

The PENTA 27-20FT blank insert features 5 cutting edges that can beground according to end user specifications for up to 20 mm (.787")
profile width. ISCAR offers standard PCHR/L-27-JHP tools in 20 and
25 mm (.750"-1.000") shank sizes.
The tools feature rigid clamping and channels for efficient
high-pressure up to 340 bar (5000 Psi) edge cooling.
Specially tailored tools can be provided on request.

13

Shaft and Gear Parts

Shaft Machining
The shaft is located inside the rotor and, as in traditional
internal combustion engines, its purpose is to transfer rotationand torque to transmission parts.
As an electric motor generates maximum torque at zero rpm,
there is no need for a complex transmission system and asimple single speed transmission is sufficient. Shaft and gearparts are made from alloy steel, machined both before andafter hardening.

TOGT

Shaft Deep Drilling

The TOGT insert features 3 chip splitting cutting edges
to produce narrow chips for efficient chip evacuation.
This process requires special consideration in alloy steel
machining. Designed with a positive rake chipbreaker and awiper for high hole surface quality, the insert is suitable fordedicated deep drilling machines or machining center and lathes.
14ISCARStd. range Ø12-28 (0.55"-1.250")
10xD-25xD depth

15

Shaft and Gear Parts

Grooving

Featuring 5 cutting edges, a variety of chip formers, precise
profile, and durability, the PENTACUT insert is a popular choicefor grooving operations. The JETCUT tool holders with two highpressure coolant holes guarantee optimal chip breakage.

Computational FluidDynamics (CFD)ISCAR has the ability to simulate both the internal andexternal flow of coolant. This enables many features, such as:• Optimization of coolant holes• Optimization of volumetric flow rate and pressure• Calculation of coolant velocities at the exit of the coolant holes• Coupling with heat transfer
Dual coolant holes
directed at thecutting edge

16ISCAR

Soft TurningCoolant plays a major role in assisting with chip breakage inturning operations, especially in alloy steel. For this reason,
ISCAR designed the JETCUT line that puts emphasis on
providing high-pressure coolant directly to the cutting edge.
In the soft preparation stage, it is very important to machineclose to the final dimensions, leaving a smooth contour for
hard machining, which is why a wiper insert is used for softturning.

Frontal coolant hole underneaththe seat of the insert, to enable
coolant flow directed to theflank area of the insert

Adjustable telescopic
coolant tube17Shaft and Gear Parts

Soft Face Turningand Grooving

The MODULAR-GRIP line offers a large variety ofinterchangeable cartridges for various applications
such as turning, grooving, threading, parting and more.
They can be mounted on square shanks andCAMFIX/HSK/ISO 26622-1 adaptors.

18

ISCAR

Modular grip shank,capable of holding manytypes of cartridges
Internal high-pressure
coolant system

HFPR/L: Utility double-ended
face machining inserts

19

Shaft and Gear Parts

Hard Machining

For hard machining applications, ISCAR offers a variety ofceramic and CBN tipped inserts in a range of grades and edge
preparations that are capable of working with high cutting
parameters and generating excellent surface finish.

CBNCatalog

New Brazing Technology
ISCAR has expanded its CBN line by introducing a new
innovative technology for brazed CBN tips. Excellent for
deep depth of cut and interrupted operations.

20

ISCAR

Double-sided insert
with 4 CBN tips

21

Shaft and Gear Parts

Spline and Gear Machining
For low quantity production volumes, interchangeable solid
carbide MULTI-MASTER milling heads, solid SD connection
type tools and tools with indexable inserts are used
to machine each spline or gear profile one by one.

INDEXABLE

22ISCARHEADSPower Skiving

For this application, ISCAR developed a special exchangeable
milling head with rigid clamping, which ensures stable andaccurate machining of the spline profile. Power skiving is becoming
more relevant as a growing number of automakers prefer using
multifunctional CNC centers over designated machines.

23Differential Housing
As long as the car has only one electric motor, it willneed a differential to enable driving wheels to rotate atdifferent speeds.

Internal Turning

As it is difficult to reach the turned area due to a long overhang
and narrow entering diameter, the tool body weakens significantly
and may result in vibrations during machining. ISCAR resolved thisproblem with special shanks made from tungsten, to compensate
for the thin tool body with more rigid material. Another option isto insert a carbide rod inside the tool body.

“Banana” shaped toolfor internal finish turning

DCMT/DCGT

24

ISCAR

Rough back turning

CNMG/CNGG-TF

Combined finish turning tool

WNMA/WNMA-WG25

Differential Housing

Special Milling Tools
for Dedicated Machines

For mass production of differential housings, some customers
invest in dedicated machines that enable machining the internalarea of the part with milling tools.

Step 1Tool inserted with robot
arm into the housing

Step 2
Two drivers hold thetool from both sides andtransfer torque

26

ISCAR

Special tangential insert
with 2 RH and 2 LH cutting edges

Step 3
Machining both sidesof the housing unit

27

Differential Housing

LOGI

THREE FLUTEDrilling

3CHAM
CHAMDRILLNEWSUMOCHAM drills with coolant holes and equipped withICK drilling heads are specially designed for cast iron. TheSUMOCHAM drilling heads require no setup time whenchanged due to their high accuracy. Special combined
drills with indexable chamfer inserts eliminate the needfor additional chamfer tools, or for re-sharpening solid
carbide tools and reprogramming due to dimension changes.
Standard indexable inserts and drilling heads are always
available in stock.

H3P - 3 flute drilling headStd. new range Ø12 – 25.9 (.472 to 1.020”)

HCP - Self-centering drilling headStd. range Ø6 – 32.9 (.177-1.295")

ICK - Drilling head for cast ironStd. range Ø5 – 32.9 (.197-1.295")

28ISCARReaming

The BAYO-T-REAM line is designed for high feed reaming
applications. Its quick-change bayonet mechanism requires nosetup time; users simply change the reaming head and proceedwith machining using the 6 to 8 cutting edges. Internal coolant
supply for each cutting edge results in excellent surface finish,
while the rigidity of the system and its repeatability ensures
perfect concentricity between the two holes.
RM-BN - Std. range Ø11.5-32 (.5000-1.2500")

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Battery Case

Since batteries are replacing fuel as an energy source forvehicles, the battery case is an integral component of thecar design. Large size and lightweight requirements makealuminum a natural choice for manufacturing this part.
ISCAR has an arsenal of tools specially designed to machine
aluminum and provide productive and economical solutions
for any application.

Drilling

ISCAR offers a number of options for drilling
aluminum, including ICN heads designed with asharp cutting edge and polished rake face, andICG heads with a chip splitter for better chip
removal when working with a long overhang.
Fig. 1ICN - Std. range
Ø10-19.5 (.394-.768")

30

ISCAR

ICG - Std. range
Ø14-25.9 (.551-1.020")

AOGT - Small sharp
polished insert

Fig. 1
Fig. 2

End Milling

MULTI-MASTER interchangeable solid carbide heads are
dedicated for machining aluminum and may be used for bothroughing and finishing. The design features 4 super polished flutes
for optimal chip evacuation and excellent chatter dampening
ability, easy tool change capabilities and no setup time.
Fig. 2MM EA-CF
Std. range Ø8-20 (.312-.984")

MM ERA
Std. range Ø8-25 (.312-.750")

MM EA
Std. range Ø8-25 (.315-1.000")31

Battery Case

Reaming

For machining aluminum, a special DLC coating forhigher cutting conditions and longer tool life can beapplied. Special reaming heads with PCD tips can bemade on request.

Spc. PCD Brazed

RM-BN - Std. range
Ø11.5-32 (.5000-1.2500")

RM-BN-RC-RING adjustment rings for BAYO T-REAM
holders solve tool runout caused by the machinespindle, holder weight (in horizontal applications)or long overhang.

AL1
Runout Compensation Rings for BAYO T-REAM Reamers

32

ISCARFig. 3

Fig. 3Chip Formation Analysis

ISCAR's capability to simulate how the chip develops and flows
aids in optimizing chip gullets on tool bodies and chip splitter
rake faces in inserts.
Go to the QR link above to see how a customer's chip breakage
issue was solved. The analysis facilitated the design of a special
chipbreaker in a BAYO T-REAM reaming head.

33

Battery Case

Face and Shoulder Milling
The axially adjustable face mills carry indexable tangential

inserts to ensure crystal clear surface finish and even wear
on inserts. Balancing screws allow comfortable balancing
adjustment instead of machining the tool body, enabling
operations with high rpm.

Fig. 4

LNAR 1106
Polished carbide insert

34

ISCAR

LNAR 1106 (PCD)
PCD tipped insert

LNAR 1106PN-R-S-W (PCD)
PCD wiper insert

Fig. 4

Finish Face Milling

The TANGFIN family of milling cutters is designed
for extreme surface finish requirements. The standard
HTP inserts are positioned in such way that small portionsof material are removed both in radial and axial directions.
The long wiper cutting edge of the insert and its rigid
clamping helps achieve extra fine surface finish up toRa 0.1, with no need for adjusting.

HTP…ER/ETR
For cast iron and steel

HTP…FR-P
Sharp uncoated and polished
for aluminum35Composite Materials

Composite materials, such as CFRP (Carbon Fiber ReinforcedPolymer) can be used in body and chassis parts to lower
weight without compromising strength and rigidity. Currently,
the use of composite materials in the automotive industry ismostly reserved for sport and supercars. This is due to thehigh production cost. However, as manufacturing techniques
improve, prices for composite materials continue to drop. So itis possible that in the future we will witness the use of CFRP inmass produced cars.
Whether you are making low budget vehicles or supercars,
ISCAR has the tools for you!

CFRP
CATALOG

Variety of carbide andPCD products for CFRP

36

ISCAR

Special SUMOCHAMICF Geometry

Available with diamond coating, this drilling head isdesigned to overcome all the typical CFRP machining
failures and allows you to enjoy all the benefits ofSUMOCHAM drills.
37

Find The NEOLOGIQNEOLOGIQAL
AL Tool
For Your Application!
• The virtual tool advisor features advanced AIand ‘Big Data’ analytics• Supports complicated machining tasks and challenges• Offers a wide range of functions and recommendations
to operate machining centers• Features online service 24/7 in more than 30 languages• Functions according to ISO13399

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ISCAR'S MACHINING SOLUTIONS FOR

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ELECTRIC VEHICLES

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