OCTOBER 2023AUTOTECHOUTLOOK.COM9Producing more vehicles to meet increasing demand is inevitable --the real challenge is making them greenerAluminum plays a large role in the light-weighting of EVs, weighing just a fraction of the more traditional automotive materials of choice -- steel or cast irons. In fact, aluminum is now commonly selected for a range of vehicle parts, such as the chassis, internal panels, motor housing and battery enclosures. According to the Aluminum Transport Group (ATG), using aluminum to reduce an EV's weight can result in range gains of approximately the same proportion. For instance, if the vehicle weight is reduced by 20 percent, the vehicle should be able to travel around 20 percent further on the same charge.Mastering machiningHowever, components made from aluminum are notoriously more difficult to machine. Aluminum is softer than most metals, which can make it challenging to work with. What's more, the melting point of stainless steel is 1510 degrees Celsius, whereas for aluminum, it's 660 degrees Celsius. When machining the metal, the lower melting temperature of aluminum means that chips can build up from the heat of friction at high speeds and adhere to the tool. This chip accumulation can dull the tool, making it difficult to cut through the billet. In addition, manufacturers can face issues such as time-consuming tool setups, inconsistent tool wear, burr formation and inferior surface finishes.The need for high speeds and lighter tools is also a struggle.Fortunately, these challenges can be overcome by selecting a tool with an optimized design that's made from advanced materials. For instance, the Sandvik Coromant M5C90 face milling tool, part of the M5 cutter series, was designed for solid aluminum parts with long milling operations, as well as for roughing and finishing cylinder heads, blocks and electric vehicle components. In just one efficient operation, the M5C90 can perform the entire machining process,from roughing to finishing. In many cases, this can be with a depth of cut of up to four millimeters. This tool can increase tool life by fivefold and reduce cycle time by up to 200 percent.
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