BIG Angle Head — New Energy Vehicle Machining Case Study Sharing - BIG DAISHOWA
BIG Angle Head—New Energy Vehicle Machining Case Study
From a structural perspective, new energy vehicle components have become increasingly complex. During manufacturing, it's often not only the part's surface that requires machining but also the internal cavities. This necessitates the use of angle heads to solve product machining challenges. Next, let's share an application case of BIG lightweight angle heads in machining the housing of a steering component for new energy vehicles.
• Machined Product
A steering component housing for an automobile, requiring a slot to be machined on the sidewall of an internal cavity with a diameter of 30mm.
• Workpiece Machining Difficulties
1. Machine ATC Weight Limit
The ATC (Automatic Tool Changer) weight must be controlled within 2kg.
2. Complex Internal Feature
The processed aluminum alloy product has an internal cavity diameter of D30mm. Slot machining is required on its inner sidewall.
3. Tight Slot Tolerance
The slot width is 3mm with a tolerance requirement of ±0.03mm.
• Our Adopted Machining Method
1. Lightweight Angle Head for ATC
To machine the sidewall of the workpiece cavity, we used an angle head product to avoid interference. Considering the ATC weight limit of the BT30 machining center, we employed an ultra-lightweight (under 2kg) angle head specifically designed for small BT30-type equipment.
2. Superior Anti-Interference Model
To enter the D30 diameter cavity, we selected the CA4SG type angle head (shown on the left in the image below) for its superior anti-interference capability. Its head dimensions G and R are 24mm and 21mm respectively, ensuring the interference diameter after installing the tool is less than D30mm, guaranteeing sidewall slot machining after mounting the milling cutter.
3. Short Overhang Tooling
For the cutting tool, a non-standard diamond 2-flute end mill with a shorter overhang dimension was used.
• Machining Example and Conclusion
Steering Component Housing
AlSi10Mg(Fe)
Brother Vertical Machining Center (BT30)
Machine External Coolant
Milling
Non-standard Diamond End Mill
2000 rpm
0.05 mm/rev
• Tool Advantages and Results
Meets the 2kg ATC weight limit for BT30 machines.
Enables access and machining within the D30 cavity.
Maintains good clamping accuracy even after 90° rotation of the tool orientation.
Enables successful tool changes, avoids interference, and completely satisfies the customer's machining needs.