Desiring to master the ins and outs of EV component manufacturing, German automaker supplier Schabmüller is strengthening its partnership with toolmaker Mapal. They are leveraging Mapal's expertise in high-performance machining to improve the manufacturing of electric vehicle chassis and suspension parts. These kinds of partnerships are an emerging trend in German industry. Last year, Sandvik inked a deal to acquire Almü Präzisions-Werkzeug GmbH (Almü), a renowned cutting tool and solution provider for aluminium machining.
Image source: Mapal
An old master prepares for the EV era
Based in Großmehring, Germany, Schabmüller has been a premium supplier of machined engine and chassis parts to leading manufacturers including Audi, Porsche, and Volkswagen for years. With the transition of the industry to e-mobility, Schabmüller was able to expand its portfolio successfully to include critical EV parts such as battery top plates, axle housings, and suspension parts such as control arms and hub carriers.
This transformation, however, is accompanied by new manufacturing challenges. These new components are not die-cast aluminium but are constructed from high-strength forged aluminium. Therefore, they have improved stability and load-bearing capabilities. These tougher materials are a real effort to machine to stringent tolerances and rapid cycle times. Demand for these aluminium auto parts has been surging due to the EV boom.
According to Managing director Helmut Häckl: “Demand for suspension parts has provided us with an opportunity to diversify ourselves in a new direction. Our business has developed and pursued precisely this goal.”
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Enter Mapal's high-tech tooling
To meet this challenge, Schabmüller has extended its long-term partnership with Mapal beyond traditional tool management. Mapal is now involved at the front end of the manufacturing process, and it handles CAD/CAM programming as well as simulation for new aluminium components.
Mapal's vast aluminium machining experience is proving particularly valuable. Mapal has a turnkey solution which involves not just tool logistics and management but also the utilisation of very sophisticated tooling. For instance, in producing forged aluminium hub carriers, Mapal introduced its NeoMill-Alu-QBig indexable insert milling cutter.
This high-performance machine, used for high-speed milling of aluminium, was critical in reducing the cycle time by 54% and now accounts for around 30% of the total part machining time.
The partnership is centred on beating challenges specific to machining intricate aluminium components, including chip management, reducing tool wear with advanced coatings such as diamond, and sustaining accuracy in the face of the material's thermal expansion. By embracing the entire spectrum of services from Mapal, Schabmüller is guaranteeing that it is able to provide the precision-machined, high-quality aluminium components at the centre of new electric vehicles.
Also read: Revolutionising transportation: The role of aluminium in automotive and aerospace Industries
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