Honing Machine for EV

The Indian automobile market is in the midst of a rapid paradigm shift due to the national policy of promoting EVs.^* This page looks at honing machines for EVs, which meet next-generation quality standards in this era of the electric vehicle, with its greater demand for quiet operation and motor efficiency.

4 Key Specifications For EV Honing

EV components require an even higher level of precision than ICE vehicles. We've summarized the four specifications that help you meet rigorous quality standards and increase yield.

1. Gear face finishing capabilities for suppressing noise, vibration, and harshness (NVH)

When processing the gears used in reducers such as e-Axles, close attention should be paid to the precision of the gear face finish in order to reduce noise, vibration, and harshness (NVH). EV engines are silent, so even a small amount of gear noise can prompt complaints. That's why gears need micron-level finishing. High-precision gear face processing ensures quiet operation and can help drive orders from high-end EV manufacturers.

2. High-precision approach to small components and components with ultra-small diameters

For electric power steering (EPS) and electrically controlled brakes, having the precision needed for consistent processing of ultra-small diameter components is also important. This is because for the micron-level ultra-small diameter components used in EVs, even minor deviations in the clearance between components, or their dimensions, can cause defects. Consistent high-precision mass processing contributes to higher yields and makes you more competitive in the EV market.

3. Support for new materials (aluminum alloys, etc.) and special shapes

The aluminum material and thin components essential for reducing EV weight are difficult-to-cut materials that are highly affected by heat and deformation during processing. Honing machines have advanced cutting control capabilities, so they can achieve high levels of circularity even with these special materials. This improves the performance of the motor itself and makes it possible to manufacture EVs that will stay on the road for years to come.

4. Advanced automation and CNC control for embedding in mass production lines

Some of the newest honing machines support robot transfer of components and have automatic compensation functions that perform in-process measurement while processing is being performed. These machines can maintain a high level of precision even through 24-hour-a-day unmanned operation. They process accurately and quickly, which helps reduce defect rates. They also help cut costs through labor-saving while improving productivity.

Key points to check with manufacturers when
selecting a machine

• Does the company have a track record of test processing for the new materials used in EVs, such as aluminum alloy?
• Can the company supply dedicated tools for making your target components, such as exceptionally small diameter components or gears?
• Does the company have any service sites and technical support sites in India (such as in Pune or Chennai)?
• Does the company have a track record of system integration with automation lines, such as robot transport?
• Does the company provide support for data verification such as verification of NVH reductions after processing, circularity, or the like?

EV components require a high level of precision, so you should avoid choosing a honing machine based solely on how low its initial cost is. The genuine machines from low-cost domestic manufacturers and used machines from overseas manufacturers (obtained via unofficial distribution channels) sold in India come with risks, such as the risk of not having inventory for repair parts or not being able to provide technical support in the event of a machine malfunction, leading to machine downtime.

If you're going to install a machine, we recommend choosing one from a high-precision overseas manufacturer, bought through official channels. It's important not to pick a company that simply sells machines, but one that serves as a solution partner, accompanying their machines with processing know-how on topics such as the optimal honing stones and coolant to choose.

We have carefully selected recommended honing machines, categorized by the business sector they are best suited for, that enable you to achieve the ultra-high-precision processing needed to come out on top in the Indian EV market. It also presents the technical support systems of each manufacturer, so please use it in your comparison and deliberations.

G Series (Standard Model) "G25 type"

Resource: NISSIN ProSOL official website
https://mktg.nissin-mfg.co.jp/product/gseries/001/

A model for mass-producing ultra-small valves

The shift towards EVs is driving a surge in demand for models that can process the ultra-small valves used in electric power steering (EPS) and brake systems. The G25 is a reasonably priced general-purpose machine that can also maintain consistent shape precision during mass production thanks to its servo-controlled honing stone expansion. It's a great honing machine for mass production lines, keeping down costs while meeting severe precision requirements.

260HMS Single Spindle Honing Solution

Resource: Gleason official website
https://www.gleason.com/jp/products/machines/cylindrical/gear-honing/260hms-the-versatile-single-spindle-honing-solution-for-gears-and-shafts

A model for companies striving for noise reduction

The 260HMS is specially designed to reduce NVH for EV gears like those used in e-Axles. One of its features is its combo honing function, which handles everything from rough cutting to finishing with a single set-up. It achieves micron-level surface precision and contributes to the overwhelming noise reductions needed by high-end EVs.

Small Production Machine

Resource: Engis official website
https://www.engis.com/bore-finishing-machines

A multi-spindle model for electrical compressors

Electrical compressors are vital components in car air conditioners and batteries, and this model is perfect for performing electrical compressor processing. It uses a single-pass approach, with multiple spindles that perform processing in a single step, so it isn't just highly precise, but also highly efficient and suited for mass production.

Honing machines for EVs - Frequently Asked Questions

Q. Can we use the honing machines we've been using for engines on EV components, as well?

They may be usable in some cases. However, to achieve the quietness and exceptionally small diameters that are typical for EVs, machines specialized for gears and higher-precision CNC honing machines are virtually essential.

Q. What should I keep in mind when processing aluminum material, like motor housings?

Care needs to be taken with regard to aluminum's thermal expansion and clogging issues. To deal with these, it's important to choose an appropriate diamond honing stone and to cool the machine with high pressure coolant. To meet the high precision requirements of EVs, we recommend consulting with a manufacturer with expertise and a track record of working with aluminum.

EV Honing Machines: Essential for
Quality Standards

The Indian automobile industry is in the midst of a major transition, from engines to motors. What customers look for in a component manufacturers isn't a manufacturer that makes components that are as cheap as possible, but a manufacturer that can satisfy the strict precision requirements (for noise and efficiency) of EV manufacturers.

We have carefully selected honing machines that you can make you competitive in new markets, without being left behind by the shift to EVs. Use it in your comparison and deliberations as you build your own next-generation lines.