Global transport activity is expected to double by 2050 compared to 2015 levels, according to a report by the International Transport Forum. As climate change becomes a global concern, we must produce vehicles that are more efficient and use greener fuels. This article explores how material selection and innovation in metal cutting can contribute to the transition to greener vehicles.
As the global population increases and economies continue to develop, car use will continue to rise in the coming decades. The International Energy Agency (IEA) reports that transport already accounts for 24 percent of direct CO2 emissions from fuel combustion, with road vehicles accounting for nearly three-quarters of this. That’s why the United Nations Framework Convention on Climate Change (UNFCCC) published its climate action pathway for transport in early 2021, hoping that passenger and freight transport will be fully decarbonized by 2050 after switching to more sustainable vehicle technologies.
Achieving this transition will require both a transition to zero-emissions transport and improved vehicle efficiency. One of the zero-emission modes of transportation is electric vehicles (EVs), which play an integral role in achieving net-zero emissions worldwide. According to the International Energy Agency's "Global Electric Vehicle Outlook 2021" report, by the end of 2020, there will be a total of 10 million electric vehicles on the road worldwide.
While EV use is clearly on the rise, adoption could be accelerated by further overcoming range anxiety (ie, the fear that a vehicle will not travel enough distance to reach its destination). The range issue will require weight reduction in every component of the vehicle, in addition to more robust charging infrastructure and improvements to EV battery design.
Aluminum material plays an important role in the lightweighting of electric vehicles, and its weight is much lower than that of traditional automotive materials (steel or cast iron). In fact, aluminum is now a common material for a range of vehicle components such as chassis, interior panels, motor housings and battery housings. According to the Aluminum Institute's Aluminum Transportation Group (ATG), the use of aluminum to reduce weight in electric vehicles results in roughly the same proportional range gain. For example, if the vehicle weighs 20 percent less, it should be able to drive around 20 percent more on the same charge.
However, aluminum components are notoriously more difficult to machine. Aluminum is softer than most metals, with a melting point of just 660°C. During machining, aluminum's lower melting temperature means chips build up and stick to the tool due to high-speed friction and heat. This chip buildup dulls the knives, making it difficult to cut the stock. Additionally, manufacturers may face time-consuming tool setup, inconsistent tool wear, burr formation, and poor surface finish.
These challenges can be overcome by choosing tools with optimized designs made of advanced materials. For example, the M5C90 face milling cutter from Sandvik Coromant's M5 tool range is designed for long milling operations in solid aluminum parts as well as roughing and finishing cylinder heads, cylinder blocks and electric vehicle components. With only one high-efficiency operation, M5C90 can complete the entire machining process from roughing to finishing. The depth of cut can reach 4mm, the tool life can be extended by five times, and the processing time can be shortened by up to 200%.
In addition, the M5 tool series features stepped technology, with extremely wear-resistant polycrystalline diamond (PCD) inserts that are helically arranged and vertically staggered to remove material from the workpiece both axially and radially. One tooth has a wiper geometry to further ensure a high quality, flat surface finish. The wiper edge remains in a fixed position, eliminating the need for time-consuming set-up. Other tools in the M5 range include the M5B90 face mill concept for finishing and the M5F90 combined milling cutter for small-size roughing and finishing.
The transition to electric vehicles can help reduce transport emissions, while electric vehicles can accelerate their adoption by improving efficiency. Electric vehicles utilizing aluminum components can travel farther per charge, helping to overcome range anxiety. By selecting machining tools optimized for aluminum, automakers will be able to manufacture high-quality aluminum electric vehicle components, thereby contributing to the trend of green mobility.