New energy vehicle cutting tool solutions

The impact of the development of new energy vehicles on the cutting tool industry

As new energy vehicles become a core sector in the global automotive industry's transformation, their development has had multifaceted impacts on the cutting tool industry. The automotive industry is the largest end-consumer market for tungsten, cemented carbide, and machine tool cutting tools. However, changes in the structure, materials used, and manufacturing processes of new energy vehicles have led to a decline in the amount of cemented carbide cutting tools and tungsten used per vehicle.

From a structural perspective, compared to traditional gasoline-powered vehicles, new energy vehicles eliminate or simplify the use of engines and complex transmissions, resulting in a decrease in the number of cutting tools required. In terms of materials, new energy vehicles have accelerated the use of difficult-to-machine materials such as aluminum alloys, magnesium alloys, and fiber-reinforced composites, putting tools made of cemented carbide at a relative disadvantage in the cutting processes of new energy vehicle manufacturing. Simultaneously, the machinability of lightweight metal alloys such as magnesium and aluminum has led to the partial replacement of traditional subtractive manufacturing processes with integrated die-casting, again contributing to a decline in the number of cutting tools used.

Tooling solutions for new energy vehicles from MAPAL Germany

MAPAL, a German manufacturer of high-precision cutting tools, specializes in the development and application of non-standard cutting tools. Renowned for its valve body combination tools and guide bar reamers, its products have been a mainstay in the automotive manufacturing industry since the 1980s. Facing the rapidly growing manufacturing demands of electric vehicles, MAPAL has quickly launched innovative machining solutions for electric vehicle components, leveraging its universal component solutions.

First, Mappa offers complete workpiece machining solutions for new energy vehicles. These solutions meet the diverse workpiece machining needs of new energy vehicle production, improving production efficiency. Second, Mappa develops non-standard cutting tools for electric vehicle components, providing expert-level solutions for seamless continuous machining. These non-standard tools can be customized to meet the specific requirements of new energy vehicle components, improving machining accuracy and efficiency. Finally, Mappa's unique complex tool body and adjustable cutting edge design enable efficient and flexible workpiece machining. This design adapts to different machining scenarios and needs, enhancing the versatility and applicability of the tools.

Gangyang Tools solves welding problems in new energy.

As new energy vehicles become the core track for the transformation of the global automotive industry, lightweight and high-strength body designs are driving the widespread application of new materials such as aluminum alloys and high-strength steel. However, this also brings new challenges to the body welding process. Traditional electrode grinder blades are prone to problems such as rapid wear and "blade sticking" in the high-temperature and high-viscosity aluminum alloy welding environment, which seriously affects production efficiency and weld quality.

Gangyang Tools, leveraging a "focus on niche markets + collaborative innovation" model, collaborated with the technology centers of renowned automakers to conduct technical research and partnered with a university in Suzhou to form a dedicated R&D team, successfully developing specialized cutting tools for aluminum alloy welding in new energy vehicles. During the R&D process, Gangyang Tools first conducted in-depth joint research with multiple automakers, precisely identifying the core problems from frontline production scenarios. Team members entered the welding workshop of a Volkswagen New Energy component supplier, recording the entire aluminum alloy welding process data, and discovered that the main problems with traditional cutting tools were insufficient high-temperature resistance of the material and inadequate surface finish of the cutting edge.

To verify the accuracy of the data, the Gangyang Tools team also collaborated with several automobile manufacturers to conduct comparative tests, determining that a two-pronged approach focusing on both materials and coatings was necessary to completely break through the limitations. Subsequently, Gangyang Tools partnered with the School of Materials Science and Engineering at a university in Suzhou to jointly establish a dedicated R&D team. The team proposed an "Al₂O₃-TiC composite nano-ceramic coating" solution. Through physical vapor deposition technology, a 3-micron-thick composite coating was formed on the blade's cutting edge surface, improving the blade's high-temperature resistance and reducing the coefficient of friction with aluminum alloys. In terms of material selection, imported Swedish ultrafine-grained cemented carbide was chosen, resulting in a qualitative leap in the performance of the specialized blades.

To ensure perfect compatibility between cutting tools and various shaving equipment, Gangyang Tools has further collaborated with end-users of shaving equipment manufacturers such as Guangzhou Jidong and Nanjing Xiaoyuan to conduct collaborative optimization of "equipment + cutting tools". Through these efforts, Gangyang Tools' specialized cutting tools have achieved full compatibility with mainstream equipment from Guangzhou Jidong, Nanjing Xiaoyuan, Faxin, and Luz, providing "out-of-the-box" solutions for different automakers and saving customers over ten million yuan in consumable costs.

Guangdong Zhaofengtai Electromechanical's patented high-efficiency milling inserts

In the processing of new energy vehicle parts, the heat dissipation performance of cutting tools has become crucial. In 2024, my country's new energy vehicle production exceeded 10 million units, driving the rapid development of upstream and downstream industrial chains. However, technological bottlenecks in the processing stage have also gradually emerged. Especially in the manufacturing of high-precision, high-strength parts, cutting tools often suffer from overheating, affecting both efficiency and accuracy.

Recently, Guangdong Zhaofengtai Electromechanical Technology Co., Ltd. obtained a patent for "A High-Efficiency Milling Insert for Processing New Energy Vehicle Parts." The core of this technology lies in the optimized heat dissipation structure of the insert. A gap is provided between the insert and the mounting slot, allowing cooling water and natural airflow to enter the insert through guide holes and then flow out through the countersunk holes, thus effectively controlling the insert temperature. The insert also features a warning bracket structure that can monitor the status of the fixing bolts in real time, eliminating the need for manual inspection and saving significant time and costs. This design not only improves production efficiency but also reduces maintenance costs, meaning that each piece of equipment can operate stably for a longer period for the company.

A Review of Selected Cutting Tool Products in 2025

By 2025, the new energy vehicle industry will be accelerating its integration, lightweighting, and high-end development. Core processes such as integrated die casting and precision manufacturing of batteries, electric drives, and electronic controls will place more stringent demands on the wear resistance, cutting efficiency, precision control, and environmental adaptability of cutting tools. The following is an introduction to some cutting tool products:

Sandvik CoroDrill® DE10 Interchangeable Drill Bit

Designed for efficient drilling of aluminum alloy structural components and motor housings in new energy vehicles, this drill features an M5 drill tip flute, eliminating the need to change the flute shape when transitioning from aluminum alloy to alloy steel. It boasts strong cutting edge toughness and stable output under harsh working conditions. Equipped with a Zertivo® nano-coating (TiAlN + TiSiN multi-layer coating), it offers high-temperature resistance, wear resistance, and long-lasting edge sharpness, reducing chipping. Cylindrical straight shank diameter: 9.00–9.90 mm; Flattened straight shank (ISO 9766) diameter: 10.00–17.90 mm; Drilling depth: 3 times, 5 times, and 8 times the diameter.

Kennametal - ROCO™ Composite End Mill Series

ROCO™ tools are comprehensively optimized for composite material properties, making them ideal for various machining scenarios such as side milling, slot milling, cavity milling, and ramp milling. They improve cutting efficiency while ensuring machining stability and surface quality. This series of tools uses the new KCC05A material, which achieves a uniform coating thickness along the tool axis, resulting in a sharper cutting edge, lower wear rate, and less coating peeling, thus significantly extending tool life.

Iscar - SUMO CHAM Drill Bit Series

In the field of hole machining, ISCAR offers a variety of solutions for drilling aluminum alloys and non-ferrous metals, all based on the SUMOCHAM modular drill bits with interchangeable solid carbide tips (including ICN and ICG tips). The ICN tip features a sharp cutting edge and a polished rake face. The ICG tip has a chip flute structure for superior chip removal during long overhang machining. SUMOCHAM modular drill bits allow for quick and easy tip changes, reducing downtime and increasing productivity. Their high drilling speed and excellent chip removal performance are particularly suitable for drilling operations in electric vehicle manufacturing.

Seco Tools - OctoMill™ 06 Extended Horizon Face Mill

Suitable for industries such as automotive manufacturing, aerospace, and mold making, especially suitable for applications requiring a balance of machining efficiency, cost, and surface finish. The optimized insert positioning groove design ensures automatic centering during installation, secure positioning, reduced indexing time, lower risk of misinstallation, and improved positioning accuracy. Insert indexing does not require complete removal of the locking screws, improving tool change efficiency. The tool body features a +12° axial angle design, increasing the helix angle of the main cutting edge for smoother entry/exit, with outstanding stability, particularly in low-rigidity conditions. Both economical M-grade roughing inserts and high-performance E-grade inserts are available, offering lower per-edge cost and superior overall performance compared to traditional double-sided or single-sided insert systems.

Walter-Drion·tec® D-Spade D5142 Double-Sided Interchangeable Insert Drill Bit

Drilling depth: 3 and 5 × Dc; simple operation via radial locking screws; 3 cooling holes per tooth for maximum cooling; grinding-type chip evacuation grooves for fast and safe chip removal; double-sided replaceable insert DS42 (symmetrical); four-edge band for excellent surface quality; flute type F58; diameter 12~25.70mm. WPP25: fine-grained substrate and HiPIMS AlTiN coating ensure high wear resistance, gold surface coating for optimal wear identification; each replaceable insert has 2 cutting edges for great economic benefits; double ligaments on the circumference for excellent surface finish (within IT8 range); excellent centering characteristics ensure precise drilling; superior cooling and chip removal for extremely high process reliability; 2 radial locking screws ensure high stability.

Daijie-TDD Series Clamped Drill Bits

Daijie's TTD series indexable drill bits feature a unique insert positioning and locking system, extending the minimum diameter of indexable drill bits to φ10mm. For ease of use on production sites, in addition to the S-type straight shank, a standard MT-type Morse taper shank is also available. Three sizes (φ10.2, φ10.3, and φ10.4) are available for different equipment and working conditions to machine M12 threaded pilot holes. The TTD drill bits are made of solid carbide, possessing high hardness, wear resistance, and heat resistance, resulting in a long service life and effectively reducing tool change frequency. Their indexable insert design allows for quick and easy replacement, eliminating the need for regrinding and simplifying tool management. Optimized machining parameters eliminate the need for positioning holes and step feeds, enabling one-step forming, simplifying processes, and significantly improving production efficiency. This makes them particularly suitable for the modern automotive manufacturing industry, which demands high machining efficiency and precision.

Xiamen Jinlu - GT Series Cutting and Grooving Tools

The GT series of parting and grooving tools is a brand-new cutting tool product from Xiamen Jinlu, featuring a rich variety of groove types, grades, and matching tool bodies. This series includes 11 groove types suitable for parting, grooving, turning, and contouring, and comes with 6 grades to meet the machining needs of materials such as steel, stainless steel, cast iron, and high-temperature alloys. Equipped with a specially designed high-pressure cooled tool holder, it helps extend insert life and improve chip breaking performance, meeting users' more demanding machining requirements.

Future Development Trends of Cutting Tools for New Energy Vehicles

Judging from the current development trend, cutting tools for new energy vehicles will develop in multiple directions in the future. On the one hand, with the rapid development of new energy vehicles, the automotive industry's demand for PCD non-standard cutting tools will continue to increase. Polycrystalline diamond (PCD) cutting tools have advantages in machining performance and material adaptability, enabling higher machining efficiency and surface precision, which is more in line with the lightweight development of new energy vehicles. In the next five years, the automotive industry's PCD non-standard cutting tool market has broad prospects, with a potential for doubling in size.

On the other hand, innovation in cutting tools will focus more on solving pain points in actual production. For example, Gangyang Tools developed special cutting tools to address the welding challenges of aluminum alloys for new energy vehicles, while Guangdong Zhaofengtai Electromechanical optimized cutting tool design to address heat dissipation issues. These innovations are all aimed at meeting the actual needs of new energy vehicle production. At the same time, cutting tool companies will place greater emphasis on collaborative innovation, uniting the strengths of automakers, universities, equipment manufacturers, and other stakeholders to integrate resources and achieve efficient breakthroughs from "pain point research" to "product implementation."

Furthermore, as the new energy vehicle industry accelerates its integration, lightweighting, and high-end development, it places more stringent demands on the wear resistance, cutting efficiency, precision control, and green adaptability of cutting tools. Cutting tool manufacturers need to continuously improve product performance to meet the development needs of the new energy vehicle industry. This includes developing more wear-resistant and efficient tool materials, optimizing tool structural design, and improving tool machining accuracy and stability. In short, the new energy vehicle cutting tool industry will provide stronger support for the high-quality development of the new energy vehicle industry through continuous innovation and development.