Problem
Machining problem to solve
Complex automotive part geometryTight tolerance controlStable batch production
Case Study
Automotive Case Study 14 / 20Battery Module Frame Machining Case Study
The battery module frame is one of the most important structural components inside an electric vehicle battery pack.
battery module frame machining case studyautomotive cnc machining case studycnc machine for automotive parts
Case Overview
Core project data for this machining case.
Industry Electric Vehicles
Product Battery Module Frame
Material Aluminum 6061-T6 / 6063-T6 / 6005A-T6
Process Aluminum Extrusion + Laser Welding + CNC Machining
Machine Model HYR VMC1060
Tolerance +/-0.02 mm
Surface Finish Ra1.6
Production Capacity Project based
Solution
HYR-CNC machining plan
The customer is an EV battery supplier manufacturing:Prismatic battery modulesCylindrical battery modulesBlade battery framesStructural battery componentsTheir products are supplied to:
Machine Used
Recommended machine configuration
Machine: HYR CNC machining center selected according to part size, material and tolerance
Process: Rough machining, semi-finishing, finish machining and inspection based on the document case
Accuracy Control: Fixture planning, deformation control, stable toolpath strategy and CMM inspection
Cost Method: Published with existing website assets first to keep implementation cost low
Process
Timeline from raw material to inspection.
01 Typical manufacturing process:
02 Aluminum Extrusion
03 Cutting
04 Laser Welding
Full Case Article
Machining background, difficulty and solution logic.
Quick Facts
Item Details Industry Electric Vehicles Product Battery Module Frame Material Aluminum 6061-T6 / 6063-T6 / 6005A-T6 Manufacturing Process Aluminum Extrusion + Laser Welding + CNC Machining Machine HYR VMC1060 Tolerance +/-0.02 mm Cell Mounting Accuracy +/-0.015 mm Surface Finish Ra1.6 Application EV Battery Modules
Introduction
The battery module frame is one of the most important structural components inside an electric vehicle battery pack.
Its primary functions are:
A battery pack may contain:
Each module contains:
Therefore:
The dimensional accuracy of the battery module frame directly affects:
Supporting battery cells Fixing cooling plates Maintaining cell spacing Improving crash resistance Preventing thermal propagation Supporting electrical connections 4 Modules ↓ 8 Modules ↓ 12 Modules ↓ 20+ Modules Battery cells Cooling systems Busbars Sensors Structural frames Battery safety Cooling efficiency Assembly accuracy Battery lifespan
Customer Background
The customer is an EV battery supplier manufacturing:
Their products are supplied to:
The customer experienced:
HYR CNC developed a machining solution optimized for lightweight aluminum battery structures.
Prismatic battery modules Cylindrical battery modules Blade battery frames Structural battery components Passenger EVs Electric SUVs Hybrid vehicles Commercial EVs Cell installation deviation Cooling plate misalignment Welding deformation Poor flatness Difficult assembly
Industry Background
Battery systems are evolving rapidly.
Higher Energy Density
Battery manufacturers aim for:
Therefore:
Battery module frames become:
Machining requirements increase significantly.
More Cells + Less Space + Lower Weight Thinner More complex More integrated
Structural Battery Packs
Modern EVs increasingly adopt:
Advantages:
However:
The battery frame must achieve extremely high dimensional accuracy.
Cell-to-Pack (CTP) Cell-to-Chassis (CTC) Structural battery systems Reduced weight Increased energy density Better rigidity
Lightweight Structures
Manufacturers increasingly use:
Advantages:
Steel ↓ Aluminum Extrusions Lightweight Corrosion resistance Excellent machinability Good thermal conductivity
Aluminum 6061-T6
Advantages:
Applications:
Excellent strength Good machinability Superior corrosion resistance Structural battery packs Battery modules EV frames
Aluminum 6063-T6
Advantages:
Applications:
Excellent extrusion performance Smooth surface finish Lightweight Extruded battery frames Cooling system supports Module enclosures
Aluminum 6005A-T6
Advantages:
Applications:
High strength Excellent fatigue resistance Suitable for large structures Structural battery packs Heavy-duty EV batteries
Manufacturing Process
Typical manufacturing process:
CNC machining determines the final module assembly accuracy.
Aluminum Extrusion ↓ Cutting ↓ Laser Welding ↓ Stress Relief ↓ Rough CNC Machining ↓ Semi Finishing ↓ Cell Mount Machining ↓ Cooling Interface Machining ↓ Thread Hole Machining ↓ Deburring ↓ Surface Treatment ↓ Inspection ↓ Assembly
Why CNC Machining Is Necessary
Extrusion and welding cannot satisfy:
Therefore:
Critical features must be machined.
Flatness requirements Cell positioning accuracy Cooling plate interfaces Hole position accuracy
Cell Mounting Surfaces
Battery cells require:
Poor machining may cause:
Position Accuracy +/-0.015 mm Uneven cell pressure Cell deformation Reduced battery life
Cooling Plate Interfaces
Requirements:
Poor machining may lead to:
Flatness ≤0.03 mm Poor heat transfer Thermal imbalance Reduced cooling efficiency
Welding Deformation
Battery module frames are often:
Welding causes:
CNC machining compensates for these defects.
Welded Bonded Riveted Warpage Internal stress Hole deviation
1. Thin-Wall Structures
Typical wall thickness:
Challenges:
Cutting force must be minimized.
1.5 mm ↓ 4 mm Vibration Chatter Deformation
2. Large Number of Holes
Battery frames may contain:
Challenges:
Cell mounting holes Cooling interfaces Sensor holes Busbar holes Position accuracy Tool wear Cycle time
3. Long Extruded Profiles
Typical frame length:
Challenges:
500 mm ↓ 1500 mm Thermal expansion Fixture rigidity Flatness control
HYR CNC Solution
HYR recommended the VMC1060 Vertical Machining Center.
Large Machining Capacity
Travel:
Suitable for:
Axis Travel X 1000 mm Y 600 mm Z 600 mm Battery module frames Cooling plates Structural battery components
High-Speed Spindle
Spindle:
Advantages:
BT40 12000 rpm Excellent aluminum machining Smooth surface finish High efficiency
High Rigidity Structure
Features:
Benefits:
Heavy cast iron base Reinforced column Wide guideway spacing Stable flatness Better dimensional accuracy Reduced vibration
Automatic Tool Changer
24-tool ATC.
Supports:
Improving productivity.
Milling Drilling Tapping Chamfering
Step 1
Machine:
Remove excess allowance.
Rough Milling Structural surfaces Reference faces
Step 2
Machine:
Prepare for finishing.
Semi Finishing Internal structures Mounting interfaces
Step 3
Requirement:
Machine:
Cell Mount Machining +/-0.015 mm Cell interfaces Positioning features
Step 4
Requirement:
Machine:
Cooling Interface Machining Flatness ≤0.03 mm Cooling plates Thermal interfaces
Step 5
Machine:
Hole Machining Busbar holes Sensor holes Mounting holes
Step 6
Remove:
Improve assembly safety.
Deburring Burrs Sharp edges
Step 7
Processes:
Improve:
Surface Treatment Sandblasting Anodizing Corrosion resistance Surface appearance Durability
Step 8
Inspect:
Guaranteeing battery assembly quality.
Final Inspection Flatness Hole positions Surface finish
Cutting Parameters
Typical machining parameters:
Item Value Spindle Speed 11000 rpm Feed Rate 2800 mm/min Tool Material Carbide Coolant Emulsion Depth of Cut 0.5 mm Surface Finish Ra1.6
Quality Inspection
Every battery module frame undergoes strict inspection.
Flatness Inspection
Requirement:
Inspect:
≤0.03 mm Cooling interfaces Cell mounting surfaces
Hole Position Inspection
Requirement:
Inspect:
+/-0.015 mm Cell holes Sensor holes Busbar holes
Surface Finish Inspection
Requirement:
Inspect:
Ra1.6 Mounting surfaces Cooling areas
CMM Inspection
Verify:
Ensuring complete dimensional accuracy.
Hole positions Flatness Parallelism Geometric tolerances
Results
After adopting HYR CNC machining solutions:
The customer achieved:
Item Before After Flatness 0.08 mm 0.03 mm Hole Position 0.04 mm 0.015 mm Surface Finish Ra3.2 Ra1.6 Cycle Time 32 min 22 min Scrap Rate 2.7% 0.3% Better battery assembly accuracy Improved cooling efficiency Higher production efficiency Reduced manufacturing costs Increased battery reliability
HYR VMC850
Recommended for:
BDU Housings PDU Housings Electrical Enclosures
HYR VMC1060
Suitable for:
Battery Module Frames Cooling Plates Battery Accessories
HYR VMC1165
Ideal for:
Battery Trays Battery Enclosures Large EV Structural Components
Related Articles
What Is CNC Milling?
EV Battery Tray Machining Case Study BDU Housing Machining Case Study PDU Housing Machining Case Study Cooling Plate Machining Case Study Aluminum Machining Guide
What is a battery module frame?
A battery module frame is the structural component that supports battery cells, cooling systems and electrical connections inside an EV battery pack.
Which materials are commonly used?
Aluminum 6061-T6, 6063-T6 and 6005A-T6 are widely used.
Why is CNC machining necessary?
Critical cell mounting surfaces, cooling interfaces and hole positions require precision machining beyond extrusion and welding capabilities.
What flatness is required?
Most battery module frames require cooling interface flatness of 0.03 mm or better.
Which CNC machine is recommended?
The HYR VMC1060 is an excellent solution for machining battery module frames and structural battery components.
Conclusion
Battery module frames are key structural components in modern electric vehicle battery systems.
From cell mounting surfaces and cooling interfaces to busbar holes and structural features, machining accuracy directly affects battery safety, cooling efficiency and assembly quality.
With excellent aluminum machining capability, stable flatness control and high productivity, HYR CNC machining centers provide reliable and efficient solutions for battery module frame manufacturing.
HYR CNC continues to support global EV manufacturers with advanced machining technology and customized battery production solutions.
Result
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After adopting HYR CNC machining solutions: |
| Result 2 | Before optimization | Item |
| Result 3 | Before optimization | Before |
FAQ
Common buyer questions for this case.
What is this case about?
This article covers battery module frame machining requirements, challenges, process planning and CNC machine selection.
Which machine is recommended?
The final machine should be selected according to part size, material, tolerance, cycle time and fixture plan.
Can HYR-CNC support similar parts?
Yes. Send drawings, material, tolerance and volume so HYR-CNC can recommend a suitable machining proposal.
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