EV battery trays and crash structures require CNC machining of 6061-T6 and 7075-T6 aluminum with critical flatness of 0.1 mm/m and crash can energy absorption features. Key processes include FDS (Flow Drill Screwing) hole preparation and large-format face mill
Quick Answer
EV battery trays and crash structures require CNC machining of 6061-T6 and 7075-T6 aluminum with critical flatness of 0.1 mm/m and crash can energy absorption features. Key processes include FDS (Flow Drill Screwing) hole preparation and large-format face milling to ensure structural integrity during collisions.
Definition
Battery tray CNC machining involves processing large aluminum extrusions or sheet metal into structural platforms that house battery modules. These components must withstand dynamic crash loads while maintaining battery pack sealing integrity.
How It Works
Large Format Milling: 3-axis gantry machining of battery trays up to 2000mm × 1500mm.
FDS Hole Machining: Precision drilling and countersinking for flow drill screws with ±0.05mm position accuracy.
Crash Can Integration: Machining energy-absorbing structures with specific crush zones.
Sealing Surface Preparation: Face milling to 0.1mm/m flatness for IP67-rated gaskets.
Common Values and Practical Notes
- Component
- CNC Material
- Machining Process
- Critical Tolerance
- Battery Tray Base
- 6061-T6 Aluminum
- Large format milling
- Flatness 0.1 mm/m
- Module Mounting Rails
- 6061-T6 Aluminum
- Profile milling
- Rail spacing ±0.05 mm
- Crash Can Structure
- 7075-T6 Aluminum
- Thin-wall machining
- Wall thickness ±0.10 mm
- FDS Connection Points
- 6061-T6 Aluminum
- Precision drilling
- Hole position ±0.05 mm
- Side Impact Beams
- 7075-T6 Aluminum
- 5-axis contouring
- Beam profile ±0.10 mm
Advantages
- Structural Integrity: One-piece CNC machining eliminates welding distortion.
- Crash Performance: Precise energy absorption features improve collision safety.
- Sealing Reliability: Consistent flatness ensures waterproof battery enclosures.
Disadvantages
- Equipment Investment: Requires large gantry CNC machines (expensive).
- Cycle Time: Large parts take 4-8 hours to machine completely.
- Material Waste: Significant aluminum scrap generation (60-70%).
Applications
- Battery pack structural platforms.
- Side impact protection systems.
- Crash replacement parts for overseas markets.
Comparison
- Feature
- CNC Battery Tray
- Welded Steel Tray
- Weight
- 25 kg
- 45 kg
- Flatness
- 1 mm/m
- 5 mm/m
- Corrosion Resistance
- Excellent
- Poor (requires coating)
- Cost
- High
- Medium
Related Questions
- Why do EV battery trays need 0.1 mm/m flatness?
- What is FDS technology in battery tray assembly?
- How does CNC machining improve crash energy absorption?
- Why use 7075-T6 for crash cans instead of 6061?
Conclusion
EV battery trays require CNC machining of 6061-T6/7075-T6 aluminum with 0.1 mm/m flatness and precision FDS connection points. This ensures structural safety and waterproof integrity for exported Chinese EVs.
HYR-CNC Recommendation
For EV and NEV component manufacturing, HYR-CNC recommends selecting high-rigidity VMC, HMC, gantry, turning or 5-axis CNC equipment according to part size, tolerance, material and production volume.