A thin wall machining for electric vehicles: A Review on Precise, Efficient and Sustainable Approach

The relentless pursuit of extended range and efficiency in electric vehicles (EVs) necessitates the development of lightweight yet high-strength components. Thin-wall machining emerges as a crucial technique for achieving this goal by enabling the creation of intricate parts with minimal material usage. This review delves into the complexities of thin-wall machining for EV applications, focusing on aluminum alloys commonly employed in battery housings, motor housings, and other structural elements. This review explores the inherent challenges associated with thin-wall machining, including deformation, chatter vibrations, and compromised surface integrity. Established best practices for optimizing cutting parameters, tooling selection, and lubrication techniques are presented to mitigate these issues and ensure high-quality component production. Sustainability concerns are not neglected. The review examines advancements in cryogenic machining and minimum quantity lubrication (MQL) as viable solutions for minimizing environmental impact during thin-wall machining. The review identifies and discusses potential areas of further research. This includes the exploration of advanced surface engineering techniques for enhanced component performance, the development of novel lightweight alloys specifically tailored for thin-wall machining in EVs, and the integration of artificial intelligence (AI) for optimized tool-path generation. The feasibility of high-speed machining (HSM) techniques for thin-walled components and the development of biodegradable cutting fluids formulated for thin-wall machining applications are also presented as promising avenues for future investigation.