How to precisely process battery cooling system components for C-type high-gloss medium-speed wire cutting machine tools ?

"Precision ≤ ±0.003 mm, surface finish Ra ≤ 0.7-1.4 μm - how to achieve such processing standards in the manufacturing of core components of electric vehicles?" With the surge in demand for lightweight and high reliability in the new energy vehicle industry, the precision processing of internal components of the battery cooling system has become a key challenge. The C-type high-gloss medium-speed wire cutting machine tool is becoming the preferred equipment for industry benchmark companies with its high precision, high stability and excellent surface treatment capabilities. Today, we will take a well-known electric vehicle brand as an example to reveal the difficulties in processing its core components and how Zhikai CNC can help the industry break through bottlenecks with technological innovation.

Case Study: Processing Challenges of Internal Components in Battery Cooling Systems

A leading electric vehicle manufacturer uses a large number of C-type high-gloss medium-speed wire cutting machines for precision machining in the production of internal components of its battery cooling system. These components include:

1. Liquid cooling plate (heat sink)

Material: Aluminum alloy (6061/5052) or copper alloy, high thermal conductivity is required.

Processing difficulties:

The flow channel structure is complex and requires high-precision cutting to avoid burrs that affect cooling efficiency.

Thin-walled areas (0.5-1.2 mm) are prone to deformation and require low-stress cutting technology.

Zhikai solution: Adopt adaptive tension control technology to ensure a stable cutting process and a surface finish of Ra ≤ 0.7-1.4 μm.

2. Cooling system connectors (flanges, interface parts)

Material: Stainless steel (304/316) or titanium alloy, high corrosion resistance requirements.

Processing difficulties:

There are many special-shaped holes, and traditional processing is prone to position deviation.

High-hardness materials cause tool wear to accelerate and increase costs.

Zhikai Solution: Equipped with intelligent corner control technology, it achieves a hole position accuracy of ± ≤±0.00 6 mm and extends the life of the electrode wire by 30%.

3. Battery module fixing bracket

Material: high strength steel or composite material.

Processing difficulties:

It is necessary to take both lightweight and structural strength into consideration, and the hollow design increases the difficulty of cutting.

Extremely high consistency requirements are placed on mass production.

Zhikai Solution: Automatically optimize parameters through AI process database to ensure large-scale processing stability.

Data support

After this customer adopted Zhikai C-type high-gloss medium-wire wire cutting machine, the yield rate increased to 99.2% (the original process was 96.5%).

Processing efficiency is increased by 20%, thanks to Zhikai's pulse power technology, achieving both high-speed cutting and high finish.

Zhikai CNC's industry technical advantages

In addition to battery cooling system components, Zhikai CNC's C-type high-gloss medium-speed wire cutting machine tools are also widely used in the following high-value-added parts:

Motor stator/rotor silicon steel sheet: ultra-thin sheet (0.2mm) burr-free cutting.

Hydrogen fuel cell bipolar plates: complex flow channels precision machining, sealing surface Ra ≤ 0.7-1.4 μm.

Lightweight body structural parts: high-precision positioning of multiple holes, suitable for laser welding process.

Zhikai's core competitiveness:

1. Focus on R&D: Annual R&D investment accounts for more than 15%, and the company has a number of national patented technologies for medium-speed wire cutting.

2. Intelligent process library: built-in 1000+ material processing parameters, one-click call, lowering the operation threshold.

3. Full life cycle service:

24-hour remote diagnosis, response speed <2 hours.

Provide free process training to ensure maximum utilization of customers' equipment.

Summarize

"In the race for new energy vehicles, precision determines performance, and efficiency determines cost." Zhikai CNC helps every company pursuing excellence gain technological commanding heights with "millimeter-level precision and micron-level craftsmanship."

If you are looking for high-finish, high-precision medium-speed wire cutting solutions, welcome to contact Zhikai CNC - we are not only an equipment supplier, but also a lifelong partner for your process upgrade.

When traditional wire cutting encounters efficiency bottlenecks, Zhikai's third-generation intelligent knife repair technology is saving 15% of molybdenum wire loss for 3,576 customers. We have already answered your processing pain points with modular design: the self-developed constant temperature primary color processing power supply system can handle complex materials, and the rapid response ensures 7 × 24h stable operation. You can get the "White Paper on Optimization of Parameters for Medium Wire Cutting" for free by consulting now. Zhikai's team of engineers is in place to customize a combination of cost reduction and efficiency improvement for you within three minutes. "Friends from Long'an District, Tangyin County, Neihuang County, Linzhou City, Beiguan District, Yindu District, Wenfeng District, Hua County, Anyang County and other places are welcome to consult.

If you have any needs, please contact Zhikai : 18013131588