Flexibility, precision and performance for the change in the automotive drive
The transformation in the automotive drive world is a process that is increasingly gaining momentum. However, the fact remains that combustion engines will remain highly relevant for the time being. This poses a double challenge for manufacturing companies: on the one hand, existing capacities must be used efficiently and, on the other, the massive advance of electromobility must also be taken into account in the workshop. Investments in modularity, flexibility, automation and digitization are important factors here. Targeted employee training is also one of the pillars of shaping the future. Companies that focus on adaptable and sustainable manufacturing solutions therefore have the best chance of securing and, above all, successively expanding their competitiveness in the face of change.
How the transformation from combustion engine to electric drive is redefining the CNC manufacturing process chain
The mobility industry is traditionally one of the most important sales markets for machine tools worldwide. The transition from combustion engines to vehicles with electric drives and the resulting changes in the general conditions are therefore having an enormous impact on the economy - and on the CNC manufacturing ecosystem in particular. While large quantities of traditional components are still required, the focus of production is shifting noticeably. Above all, new technologies and work processes must be taken into account in this regard. The adaptability of the organization as well as the willingness to innovate and invest in future-proof manufacturing solutions are thus becoming decisive economic and competitive factors.
Precision and flexibility: universal requirements for machine tools in automotive manufacturing 4.0
In this context, precision and productivity as well as process reliability and efficiency are equally important to CNC manufacturers in all areas of application, regardless of the drive concept. Machine tools must be able to produce high quantities with minimum tolerances and maximum repeat accuracy. At the same time, flexibility requirements are increasing, as the industry is increasingly characterized by variant diversity and shorter product life cycles. Automation, digitization and sustainability are further key factors that apply to the production of combustion vehicles as well as to value creation in the electric mobility industry.
Process integration and 5-axis machining - Precision manufacturing for combustion engines & electric cars
High-precision components are essential for both vehicles with combustion engines and electric vehicles. Typical manufacturing processes such as turning, milling, drilling and grinding are used in both areas, for example for chassis, transmission and body components. The integration of several machining steps in one machine (process integration), the use of 5-axis machining and flexible automation solutions are key trends affecting the entire industry. Modern machine tools also enable efficient, resource-saving production through automation and the use of digital tools. For example, the use of digital twins, in-process measurement technology and machine learning shortens start-up times, optimizes processes and ensures high quality standards.
Combustion engine versus electric drive: requirements for machine tools
Despite many parallels, the requirements for machine tools differ fundamentally depending on the drive concept:
Complexity and cutting volume: An internal combustion engine consists of several hundred individual parts, which often have complex geometries. Production involves numerous machining processes - from the crankshaft and cylinder head to the camshaft and gearbox. Electric drives, on the other hand, require significantly fewer mechanical components, many of which are simpler in design. According to studies, the machining volume is reduced by up to 60% compared to the classic powertrain.
New components and processes: While drilling, milling and grinding dominate with combustion engines, processes such as additive manufacturing are gaining in importance with electric drives. The processing of aluminum and new lightweight materials is coming to the fore.
Flexibility and universality: As the product range for electric vehicles is changing faster and the quantities of individual components are smaller, the need for universally applicable, reconfigurable machine tools is increasing. Flexible, automated production systems that can be quickly adapted to new component geometries and materials are therefore increasingly coming into focus.
Conclusion and outlook
The transformation in the mobility industry marks a systemic structural change that is characterized by precision, flexibility and resource efficiency. 5-axis capabilities and hybrid manufacturing strategies are the fundamental part of the solution. However, the key to holistic success lies in the extended digital consistency of the process chain, combined with modular automation concepts and the consistent operationalization of sustainability goals. DMG MORI's MX strategy - the systematic dovetailing of process integration, automation, Digital Transformation (DX) and Green Transformation (GX) - provides CNC manufacturers with a tried-and-tested roadmap on the path to tomorrow, paving the way from reactive parts manufacturer to proactive solution partner in the automotive transformation.