Demand for CNC machining of new energy vehicle parts surges: Lightweighting and heat dissipation are key.

The investigation followed a structured design framework. Components were selected from critical NEV subsystems including battery housings, motor brackets, and cooling plates. Design models were prepared using SolidWorks, ensuring precise definition of dimensional tolerances and surface finishes.

Material property data were collected from manufacturer datasheets and verified against ASTM and ISO standards. Machining process parameters were derived from prior industrial reports and validated through trial production in a CNC machining center.

• Machining equipment: 5-axis vertical machining center with real-time monitoring.
• Materials: Aluminum alloys (6061, 7075), stainless steel (304, 316L).
• Simulation: Finite Element Analysis (ANSYS) to model thermal dissipation under load.
• Evaluation metrics: Dimensional accuracy (±0.01 mm), surface roughness (Ra ≤ 0.8 μm), and heat transfer coefficient.

All parameters and test setups were documented to ensure reproducibility.

Aluminum alloys achieved up to 45% weight reduction compared with stainless steel components of equal strength. Machined aluminum cooling plates exhibited enhanced thermal conductivity, supporting battery system efficiency.

Table 1 Mechanical and thermal properties of test materials

Simulation results (Fig. 1) show that aluminum plates achieved 20–25% lower operating temperatures under equivalent thermal loads compared to stainless steel. This directly supports extended battery life and reduced cooling system requirements.

Figure 1 Temperature distribution in aluminum vs stainless steel cooling plates.

When benchmarked against prior industrial studies (Li et al., 2022; Zhang & Chen, 2023), the findings confirm that CNC machining precision further improves the performance of lightweight alloys. Unlike cast or stamped components, machined parts demonstrated superior tolerance control, critical for assembly in NEVs.

The observed benefits arise from the high thermal conductivity of aluminum alloys and the precision achievable with CNC machining. Stainless steel remains indispensable for parts requiring exceptional durability, such as structural brackets, where safety margins must be maintained.

Results are based on controlled laboratory conditions with limited batch production. Large-scale industrial trials may reveal additional challenges such as tool wear and cost efficiency in mass production.

For manufacturers, adopting CNC machining for NEV components enables balancing lightweighting and performance. Integration of hybrid materials—aluminum for thermal management and stainless steel for structural loads—offers optimized solutions.

Results confirm that CNC machining is critical to advancing NEV part production. Aluminum alloys provide superior weight reduction and thermal performance, while stainless steel ensures structural safety. Combining both materials through precision machining supports the evolving needs of NEVs. Future research should focus on hybrid processes integrating CNC with additive manufacturing to further enhance design flexibility and cost efficiency.