We Start with Heavy-Duty Lathes for Large Diameter Work

Flywheel diameters are often more than 500 milímetros. Our turning centres can handle this size without any trouble. We put the billet in a four-jaw chuck and hold it tightly, which stops movement during very heavy roughing passes.

When machining, large diameters generate heat quickly. We put a lot of coolant in the cutting zone. This keeps the tools sharp and the sizes the same.

Keeping Wall Thickness Even Throughout the Cutting Process

The flywheel is out of balance because the walls are not even. We program small steps of radial cuts. Every pass takes away just the right amount of material. Our turning tools always feed at the same rate.

The final thickness of the wall stays the same all the way around the rim, en 0.1 milímetros. We take measurements at different points during machining. Before moving on to the next step, we check dimensions from digital callipers to make sure that everything is the same.

Boring Out Hub and Bearing Seats to Exact Fit

The diameter of the shaft must be the same as the hub bore. We use carbide boring bars with inserts that can be changed. Bearing seats need a certain kind of interference fit.

We drilled to within 0.01 mm of the final size. A finish pass with a sharp insert gives the surface you want. The bearing slides in easily, without any effort.

Live Probing Catches Any Deviation Before It Becomes a Problem

Touch probes that measure during the cycle are built into our lathes. After rough cuts, the probe checks the diameters. The program changes itself if something drifts. This feedback in real time stops parts from being thrown away.

Our CNC Mills Create Precision Flywheel Features and Mounting Holes

Cajas lacas, mounting holes, and weight-reduction pockets need to be in the right place. We use CAM software to plan toolpaths and machine features that will work the same way on every batch of flywheels.

Drilling Bolt Patterns While the Flywheel Stays Indexed

For assembly, the bolt holes must line up perfectly. We put the flywheel on a table that turns. The table can move to the right angles for each hole. Our CNC mills can drill all the way through in one pass.

We use peck drilling to get rid of chips that are stuck in deep holes. This keeps the holes from breaking and maintains their quality. There are no burrs or dirt in any of the holes.

Cutting Keyways That Match Your Shaft Dimensions

Keyways move torque from the shaft to the flywheel. We cut keyways using end mills that are the right size for your shaft key. The mill goes down to the bottom and then moves along the bore.

We use go/no-go gauges to measure the width of the keyway. This proves that the key won't get stuck or rattle. The connection stays strong even when it's under stress.

Removing Weight Without Weakening the Structure

Some uses need flywheels that are lighter but still strong. We cut pockets into the web or rim. Using FEA, our engineers figure out how big the pockets should be. The flywheel stays strong and doesn't break.

We use ball-nose end mills to make pockets. The radius at the bottom stops cracks from starting. The flywheel can handle high RPMs without breaking.

Adding Chamfers to Stop Cracks from Starting

Stress builds up at sharp edges, which can lead to cracks. We round off all of the edges on the outside and inside. This makes stress cover a larger area. Chamfers also make it safer to handle parts during assembly.