Sandvik Coromant, a renowned expert in metal cutting solutions, has unveiled its latest innovation in the form of the M5F90 face-milling cutter. This state-of-the-art cutter is specifically designed to process thin-wall aluminium components, particularly battery racks, with utmost precision. Its smaller cutter body and brazed Polycrystalline Diamond (PCD) tips eliminate the risk of burring, scratching, or chipping, making it a game-changer in the automotive industry.In today's automotive sector, original equipment manufacturers (OEMs) are increasingly involved in battery cell production, which is now in close proximity to car assembly factories. As battery technology and performance become crucial differentiating factors, efficient machining solutions are more vital than ever. Fernando Oliveira, Global Manager for Automotive Aluminium at Sandvik Coromant, believes that the M5F90 face-milling cutter can empower OEMs to succeed in these areas.The development of battery systems calls for the production of near-net-shaped components with intricate designs. Machining such complex patterns requires lightweight tools that minimize machine tool impact while preserving the component's integrity.OEMs are investing heavily in battery manufacturing and striving to develop lightweight electric vehicles (EVs) with enhanced efficiency and longer range per charge. The concept of "lightweight" has emerged as a strategy for improving fuel economy and maneuverability. Aluminium, being one of the lightest metals, has become a popular choice in the automotive industry for its strength, corrosion resistance, and recyclability.Aluminium battery racks present unique machining challenges due to their smaller faces, intricate features, and numerous threads and holes. The M5F90 face-milling cutter is purposefully designed to overcome these obstacles. The brazed PCD inserts of the cutter enable high feed rates, prevent cutting vibrations, and ensure consistent performance with extended tool life. Recent tests utilizing the M5F90 cutter successfully produced an aluminium battery tray, showcasing its ability to handle roughing and finishing in a single operation, thus reducing time and increasing production efficiency.