{"id":19651,"date":"2024-04-18T06:00:07","date_gmt":"2024-04-18T06:00:07","guid":{"rendered":"https:\/\/dev.guehring.com\/produkte-pkd-reibwerkzeuge-magnesiumbearbeitung-e-mobilitaet\/"},"modified":"2026-04-22T14:05:57","modified_gmt":"2026-04-22T14:05:57","slug":"products-pcd-reamers-magnesium-machining-e-mobility","status":"publish","type":"post","link":"https:\/\/guehring.com\/de-en\/products-pcd-reamers-magnesium-machining-e-mobility\/","title":{"rendered":"Using diamonds to combat wear on electric motors"},"content":{"rendered":"

[et_pb_section fb_built=”1″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.1″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

Success with electric motors <\/span>
\nUsing diamonds to combat wear in magnesium machining<\/span><\/h1>\n

A customer encounters wear problems during the production of magnesium parts for electric motors: Fine magnesium dust affects tools and surfaces. With special diamond tools featuring intelligent geometry optimisation, G\u00fchring dramatically increases tool life: from weeks to a year. Dynacast saves costs and time, while G\u00fchring demonstrates its expertise in the special field.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”3_4,1_4″ module_class=”gue-page-header” _builder_version=”4.27.4″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”3_4″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/guehring.com\/wp-content\/uploads\/2025\/09\/Dynacast_Headerbild.jpg” alt=”Magnesiumbearbeitung mit PKD-Werkzeugen von G\u00fchring” title_text=”Magnesiumbearbeitung mit PKD-Werkzeugen von G\u00fchring” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][et_pb_column type=”1_4″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_column][\/et_pb_row][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]All you hear is the chirping of the birds and the noise of the electric bike on the trail. When cycling in nature, one thing is extremely annoying: engine noise. To avoid this, the manufacturing of components in electric motors requires the highest precision \u2013 and this in series production. At 1,000 units per week, stable processes are essential.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”3_5,2_5″ module_class=”gue-row-vertical-aligned-content gue-row-2col-image-text” _builder_version=”4.21.0″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”3_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/guehring.com\/wp-content\/uploads\/2025\/09\/GUE_kugellager.jpg” alt=”Das Bauteil bei Dynacast: Ein Kugellager aus Magnesium” title_text=”Das Bauteil bei Dynacast: Ein Kugellager aus Magnesium” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][et_pb_column type=”2_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

With around 450 employees at its Austrian location south of Vienna, Dynacast<\/a> manufactures parts made of die-cast zinc, magnesium and aluminium. Dynacast parts are used in industries where precision, durability and lightweight construction are critical. \u201cThat\u2019s why high quality is so important\u201d, says Markus Beier, Production Manager at Dynacast. This also applies to housing parts for electric motors the size of an A4 sheet. The focus is on lightweight construction \u2013 a trend that relies on special materials such as magnesium. But casting and machining magnesium is challenging, especially when large batches of more than 1,000 pieces per week are produced, as is the case with Dynacast.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]This is where stable processes are fundamentally important. The good thing is that Dynacast has a strong partner at its side: \u201cEver since we have been manufacturing magnesium housings, we have been working with G\u00fchring\u201d, notes Markus Beier. \u201cWhenever we have a problem, G\u00fchring is there and we tackle the issue together.\u201d[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.27.4″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.19.5″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” hover_enabled=”0″ global_colors_info=”{}” sticky_enabled=”0″]<\/p>\n

Table of contents<\/h2>\n
\nWear due to magnesium dust<\/a>
\nG\u00fchring delivers the special solution<\/a>
\nReady for the future <\/a>
\nThe machining process in detail<\/a>\n<\/div>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ module_id=”1″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

Wear due to magnesium dust<\/h2>\n

This was also the case when Dynacast reached its limits when machining a stator hole on an electric bike motor housing. The die-cast part made of magnesium was pre-cast close to the final shape. Despite the stock removal of only approx. 1 mm per side, the wear on the PCD reamer was enormous: \u201cFor some tools, it only took us two to four weeks to send them for refurbishment\u201d, recalls Markus Beier. \u201cSuch short tool lives are not satisfactory for us.\u201d The wear also affected the surfaces on the stator bore. When looking into the machine, the reason was also quickly found: A white construction film was visible in the machine area and on the tools. After investigations at the University of Leoben, it was determined that this was magnesium dust.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”3_5,2_5″ module_class=”gue-row-vertical-aligned-content gue-row-2col-image-text” _builder_version=”4.21.0″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”3_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/guehring.com\/wp-content\/uploads\/2025\/09\/GUE_gespraech-dynacast.jpg” alt=”Beratungssituation zwischen Mitarbeitenden von G\u00fchring und Dynacast” title_text=”Beratungssituation zwischen Mitarbeitenden von G\u00fchring und Dynacast” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][et_pb_column type=”2_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]This microdust is released during machining and deposited everywhere \u2013 including on the cutting edges of the PCD reamers. Here, the fine dust particles acted like small sand grains that rub the material off the cutting edges. As a result, the otherwise wear-resistant PCD cutting edges rounded off within a very short time, which is why the tool lives were significantly shorter than planned: After about 150 m, it was already over. In addition, this wear on the cutting edge generates such a high cutting pressure that the diameter in the component was 0.1 millimetres smaller than the diameter on the reamer.[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ module_id=”2″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

G\u00fchring delivers the special solution<\/h2>\n

A special solution was needed here and G\u00fchring was able to deliver this thanks to its high level of expertise in the special field. \u201cIn two optimisation rounds, we converted the tool in such a way that its geometry counteracted excessive wear\u201d, explains Matthias Helbig, Application Manager for E-Mobility at G\u00fchring.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”3_5,2_5″ module_class=”gue-row-vertical-aligned-content gue-row-2col-image-text” _builder_version=”4.21.0″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”3_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/guehring.com\/wp-content\/uploads\/2025\/09\/GUE_haende-sonderwerkzeug.jpg” alt=”PKD-Werkzeug von G\u00fchring” title_text=”PKD-Werkzeug von G\u00fchring” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][et_pb_column type=”2_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

Instead of developing completely new tools, the aim here was to conserve resources so that the basic body of the reamers could be reused. The solution is a wear compensation cutting edge: Five adjustable cutting edges can be moved via an expansion joint. This means that the customer can quickly and easily readjust the diameter if the diameter falls below the specified value.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ module_id=”3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

Ready for the future<\/h2>\n

The result is impressive: \u201cThanks to the joint development, we have managed to get to a tool life of around twelve months from two to four weeks\u201d, says Markus Beier happily. \u201cAnd this improvement in tool life has had a very positive impact on us financially.\u201d[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”1_3,1_3,1_3″ make_equal=”on” _builder_version=”4.27.4″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”1_3″ module_class=”gue-quotebox-3col-column” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_blurb alt=”Philipp Kunze” _builder_version=”4.27.6″ _module_preset=”default” background_image=”https:\/\/guehring.com\/wp-content\/uploads\/2024\/02\/GUE_website-pikto_zitat.svg” global_colors_info=”{}”]\u201eThis improvement in tool life has had a very positive impact on us financially.\u201c<\/p>\n

Markus Beier<\/strong>
\nDynacast[\/et_pb_blurb][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_column][\/et_pb_row][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]Because Dynacast now has massive savings in tool costs and saves machining time thanks to fewer tool change cycles, the company\u2019s manufacturing can be much more cost-effective. In addition, the revised G\u00fchring tools ensure greater process reliability and consistently high quality. Thanks to this success, Markus Beier has a positive outlook on the future: \u201cI believe Dynacast will remain a major player in the housing market because we are far from finished with our innovations and die casting technology.\u201d He wants to continue working closely with G\u00fchring in the future, because \u201cthis collaboration has proved to be very fruitful so far, and together we have developed great ideas and technical solutions.\u201d[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ module_id=”4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_row module_class=”gue-row-text” _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

The machining process in detail<\/h2>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”3_5,2_5″ module_class=”gue-row-vertical-aligned-content gue-row-2col-image-text” _builder_version=”4.21.0″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_column type=”3_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_video src=”https:\/\/youtu.be\/d2V0kcYLLDA” _builder_version=”4.23.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_video][\/et_pb_column][et_pb_column type=”2_5″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n

Information on the machining setup:<\/h3>\n