{"id":7592,"date":"2026-06-23T10:51:36","date_gmt":"2026-06-23T07:51:36","guid":{"rendered":"https:\/\/axinar.com\/?p=7592"},"modified":"2026-06-23T12:52:41","modified_gmt":"2026-06-23T09:52:41","slug":"cnc-aluminum-machining-formula-student-aristurtle","status":"publish","type":"post","link":"https:\/\/axinar.com\/en\/blog\/cnc-aluminum-machining-formula-student-aristurtle","title":{"rendered":"Precision CNC Aluminum Machining for a Formula Student EV | AXINAR \u00d7 ARISTURTLE"},"content":{"rendered":"<p class=\"ax-article-byline\" style=\"color:#666;font-size:.9em;margin-bottom:1.5em;\">\n<strong>By the AXINAR engineering team<\/strong> \u00b7 Published 23 June 2026 \u00b7 Category: Case Study \/ OEM CNC<br\/>\n<em>Technical details in this article are reviewed by AXINAR&#8217;s CAM and production engineers.<\/em>\n<\/p>\n\n<p>When <strong><a href=\"https:\/\/www.aristurtle.gr\/\" rel=\"external noopener\" target=\"_blank\">ARISTURTLE<\/a><\/strong>, the <em>Formula Student<\/em> team of the <strong>Aristotle University of Thessaloniki (AUTh)<\/strong>, asked us to machine the <em>wheel hub<\/em> and the <em>planet carrier<\/em> for their new electric race car &#8220;Rea,&#8221; the brief was clear: <strong>complex aluminum geometry, tight tolerances, concentricity maintained across two machining setups<\/strong>. This case study walks through how we approached the job, what was asked, how we solved it, what we learned.<\/p>\n\n<iframe title=\"\u039a\u03b1\u03c4\u03b5\u03c1\u03b3\u03b1\u03c3\u03af\u03b1 CNC \u03a5\u03c8\u03b7\u03bb\u03ae\u03c2 \u0391\u03ba\u03c1\u03af\u03b2\u03b5\u03b9\u03b1\u03c2 \u03b3\u03b9\u03b1 \u0397\u03bb\u03b5\u03ba\u03c4\u03c1\u03b9\u03ba\u03cc \u039c\u03bf\u03bd\u03bf\u03b8\u03ad\u03c3\u03b9\u03bf | Wheel Hub &amp; Planet Carrier | AXINAR\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/x7aWRJvXO3c?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n\n<h2>What we were asked to do<\/h2>\n<p>ARISTURTLE sent us <strong>3D STEP files<\/strong> for two parts critical to the in-wheel drivetrain of the &#8220;Rea&#8221; race car:<\/p>\n<ul>\n<li>The <strong>planet carrier<\/strong>, which holds the planet gears of the reduction set<\/li>\n<li>The <strong>wheel hub<\/strong>, which connects the wheel to the in-wheel 35 kW electric motor<\/li>\n<\/ul>\n<p>Both designed by ARISTURTLE&#8217;s engineers, with <strong>internal pockets<\/strong>, precise seats for gears and bearings, and a requirement to be machined from <strong>two sides<\/strong>, with concentricity preserved across re-fixturing.<\/p>\n\n\n<blockquote style=\"border-left:4px solid #DD2B1C;padding:1.5em 1.75em;background:#1a1a1a;color:#e0e0e0;margin:2em 0;font-style:italic;border-radius:0 6px 6px 0;\">\n<p style=\"margin:0 0 .8em;font-size:1.08em;line-height:1.55;color:#fff;\">&#8220;The parts we handed to AXINAR for machining were particularly complex. Because of the difficult geometry, the operations required, and the precision needed.&#8221;<\/p>\n<p style=\"font-style:normal;font-size:.9em;color:#a0a0a0;margin:0;\">Engineer from <a href=\"https:\/\/www.aristurtle.gr\/\" rel=\"external noopener\" target=\"_blank\" style=\"color:#DD2B1C;\">ARISTURTLE<\/a>, AUTh (from the handover video)<\/p>\n<\/blockquote>\n\n\n<h2>How we approached the job<\/h2>\n<p>Our first decision after receiving the files was to <strong>split each part into two setups<\/strong>, with careful planning of <em>datum references<\/em>. On aluminum parts with internal geometry like a planet carrier, maintaining concentricity between features across the two sides is the single most important quality factor.<\/p>\n\n<p><strong>Material choice:<\/strong> For race-car components of this kind, ARISTURTLE, like most Formula Student teams, typically selects <strong>aluminum 7075-T6 or 6061-T6<\/strong>. 7075-T6 offers higher mechanical strength (yield ~503 MPa), ideal for load-bearing parts like the planet carrier. 6061-T6 is easier to weld and more economical, suitable for parts with moderate mechanical demand. Both alloys machine quickly and cleanly on CNC.<\/p>\n\n<p><strong>Fixturing strategy:<\/strong> For each part we programmed in CAM:<\/p>\n<ol>\n<li><strong>First setup<\/strong>, held in soft jaws or a dedicated fixture referenced from the outer surfaces; machining of one side (pockets, seats, outer geometry)<\/li>\n<li><strong>Re-fixturing<\/strong> referenced from the features just cut, this gives us concentricity within \u00b10.02 mm across the two sides<\/li>\n<li><strong>Second setup<\/strong>, machining of the second side, threads, final finishing<\/li>\n<\/ol>\n\n<h2>The equipment: Haas VF-2 and CAM<\/h2>\n<p>The job was run on the <a href=\"https:\/\/axinar.com\/en\/metal-cutting\/cnc-milling\/\"><strong>Haas VF-2 vertical machining center<\/strong><\/a> at our Oreokastro Industrial Park facility in Thessaloniki, Greece:<\/p>\n<ul>\n<li>3-axis VMC, 40-taper<\/li>\n<li>22.4 kW (30 HP) spindle, 8,100 rpm<\/li>\n<li>20+1 automatic tool changer<\/li>\n<li>Positioning accuracy \u00b10.02 mm<\/li>\n<li>Travels 762 \u00d7 406 \u00d7 508 mm<\/li>\n<\/ul>\n<p>For 6061\/7075 aluminum we typically run <strong>3-flute carbide end mills<\/strong> at high spindle speeds (6,000\u20138,000 rpm) and feed rates of 1,500\u20132,500 mm\/min depending on geometry, parameters tuned in CAM per part.<\/p>\n\n<h2>What is a wheel hub and a planet carrier?<\/h2>\n<p>Two mechanical terms that are often confused. In short:<\/p>\n<ul>\n<li><strong>Wheel hub:<\/strong> The component that connects the wheel to the axle or motor. It carries the wheel bearings and transmits drive to the rim. In in-wheel applications (where the electric motor sits inside the wheel), the hub also supports the torque reaction of the motor itself.<\/li>\n<li><strong>Planet carrier:<\/strong> In an <a href=\"https:\/\/en.wikipedia.org\/wiki\/Epicyclic_gearing\" rel=\"external noopener\" target=\"_blank\">epicyclic (planetary) gear set<\/a>, the carrier holds the <em>planet gears<\/em> in a fixed orbit around the <em>sun gear<\/em>. It is one of the three core elements of the planetary set (planet carrier, sun gear, ring gear).<\/li>\n<\/ul>\n<p>In electric race cars with in-wheel motors, the planet carrier is machined from aluminum because it must be light (unsprung mass is critical). Accuracy in the bores matters: a 0.05 mm offset in a planet&#8217;s seat can cause uneven loading and premature gear wear.<\/p>\n\n<h2>The result: &#8220;Rea&#8221; on track<\/h2>\n<p>The parts were delivered to ARISTURTLE and integrated into the in-wheel drivetrain of the new race car, the team&#8217;s <strong>8th car overall<\/strong> and <strong>4th autonomous<\/strong>, with:<\/p>\n<ul>\n<li><strong>4\u00d7 in-wheel 35 kW electric motors<\/strong>, custom-designed and built by the team<\/li>\n<li><strong>190 HP total output<\/strong>, all-wheel drive (AWD)<\/li>\n<li><strong>Top speed 120 km\/h<\/strong>, 25 km range for the endurance event<\/li>\n<li><strong>Autonomous driving<\/strong> via cameras and sensors (track cone detection)<\/li>\n<li>Carbon fiber external components by <strong>BNT Composites<\/strong><\/li>\n<\/ul>\n<p>ARISTURTLE is the <strong>first Greek student team to run all-wheel drive with fully custom in-wheel motors<\/strong>.<\/p>\n\n<h2>About AXINAR<\/h2>\n<p><strong>AXINAR S.A.<\/strong> is a metal processing company based in the Oreokastro Industrial Park, Thessaloniki, Greece. Founded in <strong>2010<\/strong>. Our equipment includes 3 fiber laser cutting machines (up to 12 kW), a Haas VF-2 CNC machining center, a Haas ST-15Y CNC lathe, CNC press brakes, MIG\/TIG\/laser welding equipment, and powder coating. We are the <strong>official Delem service center for Greece<\/strong> and a member of <strong>ELEABIOM<\/strong> (the Hellenic Biomass Association).<\/p>\n\n\n<section class=\"ax-faq-section\" style=\"background:#131313;color:#fff;padding:3em 2em;margin:2.5em 0;border-radius:6px;\">\n<p style=\"color:#DD2B1C;text-transform:uppercase;letter-spacing:3px;font-size:.78em;margin:0 0 .8em;font-weight:600;\">FAQ<\/p>\n<h2 style=\"color:#fff;font-size:2.2em;margin:0 0 1.8em;line-height:1.1;font-weight:300;letter-spacing:-.5px;\">Questions about<br\/><span style=\"color:#DD2B1C;font-weight:600;\">CNC aluminum machining<\/span><\/h2>\n<details class=\"ax-faq-item\" style=\"border-bottom:1px solid #2a2a2a;padding:1.25em 0;margin:0;\">\n<summary style=\"cursor:pointer;list-style:none;color:#fff;display:flex;justify-content:space-between;align-items:center;font-size:1.02em;font-weight:400;line-height:1.4;gap:1em;\">\n<span>What is the planet carrier and the wheel hub in a drivetrain?<\/span>\n<span style=\"color:#DD2B1C;font-size:1.6em;line-height:1;font-weight:300;flex-shrink:0;\" aria-hidden=\"true\">+<\/span>\n<\/summary>\n<div style=\"color:#c7c7c7;padding:1em 0 .25em;line-height:1.65;font-size:.97em;\">\n<p>The <strong>wheel hub<\/strong> connects the wheel to the axle or motor and carries the wheel bearings. The <strong>planet carrier<\/strong> holds the planet gears in a planetary reduction set. In electric vehicles with in-wheel motors, both are central to delivering torque from the motor to the wheel.<\/p>\n<\/div>\n<\/details>\n<details class=\"ax-faq-item\" style=\"border-bottom:1px solid #2a2a2a;padding:1.25em 0;margin:0;\">\n<summary style=\"cursor:pointer;list-style:none;color:#fff;display:flex;justify-content:space-between;align-items:center;font-size:1.02em;font-weight:400;line-height:1.4;gap:1em;\">\n<span>What material is used for wheel hubs and planet carriers in race components?<\/span>\n<span style=\"color:#DD2B1C;font-size:1.6em;line-height:1;font-weight:300;flex-shrink:0;\" aria-hidden=\"true\">+<\/span>\n<\/summary>\n<div style=\"color:#c7c7c7;padding:1em 0 .25em;line-height:1.65;font-size:.97em;\">\n<p>Typically <strong>aluminum 7075-T6<\/strong> (high mechanical strength) or <strong>6061-T6<\/strong> (better machinability, more economical). The combination of low weight and adequate strength is critical for unsprung mass in a race car. Higher-load applications may use steel or hybrid solutions. AXINAR machines all of the above, plus stainless steel and engineering plastics.<\/p>\n<\/div>\n<\/details>\n<details class=\"ax-faq-item\" style=\"border-bottom:1px solid #2a2a2a;padding:1.25em 0;margin:0;\">\n<summary style=\"cursor:pointer;list-style:none;color:#fff;display:flex;justify-content:space-between;align-items:center;font-size:1.02em;font-weight:400;line-height:1.4;gap:1em;\">\n<span>What tolerances can you hold in 2-side CNC aluminum machining?<\/span>\n<span style=\"color:#DD2B1C;font-size:1.6em;line-height:1;font-weight:300;flex-shrink:0;\" aria-hidden=\"true\">+<\/span>\n<\/summary>\n<div style=\"color:#c7c7c7;padding:1em 0 .25em;line-height:1.65;font-size:.97em;\">\n<p>The Haas VF-2 mill delivers positioning accuracy of <strong>\u00b10.02 mm<\/strong>. In two-side machining, concentricity between features across the two sides is maintained with proper fixturing, clean datum references, and dimensional checks between setups. For tighter tolerances, <a href=\"https:\/\/axinar.com\/en\/contact\/\">contact us<\/a> so we can review the geometry before quoting.<\/p>\n<\/div>\n<\/details>\n<details class=\"ax-faq-item\" style=\"border-bottom:1px solid #2a2a2a;padding:1.25em 0;margin:0;\">\n<summary style=\"cursor:pointer;list-style:none;color:#fff;display:flex;justify-content:space-between;align-items:center;font-size:1.02em;font-weight:400;line-height:1.4;gap:1em;\">\n<span>What CAD format do you accept?<\/span>\n<span style=\"color:#DD2B1C;font-size:1.6em;line-height:1;font-weight:300;flex-shrink:0;\" aria-hidden=\"true\">+<\/span>\n<\/summary>\n<div style=\"color:#c7c7c7;padding:1em 0 .25em;line-height:1.65;font-size:.97em;\">\n<p>We accept <strong>STEP, IGES, DXF, DWG, SolidWorks, and PDF<\/strong> with complete dimensions and tolerances. We prefer <strong>3D STEP files<\/strong> for faster CAM preparation. If you do not have a finished design, we can join in at the design stage via our <a href=\"https:\/\/axinar.com\/en\/metal-cutting\/schediasmos-kai-anaptyxi-r-d\/\">design &amp; R&amp;D<\/a> service.<\/p>\n<\/div>\n<\/details>\n<details class=\"ax-faq-item\" style=\"border-bottom:1px solid #2a2a2a;padding:1.25em 0;margin:0;\">\n<summary style=\"cursor:pointer;list-style:none;color:#fff;display:flex;justify-content:space-between;align-items:center;font-size:1.02em;font-weight:400;line-height:1.4;gap:1em;\">\n<span>Do you take on OEM machining for student teams and start-ups?<\/span>\n<span style=\"color:#DD2B1C;font-size:1.6em;line-height:1;font-weight:300;flex-shrink:0;\" aria-hidden=\"true\">+<\/span>\n<\/summary>\n<div style=\"color:#c7c7c7;padding:1em 0 .25em;line-height:1.65;font-size:.97em;\">\n<p>Yes, actively. We have worked with <strong><a href=\"https:\/\/www.aristurtle.gr\/\" rel=\"external noopener\" target=\"_blank\" style=\"color:#DD2B1C;\">ARISTURTLE<\/a><\/strong> (Formula Student, AUTh) and other research \/ racing teams. We handle anything from a <strong>single prototype<\/strong> to <strong>series production<\/strong>, with consistent precision throughout. Call us at <strong>+30 2310 808 159<\/strong> to discuss your project.<\/p>\n<\/div>\n<\/details>\n<details class=\"ax-faq-item\" style=\"border-bottom:1px solid #2a2a2a;padding:1.25em 0;margin:0;\">\n<summary style=\"cursor:pointer;list-style:none;color:#fff;display:flex;justify-content:space-between;align-items:center;font-size:1.02em;font-weight:400;line-height:1.4;gap:1em;\">\n<span>What is the lead time for aluminum race-car parts?<\/span>\n<span style=\"color:#DD2B1C;font-size:1.6em;line-height:1;font-weight:300;flex-shrink:0;\" aria-hidden=\"true\">+<\/span>\n<\/summary>\n<div style=\"color:#c7c7c7;padding:1em 0 .25em;line-height:1.65;font-size:.97em;\">\n<p>It depends on geometry and quantity. Typically, <strong>prototypes in 3-5 working days<\/strong>; series timing scales with volume. For hard deadlines (e.g. ahead of a Formula Student event), contact us early so we can schedule priority on the line.<\/p>\n<\/div>\n<\/details><\/section>\n\n\n\n<section class=\"ax-cta-section\" style=\"background:linear-gradient(135deg,#131313 0%,#1f1f1f 100%);color:#fff;padding:3em 2em;margin:2.5em 0;border-radius:8px;border-left:6px solid #DD2B1C;\">\n<p style=\"color:#DD2B1C;text-transform:uppercase;letter-spacing:3px;font-size:.78em;margin:0 0 .8em;font-weight:600;\">REQUEST A QUOTE<\/p>\n<h2 style=\"color:#fff;font-size:2.2em;margin:0 0 .6em;line-height:1.15;font-weight:300;letter-spacing:-.5px;\">Ready to build <span style=\"color:#DD2B1C;font-weight:600;\">your parts?<\/span><\/h2>\n<p style=\"color:#c7c7c7;font-size:1.05em;margin:0 0 2em;line-height:1.6;max-width:680px;\">From a single prototype to series production, with the same <strong style=\"color:#fff;\">\u00b10.02 mm<\/strong> precision. We&#8217;ve machined parts for <a href=\"https:\/\/www.aristurtle.gr\/\" rel=\"external noopener\" target=\"_blank\" style=\"color:#fff;text-decoration:underline;\">ARISTURTLE<\/a> and other research and racing teams.<\/p>\n\n<div style=\"display:grid;grid-template-columns:repeat(auto-fit,minmax(220px,1fr));gap:1em;margin-bottom:2em;\">\n<div style=\"background:rgba(255,255,255,.04);padding:1.4em;border-radius:6px;border-top:3px solid #DD2B1C;\">\n<div style=\"color:#DD2B1C;font-size:1.6em;font-weight:700;line-height:1;margin-bottom:.4em;font-family:monospace;\">01<\/div>\n<div style=\"color:#fff;font-weight:600;margin-bottom:.4em;font-size:1.05em;\">Send your drawing<\/div>\n<div style=\"color:#a8a8a8;font-size:.92em;line-height:1.5;\">3D STEP, IGES, DWG or PDF with dimensions, tolerances, material and quantity.<\/div>\n<\/div>\n<div style=\"background:rgba(255,255,255,.04);padding:1.4em;border-radius:6px;border-top:3px solid #DD2B1C;\">\n<div style=\"color:#DD2B1C;font-size:1.6em;font-weight:700;line-height:1;margin-bottom:.4em;font-family:monospace;\">02<\/div>\n<div style=\"color:#fff;font-weight:600;margin-bottom:.4em;font-size:1.05em;\">Quote within 24 hours<\/div>\n<div style=\"color:#a8a8a8;font-size:.92em;line-height:1.5;\">Detailed quote from AXINAR&#8217;s CAM engineers, with pricing and timeline.<\/div>\n<\/div>\n<div style=\"background:rgba(255,255,255,.04);padding:1.4em;border-radius:6px;border-top:3px solid #DD2B1C;\">\n<div style=\"color:#DD2B1C;font-size:1.6em;font-weight:700;line-height:1;margin-bottom:.4em;font-family:monospace;\">03<\/div>\n<div style=\"color:#fff;font-weight:600;margin-bottom:.4em;font-size:1.05em;\">Delivery in 3-5 days<\/div>\n<div style=\"color:#a8a8a8;font-size:.92em;line-height:1.5;\">For prototypes. Series timing scales with volume, with priority for hard deadlines.<\/div>\n<\/div>\n<\/div>\n\n<div style=\"display:flex;flex-wrap:wrap;gap:.8em;align-items:center;margin-bottom:1em;\">\n<a href=\"https:\/\/axinar.com\/en\/request-a-quote\/\" style=\"display:inline-block;background:#DD2B1C;padding:1em 2em;text-decoration:none;font-weight:600;border-radius:4px;font-size:1.05em;letter-spacing:.5px;color:#fff;\"><span style=\"color:#fff;\">\ud83d\udce9 Request a quote online<\/span><\/a>\n<a href=\"tel:+302310808159\" style=\"display:inline-block;background:transparent;padding:.95em 1.5em;text-decoration:none;font-weight:500;border:2px solid #fff;border-radius:4px;color:#fff;\"><span style=\"color:#fff;\">\ud83d\udcde +30 2310 808 159<\/span><\/a>\n<\/div>\n<p style=\"color:#888;font-size:.92em;margin:0;\">or email <a href=\"mailto:sales@axinar.com\" style=\"color:#fff;text-decoration:underline;\">sales@axinar.com<\/a><\/p>\n<\/section>\n\n","protected":false},"excerpt":{"rendered":"<p>Case study: AXINAR delivered 2-side CNC machining of an aluminum wheel hub and planet carrier for ARISTURTLE&#8217;s (AUTh) electric Formula Student race car.<\/p>\n","protected":false},"author":1,"featured_media":7596,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_eb_attr":"","site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center 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