RESUMEN
The manufacturing processes of electrical machines may lead to significant degradation of the magnetic properties of their magnetic core (stator, rotor) performances and, as a consequence, to a decrease of their energy efficiency. While the effects of some processes (cutting, welding ) are widely discussed in the literature, this is not the case with the compaction process although it is systematically used to maintain the assembly of electrical steel sheets that compose the magnetic circuits. In addition to the conventional one, a specific compaction process exists for high-power electrical machines. After an introduction, the paper firstly deals with the two studied processes (conventional, specific). Then, an experimental mock-up to study the impact of the two configurations on the magnetic properties (iron losses, normal magnetization curve) is presented. This mock-up is the first, in the literature, that allows to study the effect of a controlled compaction mechanical stress on magnetic properties. Obtained results in both configurations highlight a magneto-mechanical effect that is not reported in the literature where these effects are commonly considered following in-plane mechanical stresses. This paper presents a magneto-mechanical model, taking into account the compaction stress effect, as well as a modelling protocol to model the effect of 3D mechanical stress on magnetic properties, which has never been done in the literature.
RESUMEN
Nowadays, additive manufacturing of metallic materials is most often carried out using expensive and complex tools that leave the user with limited control and no possibility of modification. In order to make the printing of metal parts more accessible to small structures but also better suited for academic research, the use of a mixture of thermoplastic polymer and metal powder is a good solution as many granular feedstocks already exist for Metal Injection Molding applications. To perform the shaping process, the Fused Granular Fabrication 3D printing technology is set up by diverting the use of a feedstock in the form of pellets that are directly inserted into the print head. This solution, which is less costly, is implemented here by modifying a mid-range printer, the Tool Changer from E3D, and by making the hardware and software adaptations to mount a compact granulates extruder on it, which is also available on the market. The polymer portion present in the green part can then be removed in order to perform the heat treatments that will densify the powder by sintering and give a fully metallic dense object.
RESUMEN
NdFeB permanent magnets (PMs) are widely used in high performance electrical machines, but their relatively high conductivity subjects them to eddy current losses that can lead to magnetization loss. The Finite Element (FE) method is generally used to quantify the eddy current loss of PMs, but it remains quite difficult to validate the accuracy of the results with complex devices. In this paper, an experimental test device is used in order to extract the eddy current losses that are then compared with those of a 3D FE model.
