Manufacturing of topology optimized soft magnetic core through 3D printing

    Research output: Contribution to conferenceOther conference contributionScientific

    Abstract

    Soft magnetic cores of electrical machines are typically made of electrical steel sheets by stacking them together. Recent development of powder bed processing of metal printing, e.g., through selective laser melting, is opening up interesting opportunities in the field of electromechanics, too [1], [2]. Selective laser melting is a process where objects are formulated by melting powder particles together layer by layer.Application of additive manufacturing in the production of soft magnetic cores, especially those of reluctance machines, appears interesting and potentially groundbreaking. Soft magnetic cores are used in electrical machines to guide the flux and to improve the performance. More comprehensive optimization of the magnetic circuit without the limitations of conventional subtractive and formative manufacturing methods can result in designs with significantly enhanced performance and notably lower material consumption and costs. The former is particularly true for the transverse flux reluctance machines [3].While the possible gains of 3D printing in electrical machine manufacturing have been lately addressed in some publications [2], the number of practical examples presented in the literature is rather limited. In this work, we study the manufacturing of the soft magnetic cores through selective laser melting and perform a characterization of the samples. Our main objectives are to explore: 1) how suitable typical materials of soft magnetic cores are for selective laser melting, 2) how well the characteristics of the printed samples meet the requirements of modern electrical machines.
    Original languageEnglish
    Publication statusPublished - 2016
    EventNAFEMS Exploring the Design Freedom of Additive Manufacturing through Simulation - Helsinki, Finland
    Duration: 22 Nov 201623 Nov 2016

    Seminar

    SeminarNAFEMS Exploring the Design Freedom of Additive Manufacturing through Simulation
    CountryFinland
    CityHelsinki
    Period22/11/1623/11/16

    Fingerprint

    Magnetic cores
    Printing
    Melting
    Topology
    Lasers
    3D printers
    Fluxes
    Powders
    Magnetic circuits
    Steel sheet
    Processing
    Metals
    Costs

    Keywords

    • additive manufacturing
    • soft magnetic materials
    • electrical machines
    • selective laser melting

    Cite this

    @conference{51579bec5f12496899c3038ed1e55ea4,
    title = "Manufacturing of topology optimized soft magnetic core through 3D printing",
    abstract = "Soft magnetic cores of electrical machines are typically made of electrical steel sheets by stacking them together. Recent development of powder bed processing of metal printing, e.g., through selective laser melting, is opening up interesting opportunities in the field of electromechanics, too [1], [2]. Selective laser melting is a process where objects are formulated by melting powder particles together layer by layer.Application of additive manufacturing in the production of soft magnetic cores, especially those of reluctance machines, appears interesting and potentially groundbreaking. Soft magnetic cores are used in electrical machines to guide the flux and to improve the performance. More comprehensive optimization of the magnetic circuit without the limitations of conventional subtractive and formative manufacturing methods can result in designs with significantly enhanced performance and notably lower material consumption and costs. The former is particularly true for the transverse flux reluctance machines [3].While the possible gains of 3D printing in electrical machine manufacturing have been lately addressed in some publications [2], the number of practical examples presented in the literature is rather limited. In this work, we study the manufacturing of the soft magnetic cores through selective laser melting and perform a characterization of the samples. Our main objectives are to explore: 1) how suitable typical materials of soft magnetic cores are for selective laser melting, 2) how well the characteristics of the printed samples meet the requirements of modern electrical machines.",
    keywords = "additive manufacturing, soft magnetic materials, electrical machines, selective laser melting",
    author = "Sini Mets{\"a}-Kortelainen and Tomi Lindroos and Mikko Savolainen and Antero Jokinen and Alejandro Revuelta and Antti Pasanen and Kimmo Ruusuvuori and Jenni Pippuri",
    year = "2016",
    language = "English",
    note = "NAFEMS Exploring the Design Freedom of Additive Manufacturing through Simulation ; Conference date: 22-11-2016 Through 23-11-2016",

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    Metsä-Kortelainen, S, Lindroos, T, Savolainen, M, Jokinen, A, Revuelta, A, Pasanen, A, Ruusuvuori, K & Pippuri, J 2016, 'Manufacturing of topology optimized soft magnetic core through 3D printing', NAFEMS Exploring the Design Freedom of Additive Manufacturing through Simulation, Helsinki, Finland, 22/11/16 - 23/11/16.

    Manufacturing of topology optimized soft magnetic core through 3D printing. / Metsä-Kortelainen, Sini; Lindroos, Tomi; Savolainen, Mikko; Jokinen, Antero; Revuelta, Alejandro; Pasanen, Antti; Ruusuvuori, Kimmo; Pippuri, Jenni (Corresponding author).

    2016. NAFEMS Exploring the Design Freedom of Additive Manufacturing through Simulation, Helsinki, Finland.

    Research output: Contribution to conferenceOther conference contributionScientific

    TY - CONF

    T1 - Manufacturing of topology optimized soft magnetic core through 3D printing

    AU - Metsä-Kortelainen, Sini

    AU - Lindroos, Tomi

    AU - Savolainen, Mikko

    AU - Jokinen, Antero

    AU - Revuelta, Alejandro

    AU - Pasanen, Antti

    AU - Ruusuvuori, Kimmo

    AU - Pippuri, Jenni

    PY - 2016

    Y1 - 2016

    N2 - Soft magnetic cores of electrical machines are typically made of electrical steel sheets by stacking them together. Recent development of powder bed processing of metal printing, e.g., through selective laser melting, is opening up interesting opportunities in the field of electromechanics, too [1], [2]. Selective laser melting is a process where objects are formulated by melting powder particles together layer by layer.Application of additive manufacturing in the production of soft magnetic cores, especially those of reluctance machines, appears interesting and potentially groundbreaking. Soft magnetic cores are used in electrical machines to guide the flux and to improve the performance. More comprehensive optimization of the magnetic circuit without the limitations of conventional subtractive and formative manufacturing methods can result in designs with significantly enhanced performance and notably lower material consumption and costs. The former is particularly true for the transverse flux reluctance machines [3].While the possible gains of 3D printing in electrical machine manufacturing have been lately addressed in some publications [2], the number of practical examples presented in the literature is rather limited. In this work, we study the manufacturing of the soft magnetic cores through selective laser melting and perform a characterization of the samples. Our main objectives are to explore: 1) how suitable typical materials of soft magnetic cores are for selective laser melting, 2) how well the characteristics of the printed samples meet the requirements of modern electrical machines.

    AB - Soft magnetic cores of electrical machines are typically made of electrical steel sheets by stacking them together. Recent development of powder bed processing of metal printing, e.g., through selective laser melting, is opening up interesting opportunities in the field of electromechanics, too [1], [2]. Selective laser melting is a process where objects are formulated by melting powder particles together layer by layer.Application of additive manufacturing in the production of soft magnetic cores, especially those of reluctance machines, appears interesting and potentially groundbreaking. Soft magnetic cores are used in electrical machines to guide the flux and to improve the performance. More comprehensive optimization of the magnetic circuit without the limitations of conventional subtractive and formative manufacturing methods can result in designs with significantly enhanced performance and notably lower material consumption and costs. The former is particularly true for the transverse flux reluctance machines [3].While the possible gains of 3D printing in electrical machine manufacturing have been lately addressed in some publications [2], the number of practical examples presented in the literature is rather limited. In this work, we study the manufacturing of the soft magnetic cores through selective laser melting and perform a characterization of the samples. Our main objectives are to explore: 1) how suitable typical materials of soft magnetic cores are for selective laser melting, 2) how well the characteristics of the printed samples meet the requirements of modern electrical machines.

    KW - additive manufacturing

    KW - soft magnetic materials

    KW - electrical machines

    KW - selective laser melting

    M3 - Other conference contribution

    ER -

    Metsä-Kortelainen S, Lindroos T, Savolainen M, Jokinen A, Revuelta A, Pasanen A et al. Manufacturing of topology optimized soft magnetic core through 3D printing. 2016. NAFEMS Exploring the Design Freedom of Additive Manufacturing through Simulation, Helsinki, Finland.