A new approach in the production of electrical motors using only machining processes

Abstract

As a new possibility of producing the electrical steel sheets of electrical motors, a motor sample was produced using just machining processes such as turning, drilling, milling and sawing. Therefore several strategies in the production flow were considered and tested. The idea behind this method of producing a motor is to avoid the expensive cutting processes and material deterioration. On the one hand punching, as the most common cutting method of electrical steel sheet, is only cheap for useful for high volume and not for samples or small series, on the other hand laser cutting, which is suitable for single production of motors, requires expensive tools. Moreover punching and laser cutting deteriorate the electrical steel sheets close to the cutting edges. Since machining processes can be adjusted in speed and cooled with a fluid, a less distinctive effect can be assumed.

Material Tradeoff of Rotor Architecture for Lightweight Low-Loss Cost-Effective Sustainable Electric Drivetrains

“…These materials encompass a wide range of components, from static elements like housings and bearings to active electromagnetic components like laminations, conductors, and permanent magnets. The optimization of these materials is integral to achieving the desired balance between machine performance and manufacturing costs [2][3][4][5].…”