Cold-Spray Additive Manufacturing of a Petal-Shaped Surface Permanent Magnet Traction Motor

Singh, Sumeet; Payarou, Tamanwè; Boby, Mathews; Lamarre, J.-M.; Bernier, Fabrice; Ibrahim, Maged Hamada; Pillay, Pragasen

doi:10.1109/tte.2022.3233779

Cited by 4 publications

(2 citation statements)

References 25 publications

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“…In addition, the additive manufacturing of structural parts has also been considered in this project. The additive manufacturing of the hard magnetic parts has been discarded because, for the time being, except for very specific AM processes such as cold spray [37][38][39], the magnetic performance (coercivity, remanence) of the resulting magnets is far from that of conventional sintered rare earth magnets [40][41][42][43]. Additive manufacturing of copper coils has also not been considered due to the small size of the actuator and the high number of turns that the near-zero speed requires to achieve the desired voltage.…”

Section: Motor Brake and Resolvermentioning

confidence: 99%

Electric Aerospace Actuator Manufactured by Laser Powder Bed Fusion

Lizarribar,

Prieto,

Aristizabal

et al. 2023

Aerospace

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Recent advances in manufacturing methods have accelerated the exploration of new materials and advantageous shapes that could not be produced by traditional methods. In this context, additive manufacturing is gaining strength among manufacturing methods for its versatility and freedom in the geometries that can be produced. Taking advantage of these possibilities, this research presents a case study involving an electric aerospace actuator manufactured using additive manufacturing. The main objectives of this research work are to assess the feasibility of additively manufacturing electric actuators and to evaluate potential gains in terms of weight, volume, power consumption and cost over conventional manufacturing technologies. To do so and in order to optimise the actuator design, a thorough material study is conducted in which three different magnetic materials are gas-atomised (silicon iron, permendur and supermalloy) and test samples of the most promising materials (silicon iron and permendur) are processed by laser powder bed fusion. The final actuator design is additively manufactured in permendur for the stator and rotor iron parts and in 316L stainless steel for the housing. The electric actuator prototype is tested, showing compliance with design requirements in terms of torque production, power consumption and heating. Finally, a design intended to be manufactured via traditional methods (i.e., punching and stacking for the stator laminations and machining for the housing) is presented and compared to the additively manufactured design. The comparison shows that additive manufacturing is a viable alternative to traditional manufacturing for the application presented, as it highly reduces the weight of the actuator and facilitates the assembly, while the cost difference between the two designs is minimal.

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Section: Motor Brake and Resolvermentioning

confidence: 99%

Electric Aerospace Actuator Manufactured by Laser Powder Bed Fusion

Lizarribar,

Prieto,

Aristizabal

et al. 2023

Aerospace

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“…Ge et al [4] realized the mass reduction of the car seat greatly by changing the material and optimizing the topology structure. However, there are few researches on the parts with low mass and more concentrated force in the automobile [21].…”

Section: Introductionmentioning

confidence: 99%

A Case Study on Structural Optimization Design of Shock Absorber Brackets in Automobile Suspension

Liu,

Pan,

Cui

et al. 2023

IEEE Access

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For connecting plate of shock absorber bracket in automobile suspension, lightweight requirement is a mainstream design tendency. Based on the principle of maximum stiffness, this work conducts a case study on structural optimization design of shock absorber brackets in automobile suspension. Firstly, both TI-6AL-4V alloy material and the motion simulation function of Inspire software are employed for use in the investigation. It is expected to simulate the motion state of automobile shock absorber extract the load effectively. Hence, the load is applied to the finite element model of the shock absorber connecting plate as the boundary condition. Then, the software is used to explore the shape control method for the connecting plate under different optimization objectives. Also, the topology optimization is carried out on the premise of 2-factor 4-level orthogonal test, and the extrusion is used as the shape control method. Finally, using 8 mm thickness as constraint condition, the optimized structure with safety factor of 2.3 and weight loss rate of 72.6% can be obtained.

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Additive manufacturing of Al thick wall using high-pressure cold spraying: issues of porosity and mechanical properties

Sokore,

Li,

et al. 2024

Int J Adv Manuf Technol

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Cold-Spray Additive Manufacturing of a Petal-Shaped Surface Permanent Magnet Traction Motor

Cited by 4 publications

References 25 publications

Electric Aerospace Actuator Manufactured by Laser Powder Bed Fusion

Electric Aerospace Actuator Manufactured by Laser Powder Bed Fusion

A Case Study on Structural Optimization Design of Shock Absorber Brackets in Automobile Suspension

Additive manufacturing of Al thick wall using high-pressure cold spraying: issues of porosity and mechanical properties

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