How non-conventional machining affects the surface integrity and magnetic properties of non-oriented electrical steel

Winter, K.; Liao, Zhirong; Ramanathan, Ramkumar; Axinte, Dragoş; Vakil, Gaurang; Gerada, Christopher

doi:10.1016/j.matdes.2021.110051

Cited by 33 publications

(12 citation statements)

References 35 publications

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“…However, it should be noted that such a significant width of the damaged zone is not confirmed in other works. It was stated that the influence of the abrasive waterjet cutting on electromagnetic properties is minimal and can essentially be neglected in the case of the non-alloyed grade [47,72,73].…”

Section: Simulation Models Of Changes In Electromagnetic Properties C...mentioning

confidence: 99%

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

2023

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The global drive to reduce energy consumption poses new challenges for designers of electrical machines. Losses in the core are a significant part of losses, especially for machines operating at an increased rotational speed powered by PWM inverters. One of the important problems when calculating core losses is considering the effect of material degradation due to mechanical or laser cutting. To this aim, this paper analyzes and summarizes the knowledge about the sources of material property deterioration and ways of describing this phenomenon. The cited results of material tests indicate the lack of unequivocal relationships allowing us to estimate the degree of material damage and the resulting deterioration of material properties. The main task of this article is to present the state of knowledge on the possibility of taking into account the impact of cutting the core sheets of electric motors on core losses and their impact on the efficiency of the machine. This is a significant problem due to the need to design and manufacture energy-saving electric motors powered with a voltage of 20 to 350 Hz, whose magnetic cores are made of laminates. However, the performed analysis indicates the most important parameters of the cutting process, affecting the degree of material structure destruction. The method of the solution proposed by the authors for core punching and laser cutting, illustrated with a practical example, is also presented.

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Section: Simulation Models Of Changes In Electromagnetic Properties C...mentioning

confidence: 99%

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

2023

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“…Both cutting technologies induce an important deterioration of macroscopic properties of electrical steel in comparison to less damaging methods such as waterjet (WJ) [ 26 ] and electrical discharge machining (EDM) [ 27 , 28 ]. Winter et al [ 29 ] analyzed the effect of pulsed laser, abrasive waterjet, wire electrical discharge machining, and continuous wave laser methods on the magnetic properties of non-oriented 2.4 wt.% Si ring samples with 0.2 mm thickness. The main conclusion was that the abrasive waterjet machining determined the lowest core losses and applied magnetic field strength since the continuous wave laser induced the highest core losses and lowest saturation magnetic flux density.…”

Section: Introductionmentioning

confidence: 99%

“…The highest magnetic permeability value and the lowest losses were measured in the case of photo corrosion cut samples, and the laser-cut materials exhibited the highest coercive force and the lowest remanent magnetic flux density. The previously presented analyses [ 22 , 27 , 28 , 29 ], evidenced that the wire cut method is characterized by a minimum impact on the magnetic properties of the electrical steel but concomitantly showed its main drawbacks such as sample burned coating due to local high-temperature apparition [ 30 ] and low cutting speed [ 31 ]. Paltanea et al [ 32 ] compared mechanical and waterjet cutting techniques’ effects on NO FeSi with 0.5 mm and 0.65 mm thicknesses.…”

Section: Introductionmentioning

confidence: 99%

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review

Paltanea,

Manescu (Paltanea),

Antoniac

et al. 2024

Materials

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The problem of energy consumption reduction establishes important challenges for electric motor producers in the framework of new international regulations regarding the conditions that must be accomplished by motors in the near future. One of the most important topics is related to the core loss decrease directly linked to the effect of electrical steel degradation induced by the cutting technology. Understanding exactly how this phenomenon occurs by analyzing the chemical, mechanical, crystallographic, magnetic domain, and magnetic properties is of utmost importance when manufacturing processes must be changed and adapted to a new market characterized by high-efficiency motors. Today, mechanical and laser cutting technologies are the most used because of their reduced price and high-speed process. Still, unfortunately, these methods are not the best due to the fact that they lead, in most cases, to a high value of magnetic core losses, low electromagnetic torque, and hence reduced efficiency. This review paper shows that non-conventional technologies such as water jetting and electroerosion could be applied if proper modifications are added. This paper’s main idea is to present a comprehensive study regarding the impact of cutting technologies on microhardness and residual stresses, crystallographic texture, magnetic domain structure, and magnetic properties of some non-oriented electrical steels used in motor production. It provides a detailed analysis of the abovementioned aspects by including the authors’ research and findings in the wider context of other research group contributions. It also offers a general idea of the mechanisms present at the macro- and microscopic levels. The readers can find some of the most used analytical models, including the cutting process’s damaged effect on the magnetic properties’ variation based on a simple mathematical approach and examples of finite element modeling performed on real motor designs implemented in various programs. Last but not least, some practical implementations of the cutting procedure’s influence on motor working conditions are presented in the last section of the paper. It provides an up-to-date analysis regarding how the cutting method should be included in high-efficiency motor production by emphasizing the importance of the topic and identifying where supplementary research must be undertaken. From the investigated literature, by analyzing specific sample geometries associated with different characterization methods, it can be concluded that all the cutting technologies have an important contribution to the mechanical and magnetic quantities. When the magnetic core of an electric motor is produced through non-conventional methods, the overall influence of the cutting procedure has a low percentage in the motor efficiency, as presented in this paper.

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“…Mechanical cutting such as blanking or shear-slitting requires precise control of many processing parameters depending on the thickness of the material being shaped. These are most often cutting speed [3], cutting clearance [4], rounding of the edges of cutting tools, rake angle of the knife (guillotining), or vertical clearance (shear-sitting) [5]. If there is no knowledge of how to select these parameters, the products obtained after the process may have numerous defects, such as roll-over and wavy cut edges, burrs, and edge cracks [6].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Process and Results of High-Pressure Abrasive Water Jet Multilayer Cutting of Electrical Steel

Szada-Borzyszkowska,

Kacalak,

Bohdal

et al. 2023

Materials

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Electrical steels are magnetically soft materials and are widely used in the electrical industry for the construction of power transformer cores, distribution transformers, current transformers, and voltage transformers. An important parameter of electrical components, which determines the efficiency of devices, is energy loss during remagnetization. Energy losses are caused by eddy currents, hysteresis, and magnetic delay associated with the low quality of the cut edge after the cutting of steels, and material deformations and excessive stress concentration in the surrounding cutting zones. Common techniques for cutting electrical materials in industrial lines include mechanical cutting and laser cutting. Work has shown that mechanical cutting of electrical steel single layers results in the occurrence of large deformation zones, and in cutting processes with a high-pressure abrasive water jet (AWJ), significant uplifts of material and burrs at the bottom edges of sheets occur. The problem of increasing the cutting quality was solved through selecting the stream parameters for bundle cutting of electrical steels. It has been shown that in the process of cutting electrical sheet bundles, the height of burrs on the cut surface and the zone of plastic deformation are reduced. The work also presents comparison and analysis of characteristic features of the cut edge of electrical sheets obtained through high-pressure abrasive water jet and mechanical cutting processes. The influence of the type and processing parameters on the characteristic features of the material hysteresis loop was determined.

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How non-conventional machining affects the surface integrity and magnetic properties of non-oriented electrical steel

Cited by 33 publications

References 35 publications

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review

Analysis of the Process and Results of High-Pressure Abrasive Water Jet Multilayer Cutting of Electrical Steel

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