Calculating Iron Losses taking into account manufacturing ...mechanics and AC/DC module to calculate iron losses • Previous attempts at modelling this using Abaqus (for structural

Calculating Iron Lossestaking into account manufacturing processes

P. Goes, E. Hoferlin, M. De Wulf

COMSOL Users’ Conference Hannover, November 4-6 2008

Presented at the COMSOL Conference 2008 Hannover

24/11/2008 ArcelorMittal Research and Development Industry Gent 1

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ArcelorMittal Research Gent - Belgium

• Development of high qualityelectrical steels– High permeability– High saturation– Low loss

• Assisting customers in applying them– FE modelling


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Improving magnetic properties

0,0

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1,1

1,2

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2,1

10 100 1000 10000 Magnetic field ( A/m )

M

agne

tic p

olar

isat

ion

( T

esla

)

H

JRef. F 82631 N

50 Hz60 Hz100 Hz200 Hz400 Hz700 Hz

Mag

netic

indu

ctio

n(T

esla

)

Magnetic field (A/m)

• Increase saturation– Reduce Si and Al

• Increase permeability– Improve texture

saturation

permeability


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Improving losses

0,001

0,010

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1,000

10,000

100,000

1000,000

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8

Magnetic polarisation ( Tesla )

Spec

ific

loss

es

( W

/kg

)

W

J

700 Hz400 Hz200 Hz100 Hz60 Hz50 Hz

Spe

cific

loss

es(W

/kg)

Magnetic polarization (Tesla)

• Reduce eddy current loss– Reduce conductivity

• Increase Si and Al

– Reduce laminationthickness

– Improve coatings• Reduce hysteresis loss

– Improve microstructure

Losses


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Excellent steel can be ruined

• By mistreating it• E.g.

– Laser cutting with high heat input– Stressing during assembly

• E.g. shrink fitting the housing onto the stator

• Quantify– Measure the effects of mechanical stress– Determine mechanical stress through modelling


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Measuring magnetic properties under uniaxial stress


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Hysteresis loops: function of mechanical stress


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Hysteresis losses : function of mechanical stress


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Modelling it

• Calculate stresses using the structural mechanics module’s“plane strain” application mode (smpn)

• Modify the AC/DC module’s “perpendicular currents” applicationmode (emqa) to extend the material’s constitutive relations to include the stress dependence


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•Define motor geometry

•Add housing

•Include thermal expansion

•Solve for Plane Strain

•Get the Mises stress

•Stator only

•Line plot

Compressionin stator

Tension in housing


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Extend AC/DC emqa application mode

• Emqa:– Perpendicular induction currents– Vector potential, component Az only

• Constitutive relation:– Emqa contains: H = f(|B|).eB– We need: H = f(|B|,S).eB


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Adding the H(B,S) function

• B(H) for different S values• B(H,S) function• Emqa needs H(B,S), not B(H,S)• So invert the function• Define it as an interpolation

function0 500 1000 15000

0.5

1

1.5

2

H[A/m]

B[T

]

s=0MPas=20MPas=40MPa

0200

400600

8001000

-60

-40

-20

00

0.5

1

1.5

2

H[A/m]S[MPa]

B[T

]

00.5

11.5

2

-60

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-20

00

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B[T]S[MPa]

H[A

/m]


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HB-function in the m-file

% Functionsclear fcnsfcns{1}.type='interp';fcns{1}.name='myHB2D';fcns{1}.method='linear';fcns{1}.extmethod='extrap';fcns{1}.x={'0.1','0.119047167667739','0.138094335335478', ...'0.157141503003218','0.176188670670957','0.195235838338696', ...'0.214283006006435','0.233330173674175','0.252377341341914', ...'0.271424509009653','0.290471676677392','0.309518844345131', ...'0.328566012012871','0.34761317968061','0.366660347348349', ...'0.385707515016088','0.404754682683828','0.423801850351567', ...'0.442849018019306','0.461896185687045','0.480943353354784', ...'0.499990521022524','0.519037688690263','0.538084856358002', ...'0.557132024025741','0.57617919169348','0.59522635936122', ...


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Edit the equation system

H = myHB2D(normB_emqa,mises_smpn)


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And solve…

Use currentsolution for the stress values


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Scripted…

% solve first the smpn to determine the stresses% Solve problemfem.sol=femstatic(fem, ...

'solcomp',{'v','u'}, ...'outcomp',{'v','u'}, ...'ntol',1e-006);

% Save current fem structure for restart purposesfem0=fem;

% solve then the emqa to determine the magnetic induction% Solve problemfem.sol=femstatic(fem, ...

'u',fem0.sol, ...'solcomp',{'lm1','Az'}, ...'outcomp',{'v','u','lm1','Az'}, ...'ntol',1e-006);


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Postprocessing


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Conclusion

• It proved reasonably straightforward to use the structuralmechanics and AC/DC module to calculate iron losses

• Previous attempts at modelling this using Abaqus (for structuralmechanics) and FLUX2D (for electromagnetics) were veryelaborate and time-consuming

• We intend to perform similar simulations modelling other factors influencing the magnetic properties and losses, e.g. cutting edgeeffects


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Thank you !

Any questions ?

Documents

Calculating Iron Losses taking into account manufacturing ...mechanics and AC/DC module to calculate iron losses • Previous attempts at modelling this using Abaqus (for structural