Project 5: Modeling of soft magnetic materials under consideration of the relevant parameters for electric drives

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The focus of new developments in the area of energy-efficient machines is in particular on an increase in the power density and the efficiency. The soft-magnetic material at the core of the machines is the central component of the energy conversion from electrical to mechanical energy. In order to achieve a noticeable increase in the performance of the machine even at high speeds, the methodological improvement is an effective strategy on the part of the material. Both target values, losses and magnetizability are influenced by the design of the machine in combination with the soft-magnetic materials used. As the potential for efficiency gains is largely exhausted by design measures, the focus of current research and development is on material design. However, not only the mechanical and magnetic properties of the strip material are decisive, but also the processing which, by its influence on the magnetic behavior of the material, requires a reciprocal view of material production and processing.The main research work of the IEM in the first three project years of the research group is the development of a semi-physical correlation model as an interface between relevant microstructural parameters and macroscopic, measurable magnetic and mechanical properties of non-grain oriented electrical steel.The sub-project-wide overall objectives of the requested second funding phase of the research group aim at a holistic understanding of the entire non-grain oriented electrical steel production and processing, with the aid of which a control of the processes and, thus, a tailored use for electric drives will be made possible. The transferability, which is examined by means of a new alloy concept, the validation of the modeling as well as the application-optimized adaption of the production strategies by the continuous modeling of the process chain up to the application in electrical machines are the core task of the cooperation of the project partners. In this context, the IEM develops the key aspects of the metrological characterization of the produced electrical steel samples, the coupling of mechanical and magnetic simulation taking into account the material, the quantitative imaging of the microstructure and the processing influence, and the determination and production of specific material microstructures for different operating points. At the end of the project, the design, construction and testing of a demonstrator will be evaluated and validated for the microstructures, components, models used and their application.