MANUFACTURING EFFECTS IN ELECTRICAL STEELS FOR AUTOMOTIVE DRIVES

电工钢是所有电机和发电机中的活性材料，其性能对这些设备的性能和效率至关重要。因此，它们是实现运输部门电气化和可再生能源发电的关键材料。这些材料的加工非常复杂，但由于讨论的主要驱动因素，这些材料的加工仍在以加速的速度发展。这些材料的性能是高度非线性的，对广泛的工艺、制造和操作参数很敏感，因此很难预测完成的器件的性能。其中最具挑战性的是了解制造工艺对电工钢片磁性能的影响。这一过程包括切割、冲压、连接、缠绕和收缩装配，所有这些都会给材料带来机械损伤和/或应力。卡迪夫大学之前曾率先推出了一种局部磁测量技术，该技术用于评估切割边缘的可行性在最近与Cogent Power的合作中得到了证明。有人建议改进这项技术，并将其应用于一系列受模拟和真实制造工艺影响的当前和实验电工钢，以便充分描述它们的响应。这将用于开发机械过程的物理模型，并将其与磁性相耦合，从而可以创建计算机模拟，从而允许对材料和制造过程两者进行优化。与此同时，还将开发一种计算效率高的工程模型，以纳入有限元设计包，以便机器设计者在设计过程中考虑这些重要影响。该项目还将建立在加的夫大学化学和工程学院(再次与Cogent Power合作)进行的工作的基础上，以开发增强的和新的涂层技术。这项工作开发和提出的涂层将通过制造过程对其性能进行调查，以及它们在减轻一些加工影响方面的可能作用。通过粘结、高强度或工具润滑提供额外性能的功能涂层将被彻底研究。

Electrical steels are the active material in all electric motors and generators and their properties are crucial to the performance and efficiency of these devices. As such they are critical materials for the delivery of the electrification of the transport sector and renewable energy generation. The processing of these materials is highly complex but continues to develop at an accelerating rate due to the primary drivers discussed. The properties of these materials are highly non-linear and sensitive to a wide range of processing, manufacturing and operational parameters such that the performance of completed device is difficult to predict. The most challenging of these is to understand the influence of the manufacturing process on the magnetic properties of the electrical steel laminations. The process consists of cutting, stamping, joining, winding and shrink fitting all of which introduce mechanical damage and/or stress into the material. Cardiff University has previously pioneered a local magnetic measurement technique whose viability for the assessment of cut edges was proven in a recent collaboration with Cogent Power. It is proposed to refine this technique and apply it to a range of current and experimental electrical steels subject to simulated and real manufacturing processes in order to fully characterise their response. This will be used to develop a physical model of the mechanical processes and couple this to the magnetic properties such that computer simulations may be created allowing the optimisation of both the materials and the manufacturing process. In parallel to this a computationally efficient engineering model will be developed for incorporation into finite element design packages such that machine designers can take these important effects into account during the design process.The project will also build on work conducted within the schools of Chemistry and Engineering at Cardiff University (again in collaboration with Cogent Power) to develop enhanced and new coating technologies. Coatings developed and proposed by this work will be investigated for their performance through the manufacturing process and their possible role in mitigating some of the effects of processing. Functional coatings offering additional performance through bonding, high strength or tool lubrication will be thoroughly investigated.