Analysis of Electric Motor Magnetic Core Loss under Axial Mechanical Stress

The electrical machine core is subjected to mechanical stresses during manufacturing processes. These stresses include radial, circumferential and axial components that may have significant influence on the magnetic properties and it further leads to increase in iron loss and permeability in the stator core. In this research work, analysis of magnetic core iron loss under axial mechanical stress is investigated. The magnetic core is designed with Magnetic Flux Density (MF) ranging from 1.0 T to 1.5 T with estimated dimensions under various input voltages from 5 V to 85 V. Iron losses are predicted by the axial pressure created manually wherever required and is further applied to the designed magnetic core in the range of 5 MPa to 50 MPa. Finite element analysis is employed to estimate the magnetic core parameters and the magnetic core dimensions. A ring core is designed with the selected dimensions for the experimental evaluation. The analysis of iron loss at 50Hz frequency for non-oriented electrical steel of M400-50A is tested experimentally using the Epstein frame test and force-fit setup test. Experimental evaluation concludes that the magnetic core saturates when it reaches its knee point of the B-H curve of the chosen material and also reveals that the axial pressure has a high impact on the magnetic properties of the material.