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Modelled optimisation approaches for laser cutting sheets simultaneously applied to EV component production.

Nathan Dodd1,2,3, Russell Goodall4, Erica Ballantyne2

  • 1Department of Mechanical Engineering, The University of Sheffield, Sir Frederick Mappin Building, Sheffield, United Kingdom.

Plos One
|October 21, 2022
PubMed
Summary

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Structural Steel Products01:24

Structural Steel Products

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Structural steel products are created within a structural mill. The process begins with a beam blank that is reheated and then fed through a series of rollers. These rollers progressively shape the metal into its final form. Adjusting the spacings between the rollers allows for the production of different sections with the same nominal dimensions.
Once shaped, the steel's final form emerges as a continuous length, which is then segmented by a hot saw into manageable pieces. These segments...
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This summary is machine-generated.

Polystromata laser cutting offers a cost-effective alternative to stamping for electric vehicle components. While slower, this advanced laser cutting method can reduce manufacturing costs by 37%.

Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Automotive Manufacturing

Background:

  • Stamping is the traditional method for mass-producing thin steel components like stators and rotors.
  • Current laser cutting is flexible but less efficient for mass production.
  • Electric automotive sector requires efficient and cost-effective component manufacturing.

Purpose of the Study:

  • To assess the potential of simultaneous multi-sheet laser cutting (polystromata cutting) as an alternative to stamping.
  • To evaluate and compare the manufacturing performance of stamping, traditional laser cutting, and polystromata laser cutting.
  • To develop an optimization methodology for polystromata laser cutting processes.

Main Methods:

  • Numerical modeling was employed to simulate and analyze manufacturing performance.

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  • Comparison of cost-effectiveness and production time between stamping, traditional laser cutting, and polystromata laser cutting.
  • Assessment of manufacturing setup variations on polystromata cutting efficiency.

    • Main Results:

    • Polystromata laser cutting demonstrated a 37% cost reduction compared to stamping.
    • Polystromata cutting was 79% slower than stamping for producing stator stacks.
    • Process optimization for polystromata cutting is complex and highly dependent on the manufacturing setup.

    Conclusions:

    • Polystromata laser cutting presents a viable, cost-saving alternative for mass production of thin steel automotive components.
    • Further research and optimization are needed to address the slower production speed and setup variability.
    • Developing best-practice methodologies is crucial for realizing the full potential of polystromata laser cutting.