Browse Publications Technical Papers 2024-28-0006

Study of effect on structural strength of locally strengthened rotor lamination stack through virtual validation. 2024-28-0006

Rotor and Stator are the key constituents of an electric motor that are made of several laminates punched from a sheet metal and stacked together. The rotor stack is inserted with magnets at the punched-out pockets and is assembled with a shaft via press fitting. Rotor assembly being the rotating part of an E-Motor is subjected to centrifugal loads due to masses of magnets, lamination stack and shaft rotating at high speeds, temperatures and assembling loads because of which rotor laminates experience failures as the high strains develop in the regions on the laminate that support magnets. Typically, these high strain locations are the sections of the magnet pockets one on the outer diameter of the laminate and the other at the sections between the magnet pockets. Traditionally, these high strains are addressed by increasing the area of these sections, but this has a detrimental effect on the electromagnetic performance. Instead of increasing the area of these sections, the proposed solution of Hall Petch or Grain boundary strengthening influences localized strength of these sections on the lamination stack by altering the grain size based. Along with this, Nitriding can be used to harden the localized sections on the magnet pockets of the lamination stack which will increase the local strength. In the current study, an approach for investigating the effect of both these processes on the improvement in strength using Finite Element Analysis is put forward. A comparison is made between the locally strengthened and non-strengthened rotor laminate in terms of deformations, stresses, and strains. Further, a parametric analysis is performed to find out the optimum depth of hardening that corresponds to the desired strength.


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