Modeling of 3D Printable Electrical Machineries Ferromagnetic Parts

TL;DR

This paper introduces a 3D printable model for ferromagnetic cores in electrical transformers, evaluating different materials and shapes to optimize magnetic performance and reduce losses using finite element simulations.

Contribution

It presents a novel 3D printable design for transformer cores, analyzing material and shape effects on magnetic efficiency through simulation.

Findings

U-I shaped transformer offers higher frequency operation feasibility.

Ferrite material shows promising magnetic properties for 3D printed cores.

3D printing can potentially reduce manufacturing costs and improve design flexibility.

Abstract

The electrical machinery core is formed with a ferromagnetic material that offers high magnetic properties. As ferromagnetic materials have high relative magnetic permeability, they are important in the formation of electromagnetic device cores. Conventional subtractive and powder metallurgy methods for fabrication electrical machineries offer significant core losses and reduce magnetic flux density and magnetic permeability. With the advancement of technology, the limitation of the traditional process can be overcome by using the additive manufacturing process. Hence, this paper proposes a 3D printable model of two types of single-phase transformers, referred to as E-I shape and U-I shape transformers respectively. Possibilities of designing the electrical machinery part which has a ferromagnetic core are investigated. The efficiency of the transformers is evaluated in terms of magnetic flux density distribution and volumetric loss density based on the results of a large number of Finite element simulation methods under various operating situations on COMSOL. The performance of various ferromagnetic materials such as Soft Iron (Fe) and Ferrite (Fe2O3) on the transformer core is evaluated. This analysis reveals that if U-I shaped transformer can be made from 3D printing, it will be the best feasible structure for higher operating frequency.