Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor
Additive manufacturing is acknowledged as a key enabling technology, although its adoption is still constrained to niche applications. A promising area for this technology is the production of electrical machines (EMs) and/or their main components (e.g. magnetic cores, windings, heat exchangers, etc...
| Main Authors: | , , , , , , , |
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| Format: | Article |
| Language: | English |
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Institute of Electrical and Electronics Engineers Inc.
2020
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| Online Access: | https://eprints.nottingham.ac.uk/64183/ |
| _version_ | 1848800099765846016 |
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| author | Gargalis, Leonidas Madonna, Vincenzo Giangrande, Paolo Rocca, Roberto Hardy, Mark Ashcroft, Ian Galea, Michael Hague, Richard |
| author_facet | Gargalis, Leonidas Madonna, Vincenzo Giangrande, Paolo Rocca, Roberto Hardy, Mark Ashcroft, Ian Galea, Michael Hague, Richard |
| author_sort | Gargalis, Leonidas |
| building | Nottingham Research Data Repository |
| collection | Online Access |
| description | Additive manufacturing is acknowledged as a key enabling technology, although its adoption is still constrained to niche applications. A promising area for this technology is the production of electrical machines (EMs) and/or their main components (e.g. magnetic cores, windings, heat exchangers, etc.) due to the potential of creating lightweight, highly efficient rotating motors, suitable for applications requiring a low moment of inertia. This work investigates the readiness of metal additive manufacturing, specifically Laser Powder Bed Fusion (LPBF), applied to the field of EMs to bridge the gaps of how to use this technological approach in this field. A soft magnetic material featuring high silicon content (Fe-5.0%w.t.Si) has been developed for LPBF and a rotor has been 3D-printed for a switched reluctance machine. The printed rotor was assembled into a conventionally laminated stator and the performance of the whole machine was evaluated. Its performance was compared against an identical machine equipped with a laminated rotor of the same dimensions made of conventional non-oriented silicon steel. A comparative study was carried out through both finite element simulations and experimental tests. The efficiency of the two machines was assessed together with the principal electrical and mechanical quantities under several operating conditions. |
| first_indexed | 2025-11-14T20:46:11Z |
| format | Article |
| id | nottingham-64183 |
| institution | University of Nottingham Malaysia Campus |
| institution_category | Local University |
| language | English |
| last_indexed | 2025-11-14T20:46:11Z |
| publishDate | 2020 |
| publisher | Institute of Electrical and Electronics Engineers Inc. |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | nottingham-641832020-12-31T06:01:28Z https://eprints.nottingham.ac.uk/64183/ Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor Gargalis, Leonidas Madonna, Vincenzo Giangrande, Paolo Rocca, Roberto Hardy, Mark Ashcroft, Ian Galea, Michael Hague, Richard Additive manufacturing is acknowledged as a key enabling technology, although its adoption is still constrained to niche applications. A promising area for this technology is the production of electrical machines (EMs) and/or their main components (e.g. magnetic cores, windings, heat exchangers, etc.) due to the potential of creating lightweight, highly efficient rotating motors, suitable for applications requiring a low moment of inertia. This work investigates the readiness of metal additive manufacturing, specifically Laser Powder Bed Fusion (LPBF), applied to the field of EMs to bridge the gaps of how to use this technological approach in this field. A soft magnetic material featuring high silicon content (Fe-5.0%w.t.Si) has been developed for LPBF and a rotor has been 3D-printed for a switched reluctance machine. The printed rotor was assembled into a conventionally laminated stator and the performance of the whole machine was evaluated. Its performance was compared against an identical machine equipped with a laminated rotor of the same dimensions made of conventional non-oriented silicon steel. A comparative study was carried out through both finite element simulations and experimental tests. The efficiency of the two machines was assessed together with the principal electrical and mechanical quantities under several operating conditions. Institute of Electrical and Electronics Engineers Inc. 2020-11-11 Article PeerReviewed application/pdf en cc_by https://eprints.nottingham.ac.uk/64183/1/Gargalis-2020-Additive-manufacturing-and-testing-.pdf Gargalis, Leonidas, Madonna, Vincenzo, Giangrande, Paolo, Rocca, Roberto, Hardy, Mark, Ashcroft, Ian, Galea, Michael and Hague, Richard (2020) Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor. IEEE Access, 8 . pp. 206982-206991. ISSN 2169-3536 Additive manufacturing; laser powder bed fusion; soft magnetic material; silicon steel; switched reluctance machine; 3D printed rotor; finite element simulation; AC electric drives. http://dx.doi.org/10.1109/ACCESS.2020.3037190 doi:10.1109/ACCESS.2020.3037190 doi:10.1109/ACCESS.2020.3037190 |
| spellingShingle | Additive manufacturing; laser powder bed fusion; soft magnetic material; silicon steel; switched reluctance machine; 3D printed rotor; finite element simulation; AC electric drives. Gargalis, Leonidas Madonna, Vincenzo Giangrande, Paolo Rocca, Roberto Hardy, Mark Ashcroft, Ian Galea, Michael Hague, Richard Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| title | Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| title_full | Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| title_fullStr | Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| title_full_unstemmed | Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| title_short | Additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| title_sort | additive manufacturing and testing of a soft magnetic rotor for a switched reluctance motor |
| topic | Additive manufacturing; laser powder bed fusion; soft magnetic material; silicon steel; switched reluctance machine; 3D printed rotor; finite element simulation; AC electric drives. |
| url | https://eprints.nottingham.ac.uk/64183/ https://eprints.nottingham.ac.uk/64183/ https://eprints.nottingham.ac.uk/64183/ |