Abstract
Additive manufacturing has many advantages over traditional manufacturing methods and has been increasingly used in medical, aerospace, and automotive applications. The flexibility of additive manufacturing technologies to fabricate complex geometries from copper, polymer, and ferrous materials presents unique opportunities for new design concepts and improved machine power density without significantly increasing production and prototyping cost. Topology optimization investigates the optimal distribution of single or multiple materials within a defined design space, and can lead to unique geometries not realizable with conventional optimization techniques. As an enabling technology, additive manufacturing provides an opportunity for machine designers to overcome the current manufacturing limitation that inhibit adoption of topology optimization. Successful integration of additive manufacturing and topology optimization for fabricating magnetic components for electrical machines can enable new tools for electrical machine designers. This article presents a comprehensive review of the latest achievements in the application of additive manufacturing, topology optimization, and their integration for electrical machines and their magnetic components.
Highlights
The electrical machine is considered a key part in electric drives, which account for approximately 50% to 70% of electricity usage in the EU and the United States [1]
This paper presents the current research and trends on applications of additive manufacturing, topology optimization, and their integration toward magnetic components in electrical machines
Additive manufacturing provides topology optimization a method to fabricate unique 3D geometries that are challenged to be manufactured via conventional methods
Summary
The electrical machine is considered a key part in electric drives, which account for approximately 50% to 70% of electricity usage in the EU and the United States [1]. Recent technological advancements in AM allow the use of a wide range of materials, including copper [4,5], ceramics, and magnetic materials [6] These materials are key for manufacturing electrical machine components. Recent applications of AM toward electrical machine components, especially in ferromagnetic materials and permanent magnet, have revitalized the adoption of topology optimization. Featured in more detail is the current state of the art in integration of additive manufacturing and topology optimization, especially toward iron cores and permanent magnets in electrical machines. These case studies highlight the novel integration between these emerging technologies and show their potential in future design of electrical machines
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