Abstract
A motor core is formed by stacking iron sheets on top of each other. Traditionally, there are two stacking methods, riveting and welding, but these two methods will increase iron loss and reduce usage efficiency. The use of resin is the current developmental trend in the technology used to join iron sheets, which has advantages including lowering iron loss, smoothing magnetic circuits, and generating higher rigidity. The flow behavior of resin in gluing technology is very important because it affects the dipping of iron sheets and the stacking of iron sheets with resin. In this study, a set of analytical processes is proposed to predict the flow behavior of resin through the use of computer-aided engineering (CAE) tools. The research results are compared with the experimental results to verify the accuracy of the CAE tools in predicting resin flow. CAE tools can be used to predict results, modify modules for possible defects, and reduce the time and costs associated with experiments. The obtained simulation results showed that the filling trend was the same as that for the experimental results, where the error between the simulation results for the final dipping process and the target value was 0.6%. In addition, the position of air traps is also simulated in the dipping process.
Highlights
In the motor core manufacturing process, one of the sources of performance degradation is the joining method used during the stacking of iron sheets
Due to the design of the viscous flow channel and the dipping module, the resin flows into an open space and forms a free surface in contact with the air, after which the iron sheet is dipped into resin
This study explores the gluing technology used in the iron sheet stacking process of motor cores
Summary
In the motor core manufacturing process, one of the sources of performance degradation is the joining method used during the stacking of iron sheets. Due to the design of the viscous flow channel and the dipping module, the resin flows into an open space and forms a free surface in contact with the air, after which the iron sheet is dipped into resin. Based on the consistency between the experimental and simulation results, the accuracy of this method in the filling process of a three-dimensional model was verified. Azmi’s [10] and Duan’s [11] research show that using the the Cross Castro–Macosko model has good results in predicting the flow behavior of thermoset materials. Lai’s [13] research shows the 3D mold flow modeling capabilities of Moldex3D, and the use of the Cross Castro–Macosko model and Kamal’s model to obtain accurate results for thermoset materials
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