The goal of this research is the modelling by Magnetic Equivalent Circuit and topology optimization of a magnetic core, in order to maximize the inductance value function of an imposed material volume. A penalization is used in order to obtain density-based optimization results strictly made of air and magnetic material. The shapes of three magnetic cores resulting of the topology optimization are printed by additive manufacturing with fused granular fabrication process, being subject to a thermal treatment, and then compared by characterization and modelling to a reference shape in terms of magnetic properties.
LoperaLRodriguezRYakoutM, et al.Current and potential applications of additive manufacturing for power electronics. IEEE Open J Power Electron.2021; 2: 33–42.
2.
BendsøeMPKikuchiN. Generating optimal topologies in structural design using a homogenization method. Comput Methods Appl Mech. Eng.1988; 71: 197–224.
IgarashiH. Topology optimization and AI-based design of power electronic and electrical devices: principles and methods. Cambridge, MA: Elsevier academic press, 2024.
5.
DedeEMJoshiSNZhouF. Topology optimization, additive layer manufacturing, and experimental testing of an air-cooled heat sink. J Mech Des2015; 137: 111403.
6.
GaribaldiMAshcroftIHillierN, et al.Relationship between laser energy input, microstructures and magnetic properties of selective laser melted fe-6.9%wt si soft magnets. Mater Charact2018; 143: 144–151.
7.
KooBJangM-SNamYG, et al.Structurally-layered soft magnetic fe-si components with surface insulation prepared by shell-shaping selective laser melting. Appl Surf Sci2021; 553: 149510.
8.
ManninenAPippuri-MakelainenJRiipinenT, et al.The mitigation of eddy-current losses in ferromagnetic samples produced by Laser powder bed fusion. IEEE Access2022; 10: 115571–115582.
9.
Baco-CarlesVHuguetTLlibreJ-F, et al.Laser powder bed fusion applied to the manufacture of bulk or structured magnetic cores. J Mater Res Technol2022; 18: 599–610.
10.
LöfstrandJGoetzIKMarattukalamJJ, et al.Stress related magnetic imaging of iron-based metallic glass produced with laser beam powder bed fusion. Mater Des2024; 244: 113199.
11.
TiismusHKallasteANaseerMU, et al.Design and performance of Laser additively manufactured core induction motor. IEEE Access2022; 10: 50137–50152.
12.
UrbanNMasuchMPaduchJ, et al.An approach to eddy current reduction in Laser powder bed fused high silicon steel considering manufacturing influences. In: 2021 11th international electric drives production conference (EDPC). Erlangen, Germany: IEEE, 2021, pp.1–5. doi: 10.1109/EDPC53547.2021.9684214.
13.
CramerCLNandwanaPYanJ, et al.Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense fe-6.5wt.% si soft magnets. Heliyon2019; 5: e02804.
14.
PhamTQSuenHKwonP, et al.Reduction in hysteresis loss of binder jet printed iron silicon. In: In 2020 international conference on electrical machines (ICEM). Gothenburg, Sweden: IEEE, 2020, pp.1669–1675. doi: 10.1109/icem49940.2020.9270774.
15.
MartinVGillonFNajjarD, et al.MIM-like additive manufacturing of Fe3%Si magnetic materials. J Magn Magn Mater2022; 564: 170104.
16.
MartinVWitzJ-FGillonF, et al.Low cost 3D printing of metals using filled polymer pellets. HardwareX2022; 11: e00292.
17.
RalchevMMateevVMarinovaI. 3D Printing of magnetic materials by FFF technology. In: 2020 12th electrical engineering faculty conference (BulEF). Varna, Bulgaria: IEEE, 2020, pp.1–4. doi: 10.1109/BulEF51036.2020.9326060.
18.
HuberCAbertCBrucknerF, et al.Topology optimized and 3D printed polymer-bonded permanent magnets for a predefined external field. J Appl Phys2017; 122: 053904.
19.
ManninenAKeränenJPippuri-MakelainenJ, et al.Topology optimization for additive manufacturing of switched reluctance machines. 2018.
20.
GaribaldiMGeradaCAshcroftI, et al.Free-Form design of electrical machine rotor cores for production using additive manufacturing. J Mech Des2019; 141: 071401.
21.
MartinV. Fabrication additive de matériaux magnétiques doux par voie indirecte. Ecole centrale de Lille, Lille, [Online]. Available: https://theses.hal.science/tel-04282729 (2023).
