Amorphous Magnetic Component Shearing via Localized Heating
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Solution Overview
Problem
The high hardness of amorphous and nanocrystalline soft magnetic materials makes it difficult to efficiently process them into magnetic components due to excessive abrasion of press dies, as existing methods do not adequately address the hardness difference between these materials and the tools used for punching.
Innovation Solution
A method involving the preparation of a stacked body of plate-shaped soft magnetic materials, heating at least a portion of the stacked body to a temperature equal to or higher than the crystallization temperature of the materials, and then shearing the stacked body to reduce hardness and minimize tool abrasion, using techniques like laser cutting or pressing with a metal tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If amorphous or nanocrystalline soft magnetic materials are used to improve magnetic component performance, then magnetic flux density and excitation properties are improved, but the high hardness of these materials causes excessive abrasion of press dies during punching
Solution Approach 1:
The patent applies preliminary action by heating the amorphous or nanocrystalline soft magnetic material to a temperature of 100°C or higher before punching. This pre-heating treatment reduces the hardness of the material, making it more suitable for punching operations and significantly reducing abrasion of the press die while maintaining the magnetic properties of the material
Solution Approach 2:
The patent changes the temperature parameter of the soft magnetic material from room temperature to 100°C or higher. This parameter change reduces the hardness of the material, enabling efficient punching with conventional press dies and reducing tool wear, while the material retains its excellent magnetic properties after cooling
2Reliability
If the hardness of the press die is increased to match the high hardness of amorphous soft magnetic material, then tool wear is reduced, but no material exists with sufficient hardness (3 times higher than super steel)
Solution Approach 1:
Instead of changing the material of the press die, the patent changes the temperature parameter of the soft magnetic material being processed. By heating the material to 100°C or higher, its hardness is reduced to a level that can be effectively processed by conventional super steel press dies, eliminating the need for unavailable ultra-hard materials
Solution Approach 2:
The patent inverts the conventional approach by not trying to make the tool harder to match the material, but rather making the material softer (through heating) to match the tool's capabilities. This reverse strategy uses conventional press dies effectively against the soft magnetic material
3Productivity
If conventional punching methods are used on unheated amorphous soft magnetic material, then processing speed is maintained, but excessive abrasion of the press die occurs reducing efficiency
Solution Approach 1:
The patent applies preliminary heating to the soft magnetic material before punching to reduce its hardness. This preliminary action enables the use of conventional punching methods at maintained speeds while significantly reducing press die abrasion, thereby sustaining productivity without excessive tool wear
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient processing of amorphous and nanocrystalline soft magnetic materials by reducing the hardness of the materials during the shearing process, thereby minimizing tool abrasion and enabling the production of magnetic components with improved dimensional accuracy and reduced wear on the press die.
Implementation Method 1
a step of heating at least a portion of shearing in the stacked body to a temperature equal to or higher than a crystallization temperature of the soft magnetic materials
Implementation Method 2
heating at least a portion of the stacked body to a temperature equal to or higher than the crystallization temperature of the materials
Data Source
AI summary
The present disclosure provides a method for producing a magnetic component that enables efficient processing of an amorphous soft magnetic material or a nanocrystalline soft magnetic material. The method for producing a magnetic component comprising an amorphous soft magnetic material or nanocrystalline soft magnetic material comprises: a step of preparing a stacked body comprising a plurality of plate-shaped amorphous soft magnetic materials or nanocrystalline soft magnetic materials; a step of heating at least a portion of shearing in the stacked body to a temperature equal to or higher than the crystallization temperature of the soft magnetic materials; and a step of shearing the stacked body at the portion of shearing after the step of heating.