Layered Magnetic Core Mass Machining
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Solution Overview
Problem
Conventional three-dimensional machining processes for creating cores with radial channels or holes can distort the material and stress both the core and machine tools, leading to performance degradation and reduced tool life, especially when rapid cutting is involved.
Innovation Solution
A method of machining thin ribbon or tape materials one layer at a time, which are then spooled onto a template, allowing for the gradual buildup of the core shape with reduced mechanical and heat stress, and optionally using a wicking method with powdered metal slurry to form composite cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If three dimensional machining process is used to manufacture core mass with radial channels or holes, then manufacturing speed is improved, but material structural performance deteriorates due to excessive mechanical or heat stress
Solution Approach 1:
The core mass is manufactured by stacking multiple thin layers (0.002-0.020 inches thick) individually machined with slots, channels, or holes, rather than machining the entire three-dimensional core mass at once. This segmentation allows each layer to be processed with minimal stress while maintaining the desired radial features, and the layers are subsequently bonded together to form the complete core structure.
2Loss of time
If rapid cutting is used in three dimensional machining, then manufacturing time is reduced, but machine tool performance and life deteriorate due to stress
Solution Approach 1:
The machining operation is divided into multiple separate processing steps, one for each thin layer, rather than performing rapid cutting on the entire core mass. This reduces the cumulative stress on the machine tool while maintaining manufacturing efficiency through automated layer-by-layer processing and bonding.
3Productivity
If conventional machining is used to create radial channels or holes, then core shape is achieved quickly, but annealing is required to restore material performance
Solution Approach 1:
By machining each thin layer individually with minimal stress before bonding, the need for post-machining annealing is eliminated or reduced. The layer-by-layer approach allows slots, channels, and holes to be created in each layer during the machining process itself, without requiring subsequent thermal treatment to restore material properties.
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 minimizes material and tool stress, potentially eliminating the need for annealing, and results in cores with improved magnetic and electrical performance, suitable for high-frequency transformers and electric machines, while also reducing machining time and tool wear.
Implementation Method 1
when an appropriate magnetic material, such as magnetic metal or amorphous metal ribbon or tape is used as the raw ribbon material
Data Source
AI summary
A three dimensional shape core mass is manufactured by machining a ribbon or tape of any material with various slots, channels, or holes of any shape before the ribbon or tape is spooled or layered onto a layering template or spooler. The machining is adjusted so the slots, channels, or holes of any shape extend in a radial or stacked direction perpendicular to the axis of spooling rotation or the plane of layering but with any curve or straight line and with any stacked length. For example, core masses that are manufactured as described are suitable as magnetic cores for high frequency rotating or linear transformers or for rotors and for stators of rotating or linear electric machines when an appropriate magnetic material is used, such as magnetic metal or amorphous metal ribbon or tape.