Numerical Simulation of the Laser Welding Process for Electrical Steel Laminations

M. Ziegler, F. Brandl, J. Franke, A. Kühl
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Abstract

Soft magnetic cores in electric machines conduct and enhance the magnetic flux. The magnetic properties of the single sheets are mainly influenced by the alloying elements, the microstructure and the rolling and annealing process. To reduce eddy current losses during operation, soft magnetic cores are laminated. However, all manufacturing processes and the further assembling steps, like mounting of the stator, change the magnetic properties of the stack. Laser welding is a common method for producing lamination stacks, as very thin sheets can be welded automatically with high velocities. However, the weld seams are electrically conductive connections, which lead to an increase in eddy current losses. Furthermore, the microstructure in the heat-affected zone is impaired, which leads to a higher demand for magnetization and increased hysteresis losses. A main reason for this is the magneto-mechanical effect, as mechanical stresses influence the magnetic properties. For improvement, the process parameters must be adapted to the specific material system and the requirements. In this paper, a numerical simulation model for visualizing and optimizing the heat distribution in welded electrical steel laminations is presented. The main objective is the analysis of the weld dimension for different welding parameters. For this purpose, a transient thermal analysis is carried out with Ansys Workbench. The welding process is mapped in a simplified way with a moving heat source for different conditions. To validate the results, a comparison to experimental tests is applied. In this way, the simulation results are verified and potential sources of errors are identified.
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电工钢板激光焊接过程的数值模拟
电机中的软磁磁芯传导并增强磁通量。单片的磁性能主要受合金元素、组织和轧制退火工艺的影响。为了减少工作时的涡流损耗,软磁铁芯被层压。然而,所有的制造过程和进一步的组装步骤,如安装定子,都会改变堆的磁性。激光焊接是一种常见的生产叠层的方法,因为非常薄的薄片可以以很高的速度自动焊接。然而,焊缝是导电连接,这导致涡流损失增加。此外,热影响区的微观结构受到破坏,导致磁化要求更高,磁滞损失增加。造成这种情况的一个主要原因是磁机械效应,因为机械应力影响磁性能。为了改进,工艺参数必须适应具体的材料系统和要求。本文提出了一种用于可视化和优化焊接电钢片内热分布的数值模拟模型。主要目的是分析不同焊接参数下的焊缝尺寸。为此,利用Ansys Workbench进行了瞬态热分析。对不同条件下的移动热源进行了简化的焊接过程映射。为了验证结果,应用了与实验测试的比较。通过这种方法,验证了仿真结果,并识别了潜在的误差来源。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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