Electrical machines have recently received a lot of attention due to a variety of applications in several industries. Although advances in digital technologies have enabled more efficient production of electrical machines, faults are still identified at the end of the line tests. In order to avoid accumulation of defects during the production chain, it is desirable to identify faults early in the process. This can be achieved by identifying how critical process parameters and the interdependencies between them influence the occurrence of faults. This poses a challenge in electrical machine manufacturing because of the complexity involved in various manufacturing steps involving deformable material, an example is coil winding. This paper proposes a computational framework to model interdependencies in a complex electrical machine manufacturing process involving deformable material. A Discrete Event Simulation model representing the coil winding process demonstrated that input parameters such as wire tension and winding speed influence physical and electrical properties of the coil (enamelled copper wire) leading to generation of defects in the final product.
Formulas are derived to take into account the effect of hardening of a deformable material on stresses and force parameters of the extrusion process, as well as on the results of shaping.
Keywords: die forging, extrusion, misalignment, punch, matrix, plane deformation, accumulated deformations, hardening
[email protected]
The results of an experimental verification of the obtained theoretical formulas are presented, which make it possible to determine the most important parameters for extruding glasses with a counter-punch, by the method of dividing (coordinate) grids. The characteristics of the tools used, the geometric parameters of the extrusion experiment, the strength characteristics of the deformable material, and also its lubrication are described in detail. The implementation of theoretical calculations of the stress and strain states of the workpiece is described in detail. The high accuracy of the obtained calculation formulas is confirmed.
Technological scheme and ratios for calculating of the extrusion modes of thickenings and flanges on pipe workpieces are proposed. The viscous-plasticity state of the deformable material is accepted. The kinematics and power mode of the process are established using the extreme upper-boundary plasticity theorem with the involvement of the discontinuous fi eld of displacement velocities. Estimate of the continuity loss of the workpiece material is given. The diagram of the die tooling and sample of product are presented.
A three dimensional model to predict the hydro-mechanical state of unsaturated and deformable material during hot air drying has been proposed. The material viscoelastic behaviour was formulated using Bishop’s effective stress theory for partially saturated material using the liquid saturation as the Bishop parameter. The hydro-thermal and mechanical equations were coupled by the fluid pressure and the solid matter velocity. The model was applied to a deformable material (innovative clay-cellulose fibers composite) subjected to convective drying. A generalized Maxwell model with five elements, whose parameters were measured experimentally and correlated to water content was used to describe the material’s viscoelastic behavior. The hydro-thermal part of the proposed model was validated on the basis of a comparison of experimental and simulated drying rate curves. The Von Mises stress was simulated and compared to the experimental tensile strength in order to predict the time and the region of material failure. For a drying process at95°C, the region of failure risk was identified. The failure may occur on the lateral surface of the slab in contact with air at a drying time of 2.5h.
The paper presents the results of an experimental study of the pipe extrusion process using the method of coordinate grids. The estimation of influence of separate conditions of friction on the contact surfaces of the deformable material and the pressing tool on metal flow pattern. The calculation of the forming operation is made for extrusion process stages.
Modelling Interdependencies in an Electrical Motor Manufacturing Process Involving Deformable Material