Evaluation of new cutting methods for electric steels to reduce electrical losses in electric vehicles

Purpose and goal:

The purpose of the project was to evaluate two new cutting methods, water jet guided laser and electromagnetic pulse cutting for electrical steel to minimize the losses in an electric motor. Conventional laser and punching were used as references. Water jet guided laser achieved the lowest losses.

A concept that enables the use of water jet-guided lasers also for high-volume manufacturing was developed in the project. An initial cost analysis shows that the concept is also economically interesting. However, electromagnetic pulse cutting is not suitable for cutting electrical steel Expected results and effects:

Water jet guided laser achieved the lowest losses and can be used as a cutting method for electrical steel to produce electric motor prototypes. Water jet guided laser has the potential to be used in high volume manufacturing as well. The expected efficiency gain is in the range of 0.5% to 1%. Water jet-controlled laser also gives the possibility of using thinner sheet and electrical steel with a higher silicon content, something that is difficult today with conventional punching.

Approach and implementation: The work was carried out in the following work packages: WP 1, Laser cutting with water jet guided laser WP2 Cutting with electromagnetic pulse technology WP 4 Cutting with conventional laser and punching. A punch tool was manufactured. WP 3 Investigation of magnetic properties

WP 4 Investigations using SEM, EBSD and 3D optical measurement WP 5 Concept study on how a water jet guided laser can also be used for high volume production WP 6 A webinar has been held and a final report has been written All project partners have been committed and contributed to the project´s success