Iron Loss Calculation Methods for Numerical Analysis of 3D-Printed Rotating Machines: A Review

Three-dimensional printing is a promising technology that offers increased freedom to create topologically optimised electrical machine designs with a much smaller layer thickness achievable with the current, laminated steel-sheet-based technology. These composite materials have promising magnetic behaviour, which can be competitive with the current magnetic materials. Accurately calculating the iron losses is challenging due to magnetic steels' highly nonlinear hysteretic behaviour. Many numerical methodologies have been developed and applied in FEM-based simulations from the first introduced Steinmetz formulae. However, these old curve-fitting-based iron loss models are still actively used in modern finite-element solvers due to their simplicity and high computational demand for more-accurate mathematical methods, such as Preisach- or Jiles-Atherton-model-based calculations. In the case of 3D-printed electrical machines, where the printed material can have a strongly anisotropic behaviour and it is hard to define a standardised measurement, the applicability of the curve-fitting-based iron loss methodologies is limited. The following paper proposes an overview of the current problems and solutions for iron loss calculation and measurement methodologies and discusses their applicability in designing and optimising 3D-printed electrical machines.