Get the automotive offer application

for your smartphone or tablet now.

Europe product catalogue
Flat Carbon Europe website EN | FR | DE | ES

Advanced technical support for iCARe®

For automakers who wish to exploit the full potential of ArcelorMittal’s iCARe® steels, we can offer advanced technical support in many areas including modelling, prototyping and material handling.

This support can also be provided without the need for the customer to share their machine design with us. Any information that is shared is treated as highly confidential.

ArcelorMittal’s machine modelling services

As a steel provider, ArcelorMittal also offers our customers all the help they need to choose the most suitable steels. We can also help to design the machine. This level of assistance is possible thanks to our advanced R&D know-how and the high-tech equipment available in our research centres.

For mechanical design engineers, we can provide high temperature mechanical material characterisation at temperatures up to 250°C. This enables the engineer to determine the weakness of the material at exploitation temperatures, rather than using accepted rules of thumb. Along with static testing, ArcelorMittal can provide dynamic evaluations such as low and high cycle fatigue testing on different sample geometries. This enables engineers to predict, in detail, the transient regime behaviour of the machine.

For the magnetic design engineer, ArcelorMittal can provide full magnetic characterisation of our steels, up to 10k Hz in sine conditions. We can also provide any non-sine data, which is interesting for pulse-width modulation (PWM) fed machines or harmonic calculations. As well as magnetisation curves up to saturation for field calculations, ArcelorMittal has developed a specific loss model which allows better accuracy in post-processing loss calculations. This model can be run independently from the field calculations, so the customer does not need to share their machine design with us.

For the thermal engineer, we provide thermal conductivity data at machine exploitation temperatures. Data is available for both our steel grades and our coating solutions.

Prototyping services

Our technical support for magnetic, mechanical and thermal machine modelling enables design engineers to make precise machine calculations. This enables them to reduce the number of prototypes needed before pre-series and series production can begin.

A minimal amount of prototyping is still needed to prove that the development has led to the expected machine performance. For prototyping purposes, ArcelorMittal can offer small quantities of sheets for first stage Epstein and tensile testing, and for the next stage of laser cutting. In the industrial validation phase, ArcelorMittal can provide small slit coils for punching and machine assembly development.

Material handling issues

Even when ArcelorMittal has provided the best possible steel solution for a given electrical application, our job is not over. The production of prototype or series machines can involve production processes that have the potential to degrade the properties of the fully processed steels we have supplied.

Advanced R&D support is available to help customers quantify the impact of material handling processes (such as laser cutting or punching, stress relief annealing, stack assembly, welding, shaft shrink fitting, and housing fitting) on the magnetic performance of the machine’s lamination stack.

Further information

For more information about ArcelorMittal’s iCARe® range of electrical steels and the support we can provide, please visit: http://automotive.arcelormittal.com/automotive/icare.

Advanced mechanical characterisation for iCARe®

Mechanical design aspects

Our customers’ mechanical design departments need to be able to predict the structural integrity of the rotor and stator based on in-service loads, manufacturing aspects, component geometry and statistical material data obtained using laboratory samples.

The main aspects are summarised in the figure below:

  • In-service conditions
    • Load/deformation during rotation, acceleration and deceleration (centrifugal, electromagnetic)
    • Temperature (e.g. as a function of load and ambient temperature)
    • Etc
  • Manufacturing aspects such as punched edges and stresses introduced during assembly of the electrical motor parts
  • Design, mainly the radii used and the amount of material that remains to transmit the load
  • Material properties (statistical variation, temperature dependency, notch sensitivity, punched edge effect etc)

Fatigue design and analysis: different aspects

Click to enlarge

Static material properties

The yield stress is an important parameter for the design of electrical machines. In the simple case of a constantly spinning rotor, the magnitude of the yield strength determines the maximum rotation speed at which the material can withstand centrifugal forces without plastic deformation. The iCARe® Speed grade is specifically developed for high-speed rotors for the automotive market.


ArcelorMittal can supply elevated temperature tensile data to correctly assess the mechanical behaviour of e-machines under static loads at operating temperatures.

Dynamic material properties

As a material supplier, ArcelorMittal can provide material fatigue data for its electrical steels for the two existing design and analysis approaches, i.e.:

  • Stress-based design and analysis (high cycle fatigue, HCF)
  • Strain-based design and analysis (low cycle fatigue, LCF)

 

This data is based on standardised tests.
On request, specific machine design features can be experimentally assessed using specific laboratory set-ups.

Sign up to receive Automotive news alerts by email