Experimental Springback Validation of a Finite Element Model of Multi-stage Stator Bending

Today’s omnipresent environmental problems have led to an increased demand for electrical machines and its subcomponents – i.e. stators, rotors and control units - that show highest quality/price ratios. The flatpack technology is a multiple stage method of bending flat, comb-like stator cores with inserted copper windings into rounded rings. Despite the complexity caused by simultaneously acting bending effects, that stator manufacturing technology provides potentials regarding achievable stator performance due to its relatively high copper fill factor. In previous investigations, numerical models of one single bending operation have been validated. In contrast, this investigation focusses on predicting the stator geometry after multiple bending operations. Therefore, simulation models were extended to calculate such bending processes within one single model. Finally, results gained from experiments and simulation runs with same settings are presented. Discussion of results discloses a conformity between numerical and experimental geometries after multiple bending stages beyond 94%.