Effects of WEDM and AWJ cutting methods on induction motor efficiency and total magnetic losses: Experimental design and response surface methodology

In this study, the effect of cutting electrical steel laminations using abrasive water jet (AWJ) and wire electrical discharge machining (WEDM) techniques on 5.5 kW induction motor efficiency (MEfficiency) and total magnetic losses (TLosses) was investigated. After the stator and rotor packages were formed, winding, varnishing and mechanical assembly processes were carried out and the motors were prepared for MEfficiency and TLosses tests according to the IEC 60034-2-1-1A standard. Tests were performed using different frequencies (f) and motor loading rates (MLoad). While burr formation was observed with the effect of plastic deformation on the cutting edge of electrical steels with AWJ, recast layer formation was observed with the effect of heat in WEDM. MEfficiency decreased while TLosses increased due to increasing f and MLoad in both cutting methods. Maximum MEfficiency and minimum TLosses values were measured in WEDM, it was determined that optimum results using Response Surface Methodology (RSM) were measured at f of 50 Hz and MLoad of 100% values in both cutting methods. The statistical effects of f and MLoad on MEfficiency and TLosses were revealed with ANOVA (Analysis of variance). In addition, mathematical models were developed for the prediction of MEfficiency and TLosses.

Automated summary

This study investigates the effects of cutting electrical steel laminations using abrasive water jet (AWJ) and wire electrical discharge machining (WEDM) techniques on the efficiency and magnetic losses of a 5.5 kW induction motor. The results show that AWJ cutting leads to burr formation while WEDM cutting results in recast layer formation. Both cutting methods result in decreased efficiency and increased magnetic losses with increasing frequency and motor loading rate. The optimum results, determined using Response Surface Methodology (RSM), are achieved at a frequency of 50 Hz and a motor loading rate of 100% in both cutting methods. Analysis of variance (ANOVA) reveals the statistical effects of frequency and motor loading rate on efficiency and magnetic losses.