Development of High Quality Shaped Copper Magnet Wire by Shaped Wire drawing

Abstract

In order to reduce environmental pollution, efforts are made to minimize the use of internal combustion engines as much as possible, and the development of vehicles powered by electricity such as hybrid vehicles and electric vehicles has been actively research．However, there is a problem of low cruising distance and low power compared with engine vehicles．Therefore, in this research, we focus on the magnet wire used for the hybrid motor and aim to elucidate the optimum drawing condition for manufacturing the shaped copper magnet wire by using the deformed drawing process．First, in order to investigate the optimum reduction and die half–angle using FEM analysis, the drawing process was performed under various drawing conditions, the drawing stress at that time, the, contact area, and the die pressure were calculated, and optimum drawing conditions were established．In addition, by investigating the dimensional accuracy and surface properties of the drawn wire, it was investigated whether or not high quality shaped copper magnet wire can be produced only by shaped wire drawing．