電動モータ用高品質平角銅巻き線製造のための加工工程設計と引抜きダイス形状の最適化

抄録

To improve motor performance, motor magnet copper wires are changing from conventional round copper wires to flat (rectangular) copper wires. The market strict demands on the dimensional accuracy, surface properties, and surface defects of flat drawn copper wires, but there is almost no research on drawing to derive the optimum processing conditions for manufacturing flat wires. In this paper, we have focused on typical flat magnet wire manufacturing processes by multiple times shaped drawing from a round wire, to obtain high–quality flat magnet copper wire. Optimal processing conditions (mother wire diameter, cross–sectional reduction) and derivation of the optimal drawing die shape (angle) were studied. By Finite Element Analysis, we have investigated the possibility of shaped drawing, the lack of thickness, and the dimensional accuracy of the drawn shaped wire, and clarified the optimum processing conditions. In addition, the drawing experiments were carried out to confirm the reliability of the FEM analysis results. Based on these results, we clarified the optimum mother wire diameter, the optimum drawing conditions (die angle and reduction per pass) in the production of flat magnet copper wires.