A Study on Powder Metallurgy Process for x Electric Vehicle Stator Core

The powder metallurgy process of manufacturing the motor core and inductor core using SMC greatly changes formability depending on the process variables. Therefore, this study explored the optimal process conditions of the powder metallurgy of the SMC stator core using Fe-6.5 wt.%Si by applying the Taguchi method, and selected deviations between the maximum and minimum relative densities as characteristic values; selected the formation pressure, molding temperature, and heating time as control factors; and derived the process conditions with the maximum SNR. As a result, the molding pressure was 120 MPa, the molding temperature was 500 °C, and the heating time was 120 s, and the material properties of the electrical properties’ core loss, saturation flux density, and bulk conductivity were measured and analyzed. After that, a prototype was produced, the analysis was verified, the mechanical properties were verified by performing density and SEM analysis at 15, 9, and 3 mm points based on the press vertical direction, and a motor was manufactured to verify the electrical properties.