Shrinkage Design and Material Selection of an 160 kW Induction Electric Motor via Multi-Physics Analysis

This paper defines allowable magnitudes of shrinkage and its tolerances for an 160 kW induction electromotor. The appropriate shrinkage values and primary material of the frame are based on multi-physics analysis. After the optimization process, the designer offers a safe material and geometry that can endure under identified loads. The design process includes shrink magnitude, tolerances, and material designation. Stress analysis in the presence of all electromagnetic and thermal loads leads to the determination of appropriate material and safe model. The frame s typical manufacturing method is the casting process. In this case, it is supposed that the frame is fabricated from EN-GJL castings. So we know mechanical and physical properties which are essential to the determination of stresses, and the end of this analysis is to determine the grade of material (i.e., determination of yield and tensile strengths). A solution for this problem is based on the Finite Element Method (FEM) because the frame s and other component s geometries are complex, and the analytical method is not a good approach to reaching exact results. In this problem, stress analysis has been employed by mapping the thermal field and fault torques. The research was performed in two states including rated and overload conditions. Overload status belongs to the particular function of the motor which occurs in a short time and causes high electrical currents and high temperatures. Finally, the safety factor is calculated for the safe design of the frame material. Also, the shrink process temperature is presented.