Finite element analysis for the lamination process of a precision motor core using progressive stacking dies

In order to increase the productivity of electrical parts, manufacturing processes using progressive dies have been widely used in the industry. Motor cores have been fabricated using progressive stacking dies with lamination in order to obtain better electro-magnetic properties. For proper design of the process, a prediction of the process is required to obtain relevant design parameters. In this work, rigid–plastic finite element analysis is carried out in order to simulate the lamination process of the motor core. The effects of the embossing depth and the number of stacked sheets are investigated and compared with experimental results. The forming process can then be predicted successfully from the results of analyses, enabling the development of an appropriate design for the die and the process.