CAE-simulation-optimized flow channels increased yield from 85% to 98% for a new energy motor flat wire producer.
The Challenge
Production of rectangular copper wire for EV motor windings faced low yields (85%) due to corner cracking and uneven filling of the profile during the final pass.
Titan Engineering Solution
Using Computer-Aided Engineering (CAE) flow simulation, we redesigned the entrance angle and bearing length to balance the material flow velocity between the center (fast flow) and the corners (slow flow) of the wire.
Fig 1. Analysis and Implementation
The Results
The optimized flow eliminated stress concentrations at the corners. First-pass yield increased to 98%, and the corner radius consistency improved, ensuring better packing factor in the motor windings.
Key Takeaways
- Flow simulation prevents trial-and-error in profile design.
- Balanced flow velocity is key to preventing cracks.
- Higher yields directly improve profitability.
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