guys, i think we are moving in a wrong direction. if the cores will be made like this:
or like this:
the lower overhangs connected to each other and form the yoke. if the yoke tickness at least 0.8 of teeth's tickness, the cores support ring could be made of aluminium or any other material.
i think the cores support ring and the shaft shouldn't be that complicate shaped. the ring could be made of 1/4" aluminium sheet by water jet cut or cnc milling machine, the axle could be a bit less beefy too.
i was also confused a little because at the beginning i was thinking you're building...
could you please explain a little why it is so important for coils to be round? in most radial flux motors i've seen the coils have almost rectangular shape and the slots (and the wire inside it) are parallel.
here we go..
i did it with sizes you mentioned at your drawing and used my imagination:
- motor config is 18/16 as you mentioned
- magnets tickness is 5 mm
- cores support ring outer diameter is 200 mm
- axle length is 130 mm
- approximate weight of the parts shown at the picture is 5.8 kg (no...
sorry, i'm not agree with you that 6 mm (not 5 mm, btw) fingers would be weak. please take into account that fingers are connected to outer and inner rings of the plate. another point is that the smc cores will be glued inside of the milled slots and this will add some rigidity to all the...
APL, can you please tell why do you want to throw away your first design? i mean why can't you build it like this:
make a two stator plates like at picture below from fiberglass (5 mm tickness):
with SMC core like you want (i think you could use even simplier design):
and make aluminium hub...
afair, adding of silicon decreases electric conductivity of the steel, hence core losses. however it also decrease magnetic permeability, hence the max torque of the motor. we need a balance.
btw, i saw your experiments with composite core. your core was conductive because you didn't insulate particles of iron powder. i was digging around this before and found this description:
QYFe0SAbvH0
i thought i could use some big plactic bottle and vacuum cleaner pump to build that kind of...
i'm with you, that's why i decided to buy wound coil and then try to make slots in it by edm machining. i shall keep you informed about my progress so you'd probably join the party..
i'm not a kinda motor expert, i'm a rookie who learns every day. i've just red the patent issued in russia for the technology of making of axial flux stators. it is here: https://findpatent.ru/patent/265/2650104.html
it is in russian but i hope you can use google translator.
in short words...
i thought this point is not completely clear (for me :lol: ) so i decided to talk a little bit more about it. :D
as far as i understood the ideal shape of my design of stator core should be like this (i made a square cut for better transparency):
as you can see the tickness of back iron...