splitting a copper body into foils (multiple bends)

[jculleton3]

Simple explanation for a complex problem.

I use the sheet metal tool to make a "Hairpin" conductor similar to those found in axial flux brushless motors.

Now I want to split that body into dozens of layers so I can get the correct dimensions for foil punches.

If I punch the foils all the same as I bend them the farthest out foil in the hairpin covers more distance due to being outside the bend and the inner foils cover less.

Is there a way to cut these conviently or do I have to make each individual foil its own sheetmetal component and draw the dozens of layers by hand?

Its difficult because its so complex with lots of bends in different directions.

Without attaching the drawing (I am not allowed) the best description is an lampshade wire that is twisted so one leg is bent forward and one backwards so they no longer lie in the same plane. 

Is there a way if I have to do it manually to join sheetmetal shapes together via the join command?

Thanks JC

[jhackney1972]

Please attach your model as it will make your question a lot clearer.  If you also have sample pictures, attach them as well.

[etfrench]

This wikipedia article shows an axial flux motor.  Don't you just need to create one segment, then circular pattern it?

[jculleton3]

Actually at the frequency this motor runs it has to use litz wire or layered foils to work.

I am just trying to not have to make dozens of drawings. 

Thanks JC

[jculleton3]

And it does a lot more than a circular pattern. 

Basically to operate at higher frequency (more magnets and more phase wires) you have to either use litz wire (pain and expensive) or use layers of copper at the thickness of the skin effect (most use of copper) or smaller (less current capability). Anything bigger and its just wasted copper as only the skin depth gets used for current at say 75Khz. 

Long story short Copper foil cut to the skin depth thickness and twice the skin depth width would provide a physical stability (once layered) and of course maximum current flow with only 1 skin depth wasted copper up the middle which would then be helpful in transferring heat to the cooling channel. 

So I am trying to figure a way to draw the individual copper layers without having to draw each one individually and adjust the bends to make it fit snug to the first. 

for example take the letter "G" (not the shape but an example) If I make it 0.1" thick I would have to divide it up into say .05 layers of copper sheets cutting from the front of the "G" straight to the Rear of the "G" making progressively larger "G" shape nested tight against each other (of course the thickness of the cut includes insulation).  When I lay each of the shapes flat the bends are slightly offset and the lengths of copper for each "G" gets progressively larger.

Hope this muddies the waters... errr uhmmm clears it up a bit. 

Thanks JC

[TheCADWhisperer]

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@jculleton3 wrote:

Hope this muddies the waters... errr uhmmm clears it up a bit. 

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Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

[etfrench]

Will the offset command work?  You can extrude each line as a surface then thicken each to the thickness of the foil.

[jculleton3]

I will try that.

I would have to make each surface a sheetmetal form so I can unbend it and make the punch correct for each size blank.

I will let you know if it works.

[etfrench]

Instead of using the surface extrude and thicken, you can just use the lines in a split body  command (Assumes there is no space between each leaf).

[jculleton3]

Unfortunatley I need to use the sheetmetal function as stated in earlier posts that I need to unfold the shapes to get the correct bend lines and lengths.

So it has to be a sheetmetal form. the hardest part is forming a gentle curve vice a bend. 

I will attach a file.

[jculleton3]

That is if fusion will let me.

Ugghhhh. stupid startup problem and it won't let me generate a link. 

[jculleton3]

Here is an example. I need the bent pieces of sheetmetal to nest and make contact along the full surface.
The way it is with simply duplicating the sheetmetal is I get anywhere from .0375 to .0141 gap. 

If I align along one surface I still show a .0267 gaps in places with some surfaces touching. 

Just wondering if there is any other way to do this without having to customize each bend and each length of the windings (sheetmetal). otherwise 72*how ever many is a lot of individual drawings.

https://a360.co/3EZbL1V

[etfrench · Accepted solution]

72 isn't very many😀  Here's several done with the offset tool (grey one is yours):

Each one needs to be a separate component in order to make a flat pattern for each:

If you want the bends to look like the top set, you'll need to edit the bend for each to set the radii.  For the bottom, you just need to define the minimum and maximum bend radii.  The top bend in the image (looking at the left line only) would need the minimum while the bends in the opposite direction would need the maximum.

I wouldn't expect it to take more than a minute per leaf to extrude, convert to sheet metal, and make a flat pattern.

[etfrench]

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@etfrench wrote:

  The top bend in the image (looking at the left line only) would need the minimum while the bends in the opposite direction would need the maximum.

It's the opposite😁 The top bend in the image (looking at the left line only) would need the maximum while the bends in the opposite direction would need the minimum.

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