Design and Prototyping of Additively Manufactured Axial Flux Switched Reluctance Machine

This paper presents the development of an axial flux segmented stator dual rotor switched reluctance machine, specifically designed for high-speed propulsion applications. Due to the complex three-dimensional geometry of an axial flux machines, traditional production methods face substantial limitations in manufacturing accuracy and feasibility. However, advancements in additive manufacturing have addressed these challenges by enabling the production of intricate geometries with greater precision. The paper begins with the derivation of the output power equation for the proposed machine, followed by a detailed examination of key geometric parameters influencing performance. The design methodology is outlined from initial considerations to final performance targets, with a 3D finite element method analysis conducted to validate the calculated dimensions and assess performance. Furthermore, a physical prototype is fabricated using Selective Laser Melting, an additive manufacturing technique suited for producing complex structures with high precision. The prototype undergoes experimental testing, and the resulting performance data are compared with simulated results. The comparison between FEM simulations and experimental measurements indicates a close similarity between the experimental and simulated static and dynamic torque values.