Potentials of an explicit finite element analysis of the bending processes for coated copper wires

The advancing electrification in industry and everyday life requires powerful electric drives providing highest efficiency. The winding as the core of these drives is subject to continuous development. Furthermore, it is of decisive importance to accelerate sample production for prototype construction and small series production of electric drives to shorten the innovation cycles. Coated bar-wound winding elements are increasingly important for the application in electric drives. The process window for damage free bending processes of coated copper wires is yet not defined. Structural mechanical finite element (FE) modelling is therefore a powerful tool to reduce costly trial-and-error loops and shortening development cycles for those production techniques as it provides reliable quantitative results. The aim of this paper is to propose the basics for defining a process window for the bending of flat wires using experimental bending test setups and FE-simulation tools.