Electromagnetic Performance Analysis of Axial Flux Motors According to Rotor Core Manufacturing Processes

The electromagnetic performance of axial flux permanent magnet (AFPM) machines with different rotor core configurations was investigated. Four rotor core types, including soft magnetic composite (SMC), solid carbon steel (S45C), axially stacked electrical steel laminations, and a wound electrical steel core, were analyzed under identical motor specifications and operating conditions using finite element analysis. The results indicated that the average torque and output power were similar across all configurations, while rotor losses and efficiency varied depending on the core material and structure. The SMC rotor core exhibited relatively low losses and high efficiency, whereas the S45C rotor core showed higher losses mainly due to eddy currents. Among the electrical steel-based structures, the axially stacked lamination core showed relatively low losses, while the wound core demonstrated favorable magnetic flux characteristics.