Homogenization modeling and effective mechanical constants for EM composite conductor with cooling channel

A homogenization modeling to predict the effective mechanical properties of electric machinery composite conductor consisting of metallic core with cooling channel, and multi-layer of insulating materials was presented. A two-level homogenization scheme to model complex composite with multi-phase materials and the validation of using finite element method was developed. Composite cylinder assembly model was adopted in the Level 1 homogenization for the metallic core and the cooling channel was analyzed as a fiber void with null material properties. The effective mechanical properties of the composite insulation layers were homogenized by smearing the properties of the multiple insulation layers of bonding, insulation and insulation-fiber-reinforced composite. Level 2 homogenization derived nine effective mechanical constants for conductor through a combined homogenization sequences. The good comparisons between the analytical predictions and the results obtained from the finite element analyses demonstrated the applicability of the model.