Targeted magnetic flux guidance in the rotor cross section of rotational electrical machines is crucial for the machine’s efficiency. Cutouts in the electrical steel sheets are integrated in the rotor sheets for magnetic flux guidance. These cutouts create thin structures in the rotor sheets which limit the maximum achievable rotational speed under centrifugal forces and the maximum energy density of the rotating electrical machine. In this paper, embossing-induced residual stress, employing the magneto-mechanical Villari effect, is studied as an innovative and alternative flux barrier design with negligible mechanical material deterioration. The overall objective is to replace cutouts by embossings, increasing the mechanical strength of the rotor. The identification of suitable embossing geometries, distributions and methodologies for the local introduction of residual stress is a major challenge. This paper examines finely distributed pyramidal embossings and their effect on the magnetic material behavior. The study is based on simulation and measurements of specimen with a single line of twenty embossing points performed with different punch forces. The magnetic material behavior is analyzed using neutron grating interferometry and a single sheet tester. Numerical examinations using finite element analysis and microhardness measurements provide a more detailed understanding of the interaction of residual stress distribution and magnetic material properties. The results reveal that residual stress induced by embossing affects magnetic material properties. Process parameters can be applied to adjust the magnetic material deterioration and the effect of magnetic flux guidance.

旋转电机的转子横截面中的定向磁通量引导对于电机的效率至关重要。电磁钢板中的切口集成在转子板中，用于引导磁通量。这些切口在转子板中形成薄的结构，该薄的结构限制了离心力下可达到的最大转速以及旋转电机的最大能量密度。在本文中，利用磁机械维拉里效应，压纹引起的残余应力被研究为一种创新的替代磁通势垒设计，其机械材料的劣化可忽略不计。总体目标是通过压花代替切口，从而提高转子的机械强度。确定合适的压花几何形状，局部引入残余应力的分布和方法是一项重大挑战。本文研究了精细分布的金字塔压纹及其对磁性材料性能的影响。这项研究是基于对具有不同冲压力的20条压纹点进行单线模拟和测量的结果。使用中子光栅干涉仪和单张测试仪分析磁性材料的行为。使用有限元分析和显微硬度测量进行的数值检查可以更详细地了解残余应力分布和磁性材料特性之间的相互作用。结果表明，压纹引起的残余应力会影响磁性材料的性能。