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Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation

Excessive and unpredictable temperature rise in electrical machines can not only damage the motor over time but also induce errors in control systems within complex machinery. Conventionally, temperature reduction in electrical machines has been approached through geometric optimization of individua...

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Main Authors: Muhammad Nor Azril, Zulkafli, Mohd Azri Hizami, Rasid, Daing Mohamad Nafiz, Daing Idris
Format: Article
Language:English
Published: Springer Nature 2025
Subjects:
TJ Mechanical engineering and machinery
TS Manufactures
Online Access:http://umpir.ump.edu.my/id/eprint/43530/1/Optimizing%20material%20selection%20for%20brushed%20DC%20motor%20components%20using%20the%20VIKOR%20method%20a%20comprehensive%20performance%20evaluation.pdf
http://umpir.ump.edu.my/id/eprint/43530/
https://doi.org/10.1007/s41939-024-00716-9
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spelling my.ump.umpir.435302025-01-08T07:23:03Z http://umpir.ump.edu.my/id/eprint/43530/ Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation Muhammad Nor Azril, Zulkafli Mohd Azri Hizami, Rasid Daing Mohamad Nafiz, Daing Idris TJ Mechanical engineering and machinery TS Manufactures Excessive and unpredictable temperature rise in electrical machines can not only damage the motor over time but also induce errors in control systems within complex machinery. Conventionally, temperature reduction in electrical machines has been approached through geometric optimization of individual components. This study introduces an alternative strategy by selecting optimized material combinations for brushed DC motor components using the VIKOR multi-criteria decision-making (MCDM) method, focusing on thermal, electromagnetic, cost, and mass considerations. The proposed combinations were evaluated using a validated lumped parameter thermal network (LPTN) model, with further verification through finite element (FE) magnetic torque analysis and cost assessments. Results showed that the optimal material combination, consisting of a ferrite magnet, Al 356-T6 casing, chrome steel bearing, metal graphite brush, and nylon insulation, reduced winding temperature by 20 ℃ in a 5A copper losses test. This combination also preserved torque output within the core saturation limit and achieved a cost-effective, low-mass design. These findings validate VIKOR’s capability to holistically optimize material selection, offering a balanced approach that enhances thermal performance without compromising the motor’s functional and economic integrity. Springer Nature 2025 Article PeerReviewed pdf en http://umpir.ump.edu.my/id/eprint/43530/1/Optimizing%20material%20selection%20for%20brushed%20DC%20motor%20components%20using%20the%20VIKOR%20method%20a%20comprehensive%20performance%20evaluation.pdf Muhammad Nor Azril, Zulkafli and Mohd Azri Hizami, Rasid and Daing Mohamad Nafiz, Daing Idris (2025) Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation. Multiscale and Multidisciplinary Modeling, Experiments and Design, 8 (129). pp. 1-18. ISSN Electronic: 2520-8179 ; Print: 2520-8160. (Published) https://doi.org/10.1007/s41939-024-00716-9 10.1007/s41939-024-00716-9
institution Universiti Malaysia Pahang Al-Sultan Abdullah
building UMPSA Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Malaysia Pahang Al-Sultan Abdullah
content_source UMPSA Institutional Repository
url_provider http://umpir.ump.edu.my/
language English
topic TJ Mechanical engineering and machinery
TS Manufactures
spellingShingle TJ Mechanical engineering and machinery
TS Manufactures
Muhammad Nor Azril, Zulkafli
Mohd Azri Hizami, Rasid
Daing Mohamad Nafiz, Daing Idris
Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation
description Excessive and unpredictable temperature rise in electrical machines can not only damage the motor over time but also induce errors in control systems within complex machinery. Conventionally, temperature reduction in electrical machines has been approached through geometric optimization of individual components. This study introduces an alternative strategy by selecting optimized material combinations for brushed DC motor components using the VIKOR multi-criteria decision-making (MCDM) method, focusing on thermal, electromagnetic, cost, and mass considerations. The proposed combinations were evaluated using a validated lumped parameter thermal network (LPTN) model, with further verification through finite element (FE) magnetic torque analysis and cost assessments. Results showed that the optimal material combination, consisting of a ferrite magnet, Al 356-T6 casing, chrome steel bearing, metal graphite brush, and nylon insulation, reduced winding temperature by 20 ℃ in a 5A copper losses test. This combination also preserved torque output within the core saturation limit and achieved a cost-effective, low-mass design. These findings validate VIKOR’s capability to holistically optimize material selection, offering a balanced approach that enhances thermal performance without compromising the motor’s functional and economic integrity.
format Article
author Muhammad Nor Azril, Zulkafli
Mohd Azri Hizami, Rasid
Daing Mohamad Nafiz, Daing Idris
author_facet Muhammad Nor Azril, Zulkafli
Mohd Azri Hizami, Rasid
Daing Mohamad Nafiz, Daing Idris
author_sort Muhammad Nor Azril, Zulkafli
title Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation
title_short Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation
title_full Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation
title_fullStr Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation
title_full_unstemmed Optimizing material selection for brushed DC motor components using the VIKOR method: A comprehensive performance evaluation
title_sort optimizing material selection for brushed dc motor components using the vikor method: a comprehensive performance evaluation
publisher Springer Nature
publishDate 2025
url http://umpir.ump.edu.my/id/eprint/43530/1/Optimizing%20material%20selection%20for%20brushed%20DC%20motor%20components%20using%20the%20VIKOR%20method%20a%20comprehensive%20performance%20evaluation.pdf
http://umpir.ump.edu.my/id/eprint/43530/
https://doi.org/10.1007/s41939-024-00716-9
_version_ 1822924929797980160
score 13.235362

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