Topology optimization of reduced rare-earth permanent magnet arrays with finite coercivity

The supply chain risk of rare-earth permanent magnets has yielded research efforts to improve both materials and magnetic circuits. While a number of magnet optimization techniques exist, literature has not incorporated the permanent magnet failure process stemming from finite coercivity. To address this, a mixed-integer topology optimization is formulated to maximize the flux density of a segmented Halbach cylinder while avoiding permanent demagnetization. The numerical framework is used to assess the efficacy of low-cost (rare-earth-free ferrite C9), medium-cost (rare-earth-free MnBi), and higher-cost (Dy-free NdFeB) permanent magnet materials. Novel magnet designs are generated that produce flux densities 70% greater than the segmented Halbach array, albeit with increased magnet mass. Three optimization formulations are then explored using ferrite C9 that demonstrates the trade-off between manufacturability and design sophistication, generating flux densities in the range of 0.366–0.483 T.