Linear Proportional Actuator Design and Optimization for Aerospace Application: Influence of Ferromagnetic Material on Electromagnetic Force

Due their precise controllability, affordability, and dependability, electromagnetic actuators are often used in industrial settings. Examples include vehicle clutch systems, inverter compressors, fuel injectors, and various pneumatic or hydraulic valves. Linear proportional solenoids (LPS) are particularly favored in servo proportional valves because of their long proportional stroke and simple design, which enable high static force and rapid dynamic response. The performance of these actuators is greatly influenced by the design parameters and the magnetic properties of the materials used. This study used finite element analysis (FEA) with ANSYS Maxwell, to evaluate and optimize the electromagnetic performance, focusing on the design of the magnetic circuit and selecting of ferromagnetic materials. The study investigates how the generated electromagnetic force was affected by AISI 1008, AISI 1010, and a softer, more saturated Hiperco alloy materials. While all three materials meet the minimum force required for chip shear testing, Hiperco achieves higher force values and delays magnetic saturation compared to the steels. This demonstrates that material selection significantly impacts actuator performance. In addition to geometric and winding optimizations, this study highlights that material selection is critical to enhancing the efficacy and performance of electromagnetic actuators.