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Stacking Factor and Net Steel Area: A Transformer Core Calculation
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Net steel area depends on core geometry and stacking factor. Follow the calculation from design assumptions to the assembled packet, then review packet height, mass, steel density and duct allowance as checks on the steel section actually built.
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The outer core dimensions can be right while the steel section is wrong. Net steel area equals geometric area multiplied by stacking factor. Use the article's example: a design at one point seven zero tesla assumes ninety-seven percent. Build the same geometry at ninety-four percent, with the same flux. The steel now operates at about one point seven five tesla. This is a calculation, not a measured loss result. Burrs, sheet shape, coating space, debris and loose clamping can all reduce the factor. Check the assembled packet height under the specified clamping condition. Compare mass with steel density and geometric volume, excluding ducts. Measure the steel section you built, rather than assuming the one you designed.