Help with electromagnet build?

To start I am a novice at this, but my mind just will not let go of this. My situation is as follows: I have a 1" X 3" (1010) steel core. I want be
able to build the strongest magnet possible, power supply, wire size and amp turns ect. I have tried every loose cannon combinations and either I have power with heat or no power and no heat. Diligently been reading everything I can and getting more confused on how to get the right combination. I want a powerful strong magnet that will not self destruct. Can anyone help me???????????? Plott
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You do not specify the shape of the core. If you want high force, you want a magnet where you have the minimum possible air gap. A straight solenoid is not that shape. Look at the shapes of commercial lifting magnets (U or co-axial) which are designed so that both poles act on the object being lifted. Typically, in determining the force, iron saturation limits the maximum force at 0 gap and you want the flux density at this gap to be just below the Knee of the saturation curve (otherwise higher currents and heating with no gain. For even small non-zero gaps, the force will be determined by the gap rather than the iron (whose mmf can be neglected). So -what shape , what max force wanted, what is the magnetisation curve and dimensions of the magnet as well as ampere turns can be determined.
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Don Kelly snipped-for-privacy@shawcross.ca
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jp wrote:

No we can't unless you can learn how to ask questions! First what is the purpose of this magnet? Lifting? Make a strong field at the end of the core? We need to know! Next what does "strong as possible" mean? You didn't specify any outside diameter to the coil so "strong as possible" would be to wind a coil of infinite diameter on that core! IF all these questions are answered, we might come to some choices as to what voltage and current you'd like the thing to run on. The heating is related to the amount of power dissipated in the coil. There are standard formulas for temperature rise in transformers due to coil heating. Choose a value without too much rise for free air unless you plan to run intermittently. The heating comes from the resistance of the coil and the current through it. W = I squared times R. The resistance of the coil is given by ohms per foot of the wire times the number of feet in the coil. This is not such a simple design job, is it?
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