Your title (above) is problematic because, you cannot design a transformer core without knowing the number of turns. Forget aboutIgnore the secondary winding;winding for now; that naturally comes good after you design the primary and, whatever you might have learned or might have been taught, the primary winding is still just a plain ordinary inductoris still just a plain ordinary inductor.
So, the first part to designing a transformer is to forget that it's a transformer and, instead, design an inductor where that inductor also serves aseventually becomes the primary winding.
Ideally, you would want the inductance to be high so that when you apply an AC voltage to it, the current drawn is low. Remember I said we are designing an inductor first and foremost so, I didn't refer to that current as the magnetizationThis current (although that is what it becomes when we add a secondary and think about it as a transformer). But from now, I will call it magnetization current because it is this current that magnetizes the core and creates magnetic flux in the core.
So, what determines that flux level (and possibly saturation) and, how do we convert the magnetization current into flux? The starting formula is what we call magneto motive force (MMF). It equals the number of turns multiplied by the current that flows in that coil.
This is only part of the story; we need to calculate the \$H\$ fieldH-field (magnetic field strength) in the prospective core and, this. This is MMF divided by the length (\$\ell\$) of the magnetic field path that circulates in the core: -
$$H = \dfrac{MMF}{\ell}$$$$H \text{ (magnetic field strength)}= \dfrac{MMF}{\ell}$$
A few words about the above...
The H-field is made smallerreduced by havingusing a longer magnetic field path (\$\ell\$). SmallerA reduced H-field leads to a lower flux density and this is a(a good thing). However, a longer path length leads to a lower primary inductance and, this is not ideal given that we want high inductance to avoid a significant levelsaturation of the core saturation. So, generally, when we make the magnetic path longer we also increase the cross sectional area of the core so that the inductance isn't compromised too much.
Then we have a formula that most folk will have seen and relates to what is known as the BH curve. That curve is the amount of flux density within a core that exists due to a driven level of H-field: -
Image from my basic website.
It relates the permeability of the core to B and H: -
But, it still all comes back to the number of turns on the core and how much inductance that creates. Most cores have an \$A_L\$ figure (aka permeance) that tells you the inductance for 1 turn and, if you double the turns the inductance becomes 4 times greater hence, the working inductance of a given coil is: -
Note that I'veI've used \$A_e\$ for the core cross sectional area. The "e" stands for "effective" hence \$A_e\$ is "effective area".
And howHow does this relate to the formulas I've shown above?
Start by understandingrecognizing that V is the RMS value of the applied sinewave and that we are interested in knowing the peak magnetization current that flows due to V being applied across the primary coil of inductance L (a reactance of \$2\pi f\cdot L\$): -
