Mathematical Modelling and Simulation of Machine Calender used in Electrode Production for Running Electric Vehicles

Due to the continuous increase in demand for electric vehicles which run on lithium-ion batteries, the need to improve their performance is also increasing. As a result, optimizing each manufacturing stage is critical, out of which calendering is a final stage of electrode production in which electrodes are compressed while passing through a stack of hard/soft bowls, leading to changes in the electrode’s porosity, thickness, density, smoothness, adhesion/bonding strength, wettability, and coating homogeneity. Calendered electrodes enhance volumetric energy density, rate capability, cyclic rate, and life span of the batteries. Hard/soft bowls used in a calendering machine have a covering/layering of either chilled cast iron or fragile material (nylon, cotton, or rubber) with varying thickness. Here we report on an investigation of the influence of cover thickness along with other design and process parameters of machine calender namely bowl diameter, bulk modulus and line load on the contact width with the help of a generalized nip mechanics model. Additionally, the influence of bowl temperature and contact time on the electrode sheet was investigated with the help of heat transfer model.