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In the context of calling for low carbon emissions, lithium-ion batteries(LIBs) have been widely concerned as a power source for electric vehicles, sothe fundamental science behind their manufacturing has attracted much attentionin recent years. Calendering is an important step of the LIB electrodemanufacturing process, and the changes it brings to the electrodemicrostructure and mechanical properties are worth studying. In this work, wereported the observed cracking of active material (AM) particles due tocalendering pressure under ex situ nano-X-ray tomography experiments. Wedeveloped a 3D-resolved discrete element method (DEM) model with bondedconnections to physically mimic the calendering process using real AM particleshapes derived from the tomography experiments. The DEM model can well predictthe change of the morphology of the dry electrode under pressure, and thechanges of the applied pressure and porosity are consistent with theexperimental values. At the same time, the model is able to simulate thesecondary AM particles cracking by the fracture of the bond under force. Ourmodel is the first of its kind being able to predict the fracture of thesecondary particles along the calendering process. This work provides a toolfor guidance in the manufacturing of optimized LIB electrodes.

Computational Model for Predicting Particle Fracture During Electrode Calendering