Guangxi Li

Battery packs for new energy vehicles have evolved from simple load-bearing and protective assemblies into multifunctional safety structures integrating structural support, crash protection, thermal-runaway mitigation, flame retardancy, electrical insulation, electromagnetic interference shielding, waterproof sealing, and long-term reliability. Fiber-reinforced polymer composites are promising for upper covers, underbody shields, trays, cross beams, side frames, and local protective structures because of their low density, corrosion resistance, design flexibility, and functional-integration potential. However, composite-part performance is strongly governed by forming. Resin flow, impregnation, curing or cooling shrinkage, fiber orientation, filler dispersion, and interfacial bonding may induce voids, dry spots, resin-rich regions, delamination, warpage, and fiber waviness, thereby affecting load bearing, sealing, thermal protection, and durability. This review focuses on composite-forming technologies for new energy-vehicle battery packs. It summarizes component-level service requirements and material systems and compares representative forming routes, including sheet molding compound (SMC), prepreg compression molding/wet compression molding (PCM/WCM), resin transfer molding/high-pressure resin transfer molding (RTM/HP-RTM), vacuum-assisted resin transfer molding (VARTM), long-fiber thermoplastic direct processing (LFT-D), glass-mat thermoplastic (GMT), thermoplastic sheet forming, pultrusion, and multi-material joining. These routes are evaluated from six dimensions: material form, forming cycle, typical defects, representative mechanical performance, applicable components, and engineering maturity. The review further discusses defect mechanisms, performance effects, detection and control methods, and the roles of in-line monitoring, non-destructive testing, process simulation, machine learning, and digital twins in closed-loop quality manufacturing. Finally, engineering challenges are examined in multi-material joining, thermal-safety integration, low-carbon recycling, and standard certification. Composite-material battery-pack structures should therefore be developed as coordinated design and closed-loop manufacturing systems linking materials, processes, defects, performance, and validation.

To address severe PCD tool wear during the milling of high-volume-fraction SiC_p/Al composites, a synergistic milling process coupling pulsed laser pretreatment with ultrasonic vibration was proposed. Five-factor, four-level orthogonal experiments were conducted on 70 vol.% SiC_p/Al composites to investigate the effects of milling speed, feed per tooth, cutting depth, laser power, and ultrasonic amplitude on milling forces and tool wear, and a tool wear prediction model was established. The results showed that the factors influencing tool wear, in descending order, were feed per tooth, cutting depth, milling speed, laser power, and ultrasonic amplitude. Appropriate laser power and ultrasonic amplitude reduced cutting loads and suppressed tool wear. The model achieved a coefficient of determination of 0.7887 and was statistically significant overall. The optimal parameter combination was 50 m/min, 0.02 mm/z, 0.1 mm, 60 W, and 3.5 μm, under which the tool wear loss was 1.0 mg, representing a reduction of 61.54% compared with the maximum-wear condition. The main wear modes of the PCD tool included rake-face grooving and fatigue spalling, flank-face abrasive wear, and cutting-edge micro-chipping. These findings provide a useful reference for the precision milling of SiC_p/Al composites.

Carbon fiber-reinforced polymer (CFRP) composites are in urgent demand in the aerospace, new energy vehicle, and wind power sectors owing to their superior specific strength, specific modulus, and lightweight potential. However, molding defects, such as voids, dry spots, and delamination, arising from their anisotropy and weak interlaminar bonding, severely constrain their service performance. Advanced molding technologies represent the key to overcoming this bottleneck. This paper systematically reviews typical advanced molding technologies in the field of CFRP composites, including resin transfer molding (RTM) and vacuum-assisted resin transfer molding (VARTM) in liquid composite molding, autoclave molding and compression molding (CM) in prepreg molding, and automated fiber placement (AFP) and material extrusion (ME) in automated molding. From an integrated perspective of “technological evolution–process characteristics–defect mechanisms–optimization strategies,” this review summarizes the technical principles, development trajectories, and core advantages of each process, analyzes the formation mechanisms of typical defects, including voids, dry spots, delamination, wrinkles, warpage, and melt instability, and summarizes multidimensional optimization advances in process parameter regulation, numerical simulation, resin modification, equipment upgrading, path planning, and thermal management. Furthermore, the differences and complementarities among these processes in terms of molding precision, efficiency, cost, and applicable scope are compared. Finally, future development directions, including digital twins, green low-carbon manufacturing, ultra-large integrated structures, multi-process integration, standardized defect characterization, and low-cost collaborative design, are discussed. This paper aims to provide systematic theoretical references and technical support for the optimization and upgrading, process integration, and industrial application of advanced CFRP molding technologies.

With the core advantages of high energy efficiency, high power density, and reliable operation, high-voltage permanent magnet motors have become the mainstream development direction of modern motor technology. However, the risk of demagnetization caused by excessive temperature increases in permanent magnets has become a key bottleneck restricting motor performance and operational reliability, which makes research on the flow and heat transfer characteristics of motor cooling systems of great engineering value. Taking the 710 kW high-voltage permanent magnet motors as the research object, this study established a global flow field mathematical model covering the internal and external air duct cooling systems of the motor based on the theories of computational fluid dynamics and numerical heat transfer, and systematically analyzed the flow characteristics and distribution laws of cooling air. The thermal–fluid coupling numerical method was employed to simulate the temperature field of the motor, and the overall temperature distribution of the motor, temperature gradient of key components, and maximum temperature value were accurately obtained. To verify the validity of the established model, a test platform for the cooling system performance was designed and built. Measuring points for wind speed, air temperature, and component temperature were arranged at key positions, such as the stator radial ventilation ducts, and experimental tests were conducted under the rated operating conditions. The results show that the flow field distribution of the internal and external air ducts of the motor is reasonable and that the cooling air flows uniformly, with the external and internal circulating air volumes reaching 1.2 m³/s and 0.6 m³/s, respectively, which meets the heat dissipation requirements. The maximum temperature of 95 °C occurs in the stator winding area, and the maximum temperature of the permanent magnets is controlled within the safe range of 65 °C. The simulation results were in good agreement with the experimental data, with an average relative error of only 4%, which fell within the engineering allowable range, thus verifying the accuracy and reliability of the established global model and thermal–fluid coupling calculation method. This study reveals the thermal–fluid coupling transfer mechanism of high-voltage permanent magnet motors and provides a theoretical basis and engineering reference for the optimal design, precise temperature rise control, and reliability improvement of motor cooling systems.

An efficient cooling configuration is critical for ensuring the safe operation of electrical machines and is key for optimizing the iterative design of motors. To improve the heat dissipation performance of high-power, explosion-proof, integrated variable-frequency permanent magnet motors used in mining and reduce the risk of permanent magnet demagnetization, this study considers a 1600 kW mining explosion-proof variable-frequency permanent magnet motor as its research object. Based on the zigzag-type water channel structure of the frame, a novel rotor-cooling scheme integrating axial–radial ventilation structures and axial flow fans was proposed. The temperature field of the motor was simulated and analyzed using a fluid–thermal coupling method. Under rated operating conditions, the flow characteristics of the frame water channel and the temperature distribution law inside the motor were compared when the water supply flow rates were 5.4, 4.8, 4.2, 3.6, 3, 2.4, and 1.8 m³/h, respectively, and the relationship between the motor temperature rise and the variation in water flow rate was revealed. A production prototype was developed, and temperature rise tests were conducted for verification. The test results were in good agreement with the simulation calculation results, thereby confirming the accuracy of the simulation calculation method. The results provide an important reference for enterprises in the design optimization and upgrading of high-power explosion-proof integrated variable-frequency permanent-magnet motors.

The ultrasonic vibration-assisted milling process was used to study the difficult-to-machine aerospace material titanium alloy TC4 and explore the milling parameters that fit the processing. Based on the orthogonal experimental method, the changes in cutting force, roughness, and surface morphology under conventional and ultrasonic-assisted milling conditions were studied, and the relationship between various processing parameters and their effects was obtained. The results showed that the cutting force was most affected by the feed per tooth and cutting depth. Adding ultrasonic vibration could change the surface texture and significantly impact roughness. By adding an appropriate amplitude of ultrasonic-assisted milling, the maximum average cutting force can be reduced by more than 20.66%, and the maximum surface roughness can be reduced by 44.23%, making the workpiece surface produce regular “sine/cosine” patterns and improving the surface quality of the workpiece. Compared with conventional milling, the deformation layer of the workpiece slightly increased under ultrasonic-assisted milling. The cutting force and surface roughness of titanium alloy TC4 under ultrasonic-assisted milling were reduced. A reasonable selection of processing parameters can further improve cutting force and other parameters, providing a reference basis for the processing of aerospace materials.

This study aimed to develop a longitudinal ultrasonic-assisted milling system to investigate the machinability of titanium (Ti) Alloy Ti-6Al-4V (TC4). Aiming at reduced milling force and enhanced surface quality, ultrasonic-assisted milling was investigated taking into account the following processing parameters: spindle speed (cutting rate) n, feed per tooth f_z, milling depth a_p, and ultrasonic amplitude A. A comparison was made with conventional milling. The results of univariate tests demonstrated that the ultrasonic amplitude had the most significant impact on the milling force along the z-axis, resulting in a reduction of 15.48% compared with conventional milling. The range analysis results of multivariate tests demonstrated that a_p and f_z were the dominant factors influencing the cutting force. The minimum reduction in the milling force in ultrasonic-assisted milling along the x-, y-, and z-axes was 11.77%, 15.52%, and 17.66%, respectively, compared with that in conventional milling. The ultrasonic-assisted milling led to reduced surface roughness and enhanced surface quality; the maximum surface roughness in ultrasonic-assisted milling was 25.93%, 36.36% and 26.32% in terms of n, f_z, and a_p, respectively. In longitudinal ultrasonic-assisted milling, the periodic “separation-contact” was accompanied by microimpacts, resulting in even smaller intermittent periodic cutting forces. Hence, regular fish scale machining mesh was observed on the processed surface, and the workpiece surface exhibited high cleanness and smoothness. The reasonable configuration of ultrasonic-assisted milling parameters can effectively improve the milling force and surface quality of Ti alloys and accumulate reference data for the subsequent machining process research.

This study conducted longitudinal ultrasonic-assisted milling (UAM) tests and optimized a combination of milling technological parameters to achieve high-quality machining of TC18 titanium alloy. The motion paths of the cutter under the coupled superposition states of longitudinal ultrasonic vibration and end milling were analyzed. Based on the orthogonal test, the cutting forces, cutting temperatures, residual stresses, and surface topographical patterns of TC18 specimens under different UAM conditions (cutting speeds, feeds per tooth, cutting depths, and ultrasonic vibration amplitudes) were examined. The differences between ordinary milling and UAM in terms of machining performance were compared. Using UAM, numerous characteristics (including variable cutting thickness in the cutting area, variable cutting front angles of the tool, and the lifting of the cuttings by the tool) were optimized, reducing the average cutting force in all directions, lowering the cutting temperature, increasing the surface residual compressive stress, and significantly improving the surface morphology. Finally, fish scale bionic microtextures with clear, uniform, and regular patterns were formed on the machined surface. High-frequency vibration can improve material removal convenience, thus reducing surface roughness. The introduction of longitudinal ultrasonic vibration to the end milling process can overcome the limitations of traditional processing. The optimal combination of UAM parameters for titanium alloy machining was determined through the end milling orthogonal test with compound ultrasonic vibration, which significantly improved the surface quality of TC18 workpieces. This study provides insightful reference data for subsequent machining process optimization.

To improve the pod-picking efficiency of the combine harvester for both peanut seedlings and peanuts, a longitudinal axial flow pod-picking device is designed in this study. The fixation and adjustment modes of the pod-picking rod were determined. The pod-picking roller’s rotational speed, the pod-picking roller’s diameter, the pod-picking roller, the pod-picking roller’s effective rod-picking length, and the screw-feeding stirrer’s critical parameters were determined by theoretical calculation. A combined design of quadratic regression orthogonal rotation was achieved by using Box-Behnken design (BBD) response surface optimization analysis in Design-Expert, with the linear speed of the pod-picking roller, the clearance between the concave screen and the pod-picking roller, and the spacing between the pod-picking rods as the testing factors, and the picking rate and the crushing rate as the indicators. The optimized parameters are as follows: a linear speed of the pod-picking roller of 6.8 m/s, a clearance between the concave screen and the pod-picking roller of 28.5 mm, and a spacing between the pod-picking rods of 18.60 mm. The performances of conventional peanut full-feeding pod-picking devices and the proposed peanut root-disk full-feeding longitudinal axial flow pod-picking device were investigated and compared to clarify the pod-picking performance of the proposed peanut root-disk full-feeding longitudinal axial flow pod-picking device under optimized parameters. The results showed that the picking and crushing rates of the proposed peanut root-disk full-feeding longitudinal axial flow pod-picking device under optimized parameters were 98.93 and 1.62%, respectively, both of which were superior to those of conventional peanut full-feeding pod-picking devices. A pod-picking device matching the combine harvester for peanut seedlings and peanuts was processed under optimized parameters. Field tests revealed that the picking and crushing rates of the proposed harvester were 99.07 and 1.58%, respectively, meeting the industry standards. These findings are instrumental in the further improvement of peanut pod-picking devices.

This study attempts to optimize the arc-shaped coned disk affecting the uniformity of the earlier designed fertilizer apparatus (FA), in particular, for application in the rice–oil rotation region in the middle and lower reaches of the Yangtze River, China. Based on theoretical analysis, a circular coned disk with the curvature gradual decline (GD) from top to bottom was designed, and the equation of the circular cone was determined. The EDEM discrete element software was used, using the coefficient of variation of the fertilization amount consistency in every row, the coefficient of variation of the fertilization amount stability, and the coefficient of variation of the fertilization amount consistency in the same row as evaluation indices. Simulations and comparative tests of FA performance were performed for three cases of the busbar top-to-bottom curvature variation: (i) gradual increase (GI), (ii) gradual decline (GD), and (iii) zero (0) variation. The experimental results show that at the FA rotation speed of 100~120 r/min and tilt of 1°~5°, the optimized FA had the optimal performance. High tilts and low rotation speeds provided the worst performance, with the variation coefficient of inter-row fertilization amount consistency of the FA below 10.23%. The variation coefficient of fertilizing amount stability was lower than 6.74%. The variation coefficient of intra-row fertilizing amount consistency was lower than 3.52%, while all performance indicators met the quality requirements of fertilizer discharge. Bench tests of the FA revealed that the variation coefficient of inter-row fertilizing amount consistency of the FA was below 10.23%, the variation coefficient of fertilizing amount stability was below 6.74%, and the variation coefficient of intra-row fertilizing amount consistency was below 3.52%. Field tests of the FA revealed that the variation coefficient of inter-row fertilizing amount consistency was below 7.68%, the variation coefficient of fertilizing amount stability was below 4.95%, and the variation coefficient of intra-row fertilizing amount stability was below 3.57%. All parameters were better than the industry standard, demonstrating that the FA had good fertilizing performance and met the quality requirements of field fertilization operations.