Calendering in Battery Manufacturing (ABP)

This Application Best Practice (ABP) outlines how to simulate the electrode compression process using Ansys Rocky™ particle dynamics simulation software to improve battery performance. It covers setting up a representative volume element (RVE), injecting and homogenizing particles, creating and calibrating bonds, and analyzing outputs like porosity, thickness, and roller stress. The simulation uses advanced features such as electrostatic forces, non-uniform binder modeling, and elastoplastic contact models. Optimization is achieved through Ansys optiSLang® process integration and design optimization software and real-time control via Ansys TwinAI™ AI-powered digital twin software, enabling efficient, high-fidelity modeling of the calendering process. 

Learning Outcomes:

Following completion of this Application Best Practice (ABP), you will be able to:

• Understand the role and challenges of the calendering process in battery electrode manufacturing
• Set up a simulation using a Representative Volume Element (RVE) in Ansys Rocky software
• Model particle behavior and binder interactions using bond creation and calibration techniques
• Analyze key outputs such as porosity, thickness, and roller stress to evaluate process performance 
• Apply optimization and digital twin tools (Ansys optiSLang software and Ansys TwinAI software) for real-time process control and design improvement

Prerequisites:

• Specific knowledge needed: Discrete Element Method, Bonded Sphere Contact Model
• Specific training user should read/follow before reading this document: 
  • Ansys Rocky Tutorial: Transfer Chute | Ansys Innovation Courses 
  • Ansys Rocky: Static Angle of Repose Test | Ansys Innovation Courses 
  • Introduction to Bond Model (add-on documentation: Chapter 3: Bond Model Module) 

Please note: These training materials were developed and tested in the 2025R1 release.

Application Best Practices (ABPs) outline engineering design goals for specific applications and provide guidance for how to achieve those goals using Ansys simulation software. It is important to note that a Geometry File or other Input Files are not always available. ABPs, as opposed to the official training-material workshops/tutorials, are not meant to be a step-by-step instruction document. ABPs are a link between product-based training courses and application specific tutorials, educating on the "how" and "why" of the best modeling approach, highlighting best practices and workflows for a particular application.