Tantalum–tungsten alloys have been widely used in different industrial sectors—for example, in chemical, medical, aerospace, and military equipment. However, they are usually difficult to cut because of the large cutting force, rapid tool wear, and poor surface finish during machining. This paper presents the machining performance and cutting tool wear of AlCrN/TiAlN-coated carbide tools during the milling process of Ta-2.5W. The effects of cutting parameters on the cutting forces and surface roughness of AlCrN/TiAlN-coated carbide tools were obtained and analyzed. The results show that the wear resistance of AlCrN-coated tools is better than that of TiAlN-coated tools, and that the main wear mechanisms of both cutting tools are crater wear, adhesive wear, and diffusion wear. Compared to TiAlN-coated tools, AlCrN-coated tools reduced the cutting forces by 1% to 15% and decreased the surface roughness by 6% to 20%. A cutting speed within the range of 80–120 m/min can ensure a low cutting force while maintaining good surface roughness, which is more conducive to machining Ta-2.5W.

Interior Permanent magnet synchronous motors (IPMSMs) have become the preferred powertrain solution for electric vehicles due to their exceptional performance characteristics. However, the high-frequency electromagnetic noise generated during motor operation poses a significant challenge to occupant comfort within the vehicle. This study provides a comprehensive analysis of the electromagnetic forces, modal characteristics, and vibration noise for a 12-pole, 36-slot IPMSM, incorporating theoretical and simulation-based approaches as well as modal tests. By innovatively combining orthogonal experimental design with nonparametric regression techniques, a response surface model is developed to accurately characterize and optimize the radial electromagnetic force harmonics of the motor. The optimization results reveal a significant 37.7 % reduction in the motor’s surface vibration velocity and an 8.5 % decrease in peak noise levels, successfully meeting the engineering objectives for vibration and noise attenuation. This study not only contributes to the advancement of noise control technologies in electric vehicle power systems but also provides novel insights and methodologies for motor design, offering significant practical value and engineering relevance.

This study proposes a multiphysics coupling optimization methodology to mitigate electromagnetic noise and cogging torque in external rotor permanent magnet synchronous motors. A slot-pole interaction analysis model is developed, incorporating nonlinear magnetic permeability modulation effects, to elucidate the spatiotemporal distribution characteristics of electromagnetic forces and their resonance mechanisms with structural modes. A novel energy-based method for cogging torque calculation is introduced, achieving a 20% improvement in computational efficiency while maintaining numerical errors below 2% . Furthermore, a cylindrical shell vibration model based on nodal force mapping and a boundary element-based acoustic radiation prediction framework are established. Multiobjective optimization leveraging response surface methodology and a modified particle swarm optimization algorithm is employed to quantify the impact of temperature gradients on permanent magnet performance and nonlinear synergistic effects among parameters. Postoptimization results demonstrate a significant reduction in overall sound pressure level to 27.69 dBA under rated conditions and a 38.5% decrease in cogging torque, validating the effectiveness of the proposed electromagnetic-structural-acoustic codesign approach. This work provides a systematic framework for multiphysics collaborative optimization in high-performance motor design.