[Objective] Electromagnetic vibration characteristics are a core performance indicator of interior permanent magnet synchronous motor (IPMSM) for electric vehicles

directly determining their operational stability and playing a key role in noise control. Current research primarily focuses on the electromagnetic vibration features of IPMSM under normal operating conditions

while insufficient attention has been paid to the significant impact of stator and rotor deformations in practical scenarios. [Methods] This study focused on the air gap deformation caused by stator deformation and rotor mechanical stress deformation. The air gap permeance function after deformation was derived

and the expression of radial electromagnetic force for IPMSM under non-uniform air gap conditions was subsequently derived. Finite element simulations were conducted for validation. Finally

the difference in equivalent radiated power level on the motor housing surface before and after air gap deformation was calculated to clarify the variation patterns of vibration and noise. [Results] The simulation results demonstrated that: force waves of (n±m)p±ks orders (ks=1

2

3…8) were introduced by stator inner circular deformation through magnetic permeance modulation

depending on different deformation wave numbers. (n±m±2k)p-order force waves were generated by rotor mechanical deformation via the same modulation mechanism

and the amplitudes of inherent force waves were amplified. The low-order force waves modulated by stator deformation were found to easily couple with low-order structural modes at low rotational speeds

leading to non-negligible vibration noise. The inherent electromagnetic force wave amplitude was increased by rotor mechanical deformation at high speeds

leading to aggravated vibration. [Conclusion] This study reveals the correlation mechanism between stator/rotor deformation and electromagnetic vibration in IPMSM

providing a theoretical basis for the optimization of flux barriers and low-order modal decoupling under high-speed operating conditions.