Integrated Crashworthiness Analysis of Electric Vehicle Battery Shells and Chassis: A Finite Element Study with Abaqus

Abstract

This paper aims to comprehend and predict the mechanical behavior of the genuine Tesla Model-S chassis and the battery module during a crash in Abaqus/Explicit. The parametric method was incorporated with varying impact velocities from 27.7, 55.5, and 100m/s and battery shell thickness from 1mm to 3mm. The asymmetry model was considered for both the chassis and battery pack. Aluminum 6061 and ASI430 SS are assigned to the chassis profile and the battery shells (cells). A Johnson-Cook (JC) plastic and damage failure model has been implemented to simulate realistic crash behavior. Displacement, energy, and force results were captured during the simulation. A battery shell thickness of 3mm showed higher resistance than a 1mm thick shell at 55.5 m/s. The numerical findings reveal the dynamic response in displacement and compression under various loading conditions for both individual profiles. Additionally, the study presents a detailed inspection of each cell module, graphically demonstrating how the individual cells respond to initial positions, crashes, and external deformation (shear) caused by collision energy. The finite element model is validated against previous experimental and numerical studies, successfully simulating crashworthiness. The present study provides significant insights that have the potential to improve the safety and efficiency of battery-operated vehicles through the design and optimization of their structures.