Development of computational tools and experimental study for predicting deformation and failure of vehicle batteries under high mechanical load

Because oil is a resource that is soon exhausted. In addition, the combustion of fossil fuels produces a large quantity of CO2. Therefore, a key challenge is to secure mobility, efficient and alternative drive forms and fuels. Lithium-ion battery systems have been used as the main power source in the new generation electric vehicles.
Their mechanical performance is of great importance for vehicle crashworthiness design. From the point of view of safety of lithiumion battery packs, electric vehicle crashworthiness is under clouds of unknowns and ambiguities, even for battery and car manufacturers. In this research, a study has been performed to investigate the mechanical and failure behaviour of vehicle batteries and modules
especially subjected to a final wedge cutting test. The tests were conducted on a commercially available Li-ion battery module at low speed using a standard material testing system. The force and voltage change with the cutting depth were measured, and the failure modes were analysed in detail. Then a finite element (FE) model based on the explicit FEA solver Altair Radioss™, was developed to simulate the wedge cutting process. The model predictions compared with the test data in terms of damage modes and force-displacement response, and results demonstrate a reasonable agreement.