Sequential Multi-Scale Modeling Using an Artificial Neural Network-Based Surrogate Material Model for Predicting the Mechanical Behavior of a Li-Ion Pouch Cell Under Abuse Conditions

To analyze the safety behavior of electric vehicles, mechanical simulation models of their battery cells are essential. To ensure computational efficiency, the heterogeneous cell structure is represented by homogenized material models. The required parameters are calibrated against several characteristic cell experiments. As a result, it is hardly possible to describe the behavior of the individual battery components, which reduces the level of detail. In this work, a new data-driven material model is presented, which not only provides the homogenized behavior but also information about the components. For this purpose, a representative volume element (RVE) of the cell structure is created. To determine the constitutive material models of the individual components, different characterization tests are performed. A novel method for carrying out single-layer compression tests is presented for the characterization in the thickness direction. The parameterized RVE is subjected to a large number of load cases using first-order homogenization theory. This data basis is used to train an artificial neural network (ANN), which is then implemented in commercial FEA software LS-DYNA R9.3.1 and is thus available as a material model. This novel data-driven material model not only provides the stress–strain relationship, but also outputs information about the condition of the components, such as the thinning of the separator. The material model is validated against two characteristic cell experiments. A three-point-bending test and an indentation test of the cell is used for this purpose. Finally, the influence of the architecture of the neural network on the computational effort is discussed.