Integrated crashworthiness analysis of vehicle chassis and battery modules using Abaqus

This study explores vehicle crashworthiness through numerical simulation and analysis using Abaqus/Explicit, a finite element solver specialized in dynamic and nonlinear problems. The research evaluates deformation, stress distribution, and energy absorption in vehicle structures and battery modules under high-speed collision scenarios. Parametric studies were conducted on Tesla Model S chassis and battery shells, analyzing impact velocities from 27.7 m/s to 100 m/s and shell thicknesses of 1 mm and 3 mm. The results revealed significant variations in performance due to material properties, geometry, and impact conditions. The 3 mm battery shell demonstrated superior energy absorption and reduced deformation compared to the 1 mm shell, particularly at higher velocities. Stress analysis identified critical zones on the chassis and battery module, highlighting the need for strategic reinforcements. Thermal evaluations showed increased risks of thermal runaway in thinner shells, emphasizing the importance of robust thermal management systems for electric vehicles (EVs). Key findings include the effectiveness of thicker shells in mitigating stress and damage, the role of optimized crumple zones in enhancing chassis performance, and the necessity of high-strength materials like aluminum 6061-T6 and ASI430 stainless steel. This research provides practical recommendations for designing safer, more reliable EVs, contributing to crashworthiness analysis methodologies and laying the groundwork for future experimental validations.