COLLISION SIMULATION AND LIGHTWEIGHTING RESEARCH ON BATTERY PACK STRUCTURE OF NEW ENERGY VEHICLES

As core components of new energy vehicles, the anti-collision performance and weight of power battery packs directly affect vehicle safety and driving range.This paper conducts research on the stress concentration problem of battery pack structures under collision conditions and the demand for lightweighting.A three-dimensional model was established through SolidWorks, and FEA was conducted using ABAQUS to evaluate the stress distribution of each component under collisions in the X and Y directions.It was found that the stress of components such as the lifting lugs and the box cover exceeded the yield strength of the material.Based on this, the arrangement of battery modules, the structure of the box cover, the lifting lugs and the bottom beam were optimized, such as in a three-part stacked configuration like the character "", replacing high-strength materials, and adding energy-absorbing structures, etc.The results show that after optimization, the maximum stress of the module is reduced by 30%, the tensile bearing capacity of the lifting lugs is increased by 82%, the bottom beam is lightened by 14.3%, and the stress of the key components is all below the safety threshold.This research provides an engineering reference for the safety and lightweight design of battery packs.