Multi-objective optimization of aluminum foam-filled battery boxes for electric vehicle safety

İsmail Yay; Ahmet Remzi Özcan; Emre Demirci

Multi-objective optimization of aluminum foam-filled battery boxes for electric vehicle safety

Authors

İsmail Yay Department of Mechanical Engineering, Bursa Technical University, Turkiye https://orcid.org/0000-0002-4467-2672
Ahmet Remzi Özcan Department of Mechatronics Engineering, Bursa Technical University, Turkiye https://orcid.org/0000-0002-4093-1059
Emre Demirci Department of Mechanical Engineering, Bursa Technical University, Turkiye https://orcid.org/0000-0002-1968-0291

Abstract

In this study, a multi-objective optimization methodology is used to assess the crashworthiness of an aluminum foam-filled battery box designed for passenger cars. Unlike most research focusing on axial crushing, this research investigates the side pole impact scenario, which is less explored in electric vehicle battery boxes. Finite element simulations are conducted to reduce peak crushing force (PCF) and increase specific energy absorption (SEA) compared to the initial design. Key design variables include three different aluminum foam densities, wall thickness, and cross-sectional dimensions of battery box components. Four surrogate models are evaluated to approximate the simulation results, and the Non-Dominated Sorting Genetic Algorithm (NSGA-II) is employed to achieve optimal outcomes. The results show that multi-objective optimization significantly improves crashworthiness. The choice of aluminum foam density plays a crucial role in controlling deformation behavior under impact conditions. These findings offer a new approach to designing battery boxes with enhanced crashworthiness for electric vehicles.

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Published

2025-02-04

Issue

Articles in Press

Section

Original Article

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