Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack Volvo Group India, Pvt., Limited

Format:

Book

Conference/Event

Author/Creator:

Bhat, Sadashiv C., author.

Contributor:

Sugumar, Mohanraj

Conference Name:

Symposium on International Automotive Technology (2026) (2026-01-28 : Pune, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events.This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material properties, pressure profiles, and temperature data derived from computational fluid dynamics (CFD) analyses. Boundary conditions are carefully applied, and post-processing techniques are used to extract meaningful insights into stress distribution, deformation, sealing behavior, and structural failure modes.The simulation results also identify critical stress concentrations, sealing opening/closing, plastic strain, and potential rupture, offering a detailed understanding of how battery enclosures respond to thermal and mechanical loading. By performing analytical calculations to validate the initial design, the need for a simulation framework became evident to ensure predictive accuracy and support iterative refinement of design parameters. This approach enables early identification of design vulnerabilities, reduces dependence on extensive physical testing, and helps accelerate the overall development cycle.In conclusion, the integration of coupled thermal and mechanical simulation not only enhances design robustness and safety but also supports regulatory compliance and cost-effective development. This study highlights the vital role of virtual validation in the advancement of battery technologies, enabling the creation of safer, more efficient, and more sustainable energy storage systems for next-generation electric mobility and beyond

Notes:

Vendor supplied data

Publisher Number:

2026-26-0414

Access Restriction:

Restricted for use by site license