Structural design and simulation of Composite Metal Hybrid based battery enclosure for an electric vehicle

Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was done to optimize the weight of battery pack. The structural integrity and crash worthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Manufacturing aspects were discussed to ensure feasibility and integration. Modal analysis and load tests addressed demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications.