Approaches to Structural Optimisation of Multi-Chamber Aluminium Profiles for Side Crash Protection in Electric Vehicles
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This investigation includes two different approaches for the structural optimisation of an AA6005-T7 multi-chamber aluminium profile [1] for side crash protection of battery trays in electric vehicles. We conducted experimental material and component tests in order to build a reliable finite element model that was then used in the optimisation. Because of the complexity of the collapse mechanism and the thick walls typically used in this kind of profiles, we used 3D solid elements in our finite element model, which increases computational cost. We ran two different optimisations using a plane-strain crushing model and a full 3D pole-crushing model of the profiles, and we have compared the similarity and robustness of the optimal designs, as well as the computational time.
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