Search

The battery-pack system of electric vehicles is prone to collide with low obstacles on the road, causing battery short circuits and even explosions. It poses a great safety threat to passengers and drivers. The honeycomb structure's high energy absorption and lightweight properties have made it a popular choice in the automotive industry. This paper designs different bio-inspired honeycomb structures to a battery-pack system of electric vehicles to improve the crashworthiness performance. The effects of different bio-inspired honeycomb structures on the crashworthiness of a battery-pack system during frontal impact are analyzed based on a nonlinear finite element model. First, the geometric parameters of seven different bio-inspired honeycomb individual units are described. The overall structure of the honeycomb is applied to a battery-pack system. Second, the nonlinear finite element model of a battery-pack system and honeycomb structures are established and verified. Then, collision simulations are conducted. The deformation and the maximum stress of a battery-pack's bottom shell are computed. The energy absorbed by the honeycomb structures during frontal impact are investigated. The results indicate that the proposed bio-inspired honeycomb structure mimicking grass stems improves the safety performance of battery-pack systems most. Finally, a parametric design is carried out on the bio-inspired honeycomb structure. The effects of wall thicknesses and the number of replacement hexagons on the crashworthiness performance are analyzed. The honeycomb structure preforms best when thickness is 1 mm and the number of replacement hexagons is 2 and 4. The optimized bio-inspired honeycomb structure reduces the deformation of the battery-pack' bottom shell by up to 30%, and maximum stress by 10%. • The deformation, maximum stress, and energy absorption are investigated. • The effects of seven bio-inspired honeycomb structures are analyzed. • Parametric design is carried out to further improve the crashworthiness performance. • The deformation of the bottom shell can be reduced by up to 30%. [ABSTRACT FROM AUTHOR]

Progressive deformation of honeycomb structures subjected to in-plane loading was approximately analyzed by using the collapse modes of hexagonal unit cells. The collapse modes were categorized as freely compressive, restricted compressive, and shear. Moreover, there were five characteristic deformation patterns, namely deformation bands. Average stresses of the collapsing honeycomb models were evaluated in terms of the plastic collapse stress per hinge and total number of hinges of progressively arising deformation bands. The displacements of the models were obtained by multiplying the displacement per cell with the number of collapsed cells. The present method was used to analyze progressive deformation of typical honeycomb structures. The validity of the stress-displacement relations derived for some structures was confirmed by comparing them with finite element method (FEM) results. Our method is much simpler than FEM but just as effective. [ABSTRACT FROM AUTHOR]

Abstract: The in-plane impact behavior of honeycomb structures randomly filled with rigid inclusions was studied by using the finite element method to clarify the effect of inclusions on the deformation process, mean stress, densification strain, and absorbed energy. The deformation processes of the models were disturbed by inclusions; shear bands were pinned, and the cell regions surrounded by inclusions were shielded. Mean stress, densification strain, and absorbed energy per unit volume normalized by the values of the model without inclusions were found to be only dependent on the fraction of inclusions. As the volume fraction of inclusions increased, the normalized mean stress linearly increased and the normalized densification strain linearly decreased. The normalized absorbed energy per unit volume could be approximated by an inverted parabolic equation. The energy absorption of models with inclusions having volume fractions from 0 to 0.25 was larger than that of the models without inclusions. In particular, honeycomb models with fractions of inclusion from 0.1 to 0.2 exhibited the maximum absorbed energy. The model with a volume fraction larger than 0.4 could not be compressed because the inclusions in the model had already percolated before deformation. The in-plane impact behavior of honeycomb structures as energy absorbing materials can be designed by using the approximate equation and selecting the volume fraction of inclusions. [Copyright &y& Elsevier]