battery casing analysis and results abaqus 2.pptx

Literature

1. Structural Analysis and Cost Estimation of bottom plate of Land X-Battery Casing

2. Objective To determine the deformation and stresses in the battery casing bottom cover Material Properties of Aluminium(Al-6061) Density: 2.7 g/cc Youngs Modulus: 70 GPa Poison ratio: 0.3 Left side cover Top Cover Front Cover Rear cover Material Properties of Glass epoxy Density: 1.67 g/cc Youngs Modulus: 22 GPa Poison ratio: 0.114 In this case, only the bottom cover is considered for analysis and comparison as it is the main load carrying member.

3. Boundary conditions and Load Calculations Dimensions: Length(l): 2702.5 mm Breath(b): 953.8 mm Thickness: 6 mm Geometry for analysis. Fixed support Load Calculations Battery pack weight: 57 kg each No of battery packs: 12 Factor of safety: 1.5 Total load on component(bottom cover): 10065 N Load

4. Boundary conditions and Analysis AL-6061 Thickness: 6 mm Deformation: 6.83 mm Fixed at edges Load:10,065

5. Boundary conditions and Analysis Composite (AER 101 glass epoxy) Thickness: 13 mm Deformation: 5.62 mm Fixed at edges Load:10,065

6. Static Structural Analysis and Material Cost Estimation for bottom plate Material AL-6061 Glass-epoxy (AER 101) Thickness (mm) 6 13 Deformation (mm) 6.83 5.62 Cost (rupees) ₹ 16,078 8HS (300 gsm) - ₹ 72,592 (351%↑) Mass of the component (kg) 41.76 56 (34%↑) The deformation of the bottom plate is 6.83 mm for Aluminium. To achieve the same (nearby value) deformation using glass epoxy, a thickness of 13 mm is required as the modulus is low. Using 8H satin weaved glass epoxy increases the cost by 351% and the weight is increased by 34% when compared with aluminium. A fiber volume fraction of 43% is achieved for this analysis. The cost of araldite 40005 is almost 50% high when compared with AER 101 which makes the overall cost of about ₹ 87,072 when araldite is used as a matrix. Note: The costs calculated (both AL and composite) are only for materials and does not include manufacturing, manpower etc.

7. Summary Considering the cost of composite (glass-epoxy) and the weight due to its increased thickness, it may not be a suitable replaceable material for aluminium. Since the glass-epoxy is having a very low modulus, a higher modulus composite (ex. Carbon-epoxy) can be considered to decrease the weight of the casing. However, to reduce the cost using glass fabric, a plain weaved fabric can be considered which is cheaper than 8HS.