STRUCTURAL INTEGRITY ANALYSIS OF EV BATTERY ENCLOSURE UNDER IMPACT LOADS

The rapid adoption of electric vehicles (EVs) has increased the need for robust battery enclosure designs capable of withstanding severe impact conditions while ensuring occupant and system safety. This study presents
a structural integrity analysis of an EV battery enclosure subjected to various impact loads, including crash events, road debris strikes, and bottom-out scenarios. Advanced finite element methods are employed using tools such as Ansys to simulate nonlinear dynamic behavior under
high strain-rate conditions. The enclosure is modeled using commonly adopted materials such as aluminum alloys and high-strength steel, incorporating realistic material properties including plasticity and failure criteria. Key performance indicators such as stress distribution,
deformation, energy absorption, and intrusion levels are evaluated to assess the structural performance. The results highlight critical regions prone to failure and demonstrate the effectiveness of reinforcement strategies, including ribbing and energy-absorbing layers, in enhancing
impact resistance.