Citation :

Sonali Kaluram Sabale, Deepak Watvisave, Ravikant Nanwatkar, Vishwajeet Vinayak Gaike, "Numerical Modeling and Experimental Validation of Mechanical Performances of Li-Ion Battery Cells/Modules/Packs with Various Form-Factor Design for EV Applications," International Journal of Engineering Trends and Technology (IJETT), vol. 74, no. 1, pp. 193-216, 2026. Crossref, https://doi.org/10.14445/22315381/IJETT-V74I1P115

Abstract

The rapid electrification of conventional and Electric Vehicles (EVs) requires Lithium-ion (Li-ion) batteries that are characterized by high energy density, safety, and durability over a wide range of operating conditions. Although the electrochemical performance has received much attention, relatively limited research has been able to address the mechanical responses of Li-ion robustly during cell, module, and pack modes, and in particular, the response in the various form-factor cells, i.e., cylindrical, pouch, and prismatic cells. The currently available literature can usually be reduced to one or the other numerical or experimental studies, with no thorough cross-validation of both the computational and experimental cases. Such a gap limits the creation of predictive and dependable methods to assess structural integrity conditions due to normal operation and abuse. The proposed study fills the research gap by creating high-fidelity models of Li-ion battery cells, modules, and packs in varying form-factor designs before subjecting them to the systematic and controlled conditions of mechanical loading and testing. The suggested method applies Finite Element Modeling (FEM) in combination with multi-scale simulations to determine stress, strain, deformation, and failure modes. Predictive reliability of tested and used numerical models is strengthened by experimental resolution, which is achieved by conducting compression, vibration, and impact tests to guarantee the predictive reliability of the numerical models. This work presents a holistic framework of connecting the modeling and experiments at various form factors and at different levels of integration, in contrast to currently available literature that is mainly concentrated on single-scale or form-specific design. The novelty is associated with the connection of computational predictions with the empirical data, providing an effective and powerful approach to assess mechanical performance. Results underscore significant variation in the deformation behavior and failure limits across form factors, suggesting optimal design, safety, and structural durability of EVs in battery applications.

Keywords

Electric Vehicle, Lithium-Ion Batteries, Form Factors, Mechanical Stability, Numerical Modeling, Simulation.

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