Unlocking Electric Vehicle Efficiency: Exploring Simulation-Based Optimization in Sheet Molding Compounds (SMC)

As the automotive industry shifts towards sustainable practices, Electric Vehicles (EVs) have emerged as a promising solution to reduce carbon emissions and dependence on fossil fuels. One critical aspect of advancing #EV technology lies in optimizing the geometries of components made with Sheet Molding Compounds (SMCs) through a simulation-based approach. This method not only enhances the efficiency and performance of EVs but also contributes to their overall sustainability.

The role of simulation-based optimization in SMC component designs

Sheet Molding Compounds (SMCs) are widely used in the automotive industry due to their lightweight properties, high strength-to-weight ratio, and moldability. Optimizing the geometries of SMC components involves a comprehensive approach that integrates several advanced #simulation tools ranging from manufacturing, and material modeling, to finite element analysis. By utilizing simulation-based optimization techniques, engineers can analyze and refine the geometry of SMC components to achieve specific performance targets while minimizing material usage and production costs.

• One key aspect of the optimization is focusing on the structural optimization of the component geometry, as this is crucial for enhancing the strength and durability of SMC components while minimizing weight. By iteratively adjusting the geometry and analyzing the results, engineers can design SMC components that meet stringent safety standards while optimizing weight.
• Thermal management is a critical consideration in EV design, particularly concerning components such as battery enclosures. Optimizing the geometry of these components to improve heat dissipation and airflow can enhance the overall efficiency and lifespan of electric vehicle systems.
• Simulation-based optimization facilitates the integration of functional requirements with manufacturing constraints. By considering factors such as moldability, material flow during the molding process, and tooling complexity, engineers can develop SMC component geometries that are not only optimized for performance but also cost-effective to mass produce.

The simulation-based optimization of SMC component geometries is paramount in advancing the #efficiency, #performance, and #sustainability of electric vehicles. By leveraging advanced simulation tools and iterative design processes, engineers can tailor the geometry of SMC components to meet specific performance targets while optimizing structural integrity, thermal management, and manufacturability.

A comprehensive approach to battery cover simulation and optimization

To meet the escalating demand for a comprehensive end-to-end simulation workflow capable of simulating the entire process, we recently conducted a detailed case study focusing on an electric vehicle (EV) #battery cover.

The objectives of our case study were twofold: first, to compare the structural performance of the battery cover under different charge patterns, and second, to assess the performance of the SMC material in comparison to aluminum.

Our setup assumed the battery cover to be fixed on all edges using bolts and subjected to an impactor under a prescribed linear displacement ramp.

Employing state-of-the-art simulation tools from Hexagon Digital Materials and Moldex3D Northern America, Inc , our methodology encompassed various stages:

• Initiating the process, we constructed a detailed CAD model of the battery cover using #MSC Apex, and subsequently, a finite element model was generated using Marc.
• The Sheet Molding Compound (SMC) material model calibration was performed using #Digimat, based on a unique bundle approach and employing two-level homogenizations.
• The manufacturing simulation phase was executed using #Moldex3D, facilitating compression molding simulations for various charge patterns. The obtained results were seamlessly integrated and mapped onto the battery cover's finite element model through Digimat.
• The final step involved a coupled finite element simulation utilizing the #Marc solver, enabling a comprehensive analysis of how different charge patterns influenced displacement and failure contours.

Our study aimed at discerning the most suitable or unfavorable manufacturing strategies for optimal performance. Furthermore, we demonstrated the advantages of utilizing SMCs over aluminum, highlighting significant #weight #savings without compromising mechanical performance. This case study underscores the importance of a holistic simulation approach in evaluating and optimizing complex manufacturing processes for enhanced #product #performance.

Special thanks to Gourab Ghosh, Ph.D. and Srikar Vallury (M.S.) for their valuable contributions to this article.