Side Impact Crashworthiness of EVs: A Numerical Study in Material Efficacy

Abstract:

This study examines electric vehicle (EV) crashworthiness with a focus on side impact scenarios affecting high-voltage (around 400V) battery packs. Using a 2001 Ford Taurus model, the research compares the performance of side door beams constructed from HSLA steel, boron steel, and Dual-Phase (DP-590) steel in crash simulations. The results indicate that boron steel significantly enhances impact resistance, minimizing battery pack damage and improving occupant safety over HSLA and DP-590 steel. The findings recommend boron steel for critical areas in EV design, with DP-590 steel emerging as an alternative option that still maintains safety standards. Future research is suggested to confirm these results through empirical testing and to investigate advanced materials for further safety improvements in EVs.

• Periodical: Engineering Headway (Volume 17)
• Pages: 53-64
• DOI: https://doi.org/10.4028/p-X3J2i2
• Online since: January 2025
• Authors: Farzan Shahid, Harsh Tiwari*, Mayank Panwar, Vijay Gautam
• Keywords: Battery Safety, Boron Steel, Crashworthiness, Dual-Phase Steel, Electric Vehicles (EVs), Finite Element Analysis (FEA), High Strength Low Alloy (HSLA) Steel, Side Impact

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