Meaning
Numerical method calculating the combined effects of temperature gradients and physical loads on a solid structure. Engineers perform thermomechanical fea to predict how battery housings will warp or stress under the heat of fast charging. The simulation links thermal solvers with mechanical solvers to find coupled solutions.
The method provides a virtual estimate of component life.
Expansion Analysis
Expansion of the battery cells during heating puts pressure on the surrounding frame and fasteners. Using thermomechanical fea allows designers to see where stress concentrations might cause a crack over time. The software identifies areas that need reinforcement or more cooling.
This analysis considers the elastic modulus and thermal expansion coefficient of every material in the assembly. By simulating a full year of seasonal temperature changes, the team can predict if any joints will loosen or fail due to creep.
Thermal Mapping
Input data for the model includes the heat generation rates of the cells and the ambient temperature of the environment. A detailed thermomechanical fea map shows how heat moves through the busbars and cooling plates. Accurate material properties are essential for a valid result.
Virtual Validation
Virtual testing reduces the number of physical prototypes needed for validation. Before any metal is cut, thermomechanical fea proves that the design can survive the life of the vehicle. This approach saves time and reduces the risk of expensive recalls.
