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<p>As electric vehicles (EVs) become common place in the automotive industry, the large rechargeable energy storage system (RESS) battery packs need adequate protection against crash loads to ensure passenger safety. This paper outlines the development of an optimized patterned shear panel which exhibits high in-plane intrusion resistance. This makes them applicable for use in the RESS structure, the EV underbody, and floor subassemblies. Traditional shear panels are built-up constructions consisting of two flat panels having multiple reinforcements between. The shear panel construction presented in this paper uses two optimally patterned sheets which are joined together at the pattern locations to form a stiff structure resistant to buckling. This novel approach reduces the reliance on multiple reinforcement parts thereby simplifying manufacturing and significantly reducing cost and part complexity. This study presents the CAE methods utilized to design a structurally optimized two sheet construction for the front lower body shear panel on the Chevy Silverado EV under a full-frontal impact scenario. The resultant design enables a part reduction from 13 to 2 parts for the front panel (not counting common bolts and sleeves); and a reduction in joining from 57 laser staple welds and 110 resistance spot welds (RSW) to only 62 RSWs. Stamping simulations predict a spring back of less than ± 3&#xa0;mm while electro-deposition coating (ELPO) simulations of the panels predict a 2&#xa0;µm thicker ELPO coverage on the panel interiors.</p>

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Optimization of patterned shear panels for electric vehicle lower body structures

  • 期刊论文

  • 发表日期：

    2025年4月1日

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  • Andrew Bobel,
  • Rajan Chakravarty,
  • Jong-Eun Kim,
  • Manoj Marella,
  • Santosh Swamy

摘要

As electric vehicles (EVs) become common place in the automotive industry, the large rechargeable energy storage system (RESS) battery packs need adequate protection against crash loads to ensure passenger safety. This paper outlines the development of an optimized patterned shear panel which exhibits high in-plane intrusion resistance. This makes them applicable for use in the RESS structure, the EV underbody, and floor subassemblies. Traditional shear panels are built-up constructions consisting of two flat panels having multiple reinforcements between. The shear panel construction presented in this paper uses two optimally patterned sheets which are joined together at the pattern locations to form a stiff structure resistant to buckling. This novel approach reduces the reliance on multiple reinforcement parts thereby simplifying manufacturing and significantly reducing cost and part complexity. This study presents the CAE methods utilized to design a structurally optimized two sheet construction for the front lower body shear panel on the Chevy Silverado EV under a full-frontal impact scenario. The resultant design enables a part reduction from 13 to 2 parts for the front panel (not counting common bolts and sleeves); and a reduction in joining from 57 laser staple welds and 110 resistance spot welds (RSW) to only 62 RSWs. Stamping simulations predict a spring back of less than ± 3 mm while electro-deposition coating (ELPO) simulations of the panels predict a 2 µm thicker ELPO coverage on the panel interiors.