Static-Dynamic Coupled Lightweight Design and Multi-Objective Optimization Method for Aluminum Alloy Battery Enclosures of Electric Vehicles

Static-Dynamic Coupled Lightweight Design and Multi-Objective Optimization Method for Aluminum Alloy Battery Enclosures of Electric Vehicles | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Static-Dynamic Coupled Lightweight Design and Multi-Objective Optimization Method for Aluminum Alloy Battery Enclosures of Electric Vehicles Jun Liu, Shuai Zhang, Yiliu Wang, Mi Yan, Hao Zhang, Heng Deng This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6777559/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract The collaborative optimization of structural safety and lightweight design of battery enclosures is key to improving the driving safety and energy efficiency of electric vehicles. Aiming at the limitations of single-condition optimization and the lack of multi-physical field coupling analysis in the traditional design method, a static-dynamic coupled lightweight design and multi-objective optimization method for aluminum alloy battery enclosures of electric vehicles is proposed. Based on the modal test-validated high-fidelity finite element model of the original aluminum alloy battery enclosure, conduct modal and extrusion simulation analysis to clarify performance design indicators.Design of a new aluminum alloy battery enclosure and construction of a high-precision multi-physics simulation system covering modal, static strength, dynamic impact and extrusion conditions.Combining morphological optimization and RBF surrogate model, a multi-objective size optimization is realized based on the PSO-GA hybrid optimization algorithm. After optimization, the new enclosure mass is reduced by 11.6%, while maintaining the benchmark shock resistance performance, the first-order modal frequency is increased by 23.86%, and the static stiffness indicators are improved by 18.37%, 6.36%, and 25.26% respectively.The dynamic extrusion resistance performance is improved by 21.11% and 14.88% respectively. Compared with the original enclosure, mass is reduced by 17.7% and extrusion resistance performance is improved by 25.18% and 12.55% respectively. The complex nonlinear multivariate optimization problem under multi-physical field coupling of aluminum alloy structural design is solved, and the collaborative improvement of safety performance and energy consumption is realized. Static-dynamic coupling Multi-objective optimization method Morphological optimization PSO-GA Electric vehicles Aluminum alloy battery enclosure Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6777559","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":466631524,"identity":"b00e0456-0fb7-4d9d-afae-947ef7326535","order_by":0,"name":"Jun Liu","email":"","orcid":"","institution":"Henan University of Science and Technology","correspondingAuthor":false,"prefix":"","firstName":"Jun","middleName":"","lastName":"Liu","suffix":""},{"id":466631526,"identity":"85ee5f8c-5ab8-4ae6-b1c3-3720578122c7","order_by":1,"name":"Shuai Zhang","email":"","orcid":"","institution":"Henan University of Science and 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Aiming at the limitations of single-condition optimization and the lack of multi-physical field coupling analysis in the traditional design method, a static-dynamic coupled lightweight design and multi-objective optimization method for aluminum alloy battery enclosures of electric vehicles is proposed. Based on the modal test-validated high-fidelity finite element model of the original aluminum alloy battery enclosure, conduct modal and extrusion simulation analysis to clarify performance design indicators.Design of a new aluminum alloy battery enclosure and construction of a high-precision multi-physics simulation system covering modal, static strength, dynamic impact and extrusion conditions.Combining morphological optimization and RBF surrogate model, a multi-objective size optimization is realized based on the PSO-GA hybrid optimization algorithm. 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The complex nonlinear multivariate optimization problem under multi-physical field coupling of aluminum alloy structural design is solved, and the collaborative improvement of safety performance and energy consumption is realized.\u003c/p\u003e","manuscriptTitle":"Static-Dynamic Coupled Lightweight Design and Multi-Objective Optimization Method for Aluminum Alloy Battery Enclosures of Electric Vehicles","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-06-06 14:24:54","doi":"10.21203/rs.3.rs-6777559/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"e3ce67f7-b4f2-4ac3-9248-d753805679f2","owner":[],"postedDate":"June 6th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-07-14T13:23:55+00:00","versionOfRecord":[],"versionCreatedAt":"2025-06-06 14:24:54","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6777559","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6777559","identity":"rs-6777559","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}