Stress and Strain Characterization for Evaluating Mechanical Safety of Lithium-Ion Pouch Batteries under Static and Dynamic Loadings

The crashworthiness of electric vehicles depends on the response of lithium-ion cells to significant deformation and high strain rates. This study thoroughly explores the mechanical behavior due to damage of lithium-ion battery (LIB) cells, focusing on Lithium Nickel Manganese Cobalt Oxide (NMC) and Lithium Iron Phosphate (LFP) types during both quasi-static indentation and dynamic high-velocity penetration tests. Employing a novel approach, a hemispherical indenter addresses gaps in stress–strain data for pouch cells, considering crucial factors like strain rate/load rate and battery cell type. In the finite element method (FEM) analysis, the mechanical response is investigated in two stages. First, a viscoplastic model is developed in Abaqus/Standard to predict the indentation test. Subsequently, a thermomechanical model is formulated to predict the high-speed-impact penetration test. Considering the high plastic strain rate of the LIB cell, adiabatic heating effects are incorporated into this model, eliminating heat conduction between elements. Addressing a notable discrepancy from prior research, this work explores the substantial reduction in force observed when transitioning from a single cell to a stack of two cells. The study aims to unveil the underlying reasons and provide insights into the mechanical behavior of stacked cells.