Three-dimensional anisotropic elastoplastic finite element analysis with solid elements for forming process and springback prediction of aluminum current collector in prismatic electric vehicle batteries

Abstract

This study examines an aluminum(A1050-H18) current collector in prismatic electric vehicle batteries formed using a multi-stage progressive die. An anisotropic elastoplastic model was employed to properly consider the anisotropy of aluminum. The forming process consists of complex operations, including shearing, forging and bending. Particularly the process involves piercing and thickness-direction forging, therefore automatic remeshing was essential. Accordingly, it enabled efficient elastoplastic finite element analysis of this process using three-dimensional tetrahedral elements. The analysis model was built based on the press-type forming process used in prototype production, and its forming behavior and final geometry were predicted. The dimensional comparison and springback prediction were carried out for the validation of the analysis result, which showed good agreement between the simulation and experimental results. These findings support the applicability of elastoplastic finite element analysis with three-dimensional solid elements that account for anisotropy in progressive forming processes involving shearing, forming, and bending.