Modelling thick-walled aluminium extrusions in side- crash applications

In this study, the numerical modelling of a thick-walled aluminium extrusion which serves as a protective structure for battery trays in electric vehicles was studied. The thick-walled profile was modelled in a pole-crushing test. For this application, four aluminium alloys of different strength were considered: AA6063, AA6082, AA6005 air-cooled and AA6005 water-cooled. Shell elements proved to be inadequate in accurately describing the mechanical behaviour of thick-walled extrusions. Differences in the deformation mode and the computed force were observed between shell and solid models. Parametric studies were performed to evaluate the effect of fracture model, element formulation, contact formulation, and friction coefficient.