Simulation and Experimental Analysis of Mechanical Testing Effects on Electrical Parameters of Lithium-ion Batteries across Different Form Factors for Battery Life Prediction and Accident Prevention

Abstract

Safety and reliability of Lithium-ion batteries (LIBs) are paramount, particularly in a scenario where mechanical abuse causes catastrophic failure. This study employs the analysis of electrical results with different types of mechanical abuse, including compression, impact, puncture and vibration on cylindrical, prismatic and pouch cells of LIBs. The idea is to make a transition from mechanical stress and relate it to such electrochemical characteristics as internal resistance, capacity loss, voltage swing, and thermal effects. The experimental procedure is supported by the finite element modeling (FEM) to study the detailed structural deformations, failure propagation, and degradation phenomena. This type of monitoring is especially significant for identifying short-circuit behavior and thermal runaway prognosis, as well as analyzing performance degradation modes during mechanical abuse testing. This is a follow-up of a previous study exploring predictive modeling for the determination of the operational life of LIBs under realistic mechanical stress. Nevertheless, our work extends the prospects of ME-mechanisms and the consequences in LIBs in line with the development of safe and reliable battery structure, benchmarking, and management. The results that would be derived from such investigations would be useful in electric vehicles, aerospace, and renewable energy storage, where the battery’s life with respect to mechanical stress is paramount.