Finite element model approach of a cylindrical lithium ion battery cell with a focus on minimization of the computational effort and short circuit prediction

In this research, a parameterized beam-element-based mechanical modeling approach for cylindrical lithium ion batteries is developed. With the goal to use the cell model in entire vehicle crash simulations, focus of development is on minimizing the computational effort whilst simultaneously obtaining accurate mechanical behavior. The cylindrical cell shape is approximated by radial beams connected to each other in circumferential and longitudinal directions. The discrete beam formulation is used to define an anisotropic material behavior. An 18650 lithium ion cell model constructed in LS-Dyna is used to show the high degree of parameterization of the approach. A criterion which considers the positive pole deformation and the radial deformation of the cell is developed for short circuit prediction during simulation. An abuse testing program, consisting of radial crush, axial crush, and penetration is performed to evaluate the mechanical properties and internal short circuit behavior of a commercially available 18650 lithium cell. Additional 3-point-bending tests are performed to verify the approach objectively. By reducing the number of strength-related elements to 1600, a fast and accurate cell model can be created. Compared to typical cell models in technical literature, simulation time of a single cell load case can be reduced by approx. 90%.