Crashworthiness Analysis of Electric Vehicles During Frontal Collision Using FEA

Abstract

As electric vehicles (EVs) increasingly replace internal combustion engine (ICE) vehicles, understanding their crash characteristics is critical for ensuring safety and promoting adoption. Unlike conventional vehicles, EVs face unique challenges, including fire risks from battery damage, lightweight design constraints, and crashworthiness trade-offs with driving range. This research investigates the frontal crashworthiness of a Tesla Model S3 using finite element analysis (FEA). A 3D model was developed in CATIA, and a frontal impact simulation at 56 km/h was performed using LS-DYNA to evaluate energy absorption, structural deformation, and occupant injury criteria (HIC, CSI). The results demonstrate effective energy dissipation, with the front structure absorbing 153 kJ, controlled cabin intrusion, and injury metrics within safe limits. Simulation accuracy was validated against experimental data from the Center for Collision Safety and Analysis (CCSA). The study identifies optimal design strategies, including a front bumper thickness of 6.76 mm for balanced energy absorption and weight efficiency. Additionally, robust front-end structures and strategic battery placement are emphasized to mitigate post-crash thermal hazards. Recommendations include the use of advanced materials, multi-material designs, and optimized component layouts to enhance safety without compromising efficiency. These findings provide actionable insights for developing safer, high-performance EVs, supporting sustainable mobility.