Design and optimization of a composite battery box for a newly developed railcar

Recently, the transportation sector has placed significant emphasis on the integration of advanced materials and innovative design solutions. This study presents the design and analysis of 304 stainless steel and carbon fiber composite power battery boxes for a newly developed railcar. The research involves a comparative analysis of 304 stainless steel and a carbon fiber composite battery box. Finite element analysis and computational simulations were employed to evaluate the mechanical performance and material behavior of each design. SolidWorks software was used for modeling and structural analysis. The downward gravitational acceleration creates the G weight force acting on the battery storage box. The design acceleration of 49.05 m/s² in the left-to-right direction creates the 5G force that the construction is required to withstand. The study focuses on weight assessment and strength analysis of the two alternative battery boxes. Compared to the 304 stainless steel, the carbon fiber composite battery boxes achieved a weight reduction without compromising structural integrity. The carbon fiber composite battery box achieved approximately 9% weight reduction compared to the 304 stainless steel design. Under static analysis, the 304 stainless steel experienced a maximum stress of 227.6 MPa and a deformation of 0.532 mm. In contrast, the carbon fiber composite experienced a lower maximum stress of 6.788 MPa and relatively acceptable deformation of 1.336 mm. In general, the carbon fiber composite battery box demonstrates superior mechanical strength, durability, and lightweight performance that meets the demanding requirements of modern wagon applications. However, it has been concluded that its use is limited due to the relatively low ratio of weight reduction compared to the overall wagon weight and its significantly high cost.