Thermo-Mechanical Topology Optimization: Considerations for EV Battery Modules as Structural Elements

This thesis investigates thermostructural topology optimization, with the aim of designing efficient material layouts under coupled thermal and mechanical loads. The study begins with a general introduction to the the field of topology optimization. An analysis of the steady-state heat conduction problem is provided, followed by the formulation of the classical elasticity problem. Finally, the two fields are joined together into a thermo-mechanical framework to capture the interaction between thermal and structural responses. Two main optimization strategies are employed: the Level Set Method and the Density Based Method, each offering distinct advantages in handling topology evolution and material interpolation. These methods are implemented and tested in MATLAB, with tailored solvers developed for each physical problem and optimization loop. Simulations were conducted to observe compliance minimization in a sample subjected to prefixed constraints. The results demonstrate the model’s capability to capture the behavior of the material in response to different constraints. The results demonstrate the ability to generate optimized topologies that balance mechanical stiffness and thermal performance, with simulations conducted on a battery pack representative of an eVTOL application. Comparative analyses highlight the strengths and limitations of each method in various scenarios, providing insights into their suitability for complex multiphysics optimization tasks in advanced aerospace systems.