Yarn Geometry Effects on Mechanical Performance of Woven Glass Composites in Lightweight EV Structures

Efficient energy consumption is pivotal for electric vehicles (EVs) to function as a sustainable mode of transportation solutions. This study explores the potential advancement of glass fiber composites for lightweight EV component designs. While composites are extensively used in EV parts, current approaches focus on macroscale design considerations, overlooking mesoscale intricacies. Through multi-scale modeling, incorporating finite element analysis, this study investigates the influence of glass fiber yarn cross-sectional geometries on the mechanical properties of woven composites. The analyses reveal that an elliptical yarn model, characterized by a high-volume fraction and an optimized major-to-minor diameter, significantly enhances mechanical properties compared to its circular counterpart. The optimal yarn shape is then integrated into macroscale models to facilitate the design of lightweight EV structures, such as battery housings and bumper beams. The proposed design showcases a 450% increase in specific bending stiffness and a 21.9% reduction in peak force compared to the baseline models, underscoring the potential of this optimized design to enhance EV performance and sustainability.