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2:00 PM EDT | Wednesday, May 28, 2025 | Check Your Time

In the automotive industry’s transition toward sustainable transportation, optimizing composite components for electric vehicles (EVs) through simulation-based approaches has become crucial. Sheet molding composites (SMCs) are particularly valuable in this context, offering an advantageous combination of light weight, high strength-to-weight ratio, and excellent moldability characteristics. This research presents a comprehensive case study examining an EV battery cover manufactured from SMC material. The study evaluates three key aspects: the structural performance under various charge patterns, a comparative analysis between SMC and aluminum materials, and the benefits of anisotropic versus isotropic material modeling. The optimization process addresses both structural geometry and manufacturing considerations, including material flow and tooling requirements. The key findings indicate the most suitable or unfavorable manufacturing strategies for optimal performance, and showcase the advantages of SMCs over aluminum, emphasizing significant weight savings without compromising mechanical performance.

What Attendees Will Learn?

• Optimizing composite battery cover for EVs through anisotropic simulation
• Benefits of using composites/reinforced plastics (e.g., SMC) over metals (e.g., Aluminum)

Dr. Gourab Ghosh is a Technical Specialist in the Material Center of Excellence of Manufacturing Intelligence Division of Hexagon in Novi, Michigan, USA. Gourab has over twelve years of experience in research, analysis, and teaching of finite element analysis of composite structures, material modeling, computational mechanics, and structural health monitoring. He has expertise in damage mechanics and crack modeling, composite material modeling, nonlinear finite element analysis of structures, additive manufacturing of short fiber reinforced polymer parts, and reverse engineering to compute material properties. Dr. Ghosh has worked on multiple research projects sponsored by the US Office of Naval Research, the National Science Foundation, the Boeing Company, to name a few. Gourab got his PhD from Vanderbilt University, USA, MS from IIT Kanpur, India, and BS from Jadavpur University, India. Before joining Hexagon, Gourab was working as a Post-Doctoral Researcher at Purdue University, Composites Manufacturing and Simulation Center. Dr. Ghosh was a recipient of the prestigious University Graduate Fellowship at Vanderbilt University, and the Prof. ASR Sai Gold Medal at IIT Kanpur, among other awards.