An integrated approach for structural modeling, modal analysis, and aerodynamic evaluation of an electric vehicle body shell using finite element method and computational fluid dynamics

The overall upward trend of Electric Vehicles (EVs) replacing conventional vehicles on the roads makes safety, stability, and efficiency the prime apprehensions for an Electric Vehicle (EV) maker. Structural and aerodynamic integrity are the mainstays that fulfill these goals. This work presents an integrated approach using Finite Element Method (FEM) and Computational Fluid Dynamics (CFD) to conduct a holistic analysis of the Body Shell of an EV. Modeling was done in CATIA R2021, followed by modal analysis in ABAQUS CAE 2022, and finally, aerodynamic evaluation in ANSYS R2024. Upon performing the modal analysis, natural frequencies range from 63.20 Hz to 85.07 Hz, with critical vibrations and displacements focused on the front, rear, and pillar areas, needing selective reinforcements for dynamic stability and resonance reduction. At the rear, a maximum turbulence kinetic energy of 10.81 m2/s2 contributed to increased drag forces and aerodynamic losses. The combination of FEM and CFD analyses points to structural weaknesses and aerodynamic inefficiencies, providing recommendations to optimize the design for reduced energy consumption and improved performance. It sets the yardstick for a lightweight, energy-efficient, safer framework for developing next-generation EVs.