Research on Roll Forming Process and Modal Analysis of AHSS for Battery Pack Frame

With the rapid development of the electric vehicle industry, the safety and lightweight of battery pack frames have become key design factors. This paper studies the application of advanced high-strength steel (AHSS) in battery pack frames, especially the roll forming process. Modal analysis was used to evaluate the vibration characteristics of different AHSS materials, revealing that materials with the tensile strength from 1180MPa to 1470MPa can achieve an optimal balance between lightweight and safety performance. The study also optimised the roll forming process and die design and solved the cracking, spring-back and warping problems of AHSS in cold stamping. A 32-station roll forming line was employed to produce battery pack frames with high precision and efficiency through laser welding. The results demonstrate the suitability of roll forming technology for AHSS materials and its effectiveness in the manufacture of electric vehicle battery pack frames.