Optimization of sandwich aluminium foam as vibration damper for electric vehicle battery box cover using taguchi method

The increasing adoption of electric vehicles (EVs) has raised significant concerns regarding battery reliability under dynamic loading conditions, particularly vibration. Continuous vibration exposure may induce microstructural damage, leading to reduced performance and safety risks such as internal short circuits and thermal runaway. This study investigates the effectiveness of aluminum foam sandwich structures as vibration damping systems for EV battery casings. A finite element analysis (FEA) using Abaqus was conducted and validated against experimental modal analysis (EMA), showing a strong agreement with an average error of 2.18%. Parametric studies were performed by varying skin thickness (3–5 mm) and foam core thickness (10–19 mm). The results indicate that increasing both parameters significantly improves natural frequency and vibration performance. Optimization using the Taguchi method and ANOVA reveals that skin thickness has a more dominant influence than foam thickness. The optimal configuration demonstrates enhanced vibration resistance, suggesting that aluminum foam sandwich structures are a promising solution for improving EV battery durability and safety.