A Multi-Physics Finite Element Model for the Crashworthiness of Electric Vertical Take-Off and Landing Aircraft and Its Lithium-Ion Battery: a Preliminary Study

Electric Vertical Take-Off and Landing (eVTOL) aircraft are laying the foundations for Advanced Air Mobility (AAM), which represents a fundamental shift in how short-range air transportation is conceived and implemented. Compared to aircraft powered by internal combustion engines, eVTOLs present innovative configurations due to their use of electric propulsion systems and Lithium-Ion battery for energy storage. These differences require regulatory agencies to develop new crashworthiness standards for this category, that address both occupants' safety and the potential risk associated with the battery thermal runaway. This preliminary study aims to create a high-fidelity Finite Element model to analyze the crashworthiness of eVTOLs and their battery. The geometry and configuration selected feature a fixed-wing tiltrotor design. The expected aircraft performance metrics are estimated, including range, mean cruise speed, maximum take-off mass and system nominal voltage. A multi-physics analysis is necessary to study how battery placement affects crash safety, reflecting typical eVTOL design choices. Three battery placement configurations are being evaluated, with the battery pack installed above the subfloor in the cabin, behind the passengers, or embedded within the wing structure. This paper discusses the first case, including the complete development of multi-physics Finite Element models for the battery pack and the subfloor, and the evaluation of its battery crash-stability performance during emergency landing on hard surfaces. The simulation framework developed offers a viable approach for achieving design-through-analysis in the regulation compliance for eVTOL crashworthiness design.