A Model of a Functionally-Graded Terminal Post for Application in Lead–Acid Batteries
The terminal post is an important component of a battery. The design and manufacturing of the post are critical, especially when threaded inserts (bolt-on type) are used. This is because all the collected energy is delivered from the lead part to the threaded insert (made from copper or copper alloy). Any imperfection at the interface may, for example, cause voltage drop, high resistance, and high heat generation. To avoid this problem, a new scheme of material gradation is proposed to achieve a continuous variation of material properties for the post used in commercial lead–acid batteries. The functionally-graded (FG) material for the post is composed of different layers of homogeneous material. The volume fraction of the material corresponding to each layer is calculated by considering its variation along the direction of current flow according to a power law. Accordingly, the effective properties of the homogeneous layers are estimated and a post composed of the FG material is modelled using ANSYS software. A solid 186-layered structural element has been used for discretization of the model and a thermal electric analysis has been performed. The layered FG model has been validated by comparing experimental results with those obtained with the existing post model.
Sandeep Das is an Assistant Manager in the R&D Center of Exide Industries Ltd. Prior to joining Exide in 2017, he gained ten years of experience in plastic injection mould design and machine design components. Sandeep’s current research includes FG material and its applications, smart batteries, bio-mechanics, and the vibration of structures.