Abstract: Efficient thermal management is critical for ensuring the performance, safety, and longevity of batteries in electric vehicles (EVs). This study explores the design and optimization of battery thermal management systems using advanced simulation tools. Various fin configurations no fin, rectangular fins, elliptical fins, and irregular fins were designed using CATIA software, and their thermal and flow performance was analyzed through ANSYS and CFD simulations. The results demonstrate that while irregular fins exhibited the highest total heat flux (0.82196 W/m²), elliptical fins provided superior directional heat flux (0.095758 W/m²) and reduced eddy viscosity (7.185), leading to enhanced cooling efficiency and improved flow characteristics. These findings underline the significance of fin configuration in achieving optimal heat dissipation and efficient cooling for EV batteries. The elliptical fin design emerged as the most balanced and effective solution, making it a promising candidate for next-generation EV battery systems.

Keywords: Electric Vehicles (EVs), Battery Thermal Management, Fin Configurations, Heat Dissipation, Cooling
Efficiency.

| DOI: 10.17148/IARJSET.2025.12122