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With the development of electric vehicles, more and more high requirements for the lightweight design on EV body are put forward. This paper aims to study a new structure, aluminum alloy mortise-and-tenon structure, which is used for lightweight EVs. Two new types on aluminium alloy MT-T joint specimens are designed and tested under low-cycle reciprocating loading. And the failure characteristics, hysteretic curve, skeleton curve, restoring force model and energy dissipation curve are obtained by analyzing the experimental data. Moment and rotation angle relationship is conducted by joint geometric deformation and equilibrium relation. Based on theoretical model, a simplified bilinear model has been proposed for engineering calculation. When the beam bending performance is qualitatively analyzed, the theoretical model, simulation model and bilinear model are verified through experiments and finite element method simulations. The results show that mortise-and-tenon T joint main failure modes are plastic deformation caused by the upper contact area squeezed each other and the lower contact area divorced each other. Furthermore, it can be obtained from the theoretical model that MT-T joint deformation process consists of elastic segment and elastoplastic segment. Theoretical model, simulation model and bilinear model agree well with the experimental results. This fruit gives a useful reference to composite material used in EVs.

Flexural behavior and mechanical model of aluminum alloy mortise-and-tenon T-joints for electric vehicle