Abstract A battery pack is produced by connecting the cells in series and/or in parallel to provide the necessary power for electric vehicles (EVs). Those parameters affecting cost and reliability of the EVs, including cycle life, capacity, durability and warranty are highly dependent on the thermal management system. In this work, computational fluid dynamic analysis is performed to investigate the air cooling system for a 38,120 cell battery pack. The battery pack contained 24 pieces of 38,120 cells, copper bus bars, intake and exhaust plenum and holding plates with venting holes. Heat generated by the cell during charging is measured using an accelerating rate calorimeter. Thermal performances of the battery pack were analyzed with various mass flow rates of cooling air using steady state simulation. The correlation between Nu number and Re number were deduced from the numerical modeling results and compared with literature. Additionally, an experimental testing of the battery pack at different charging rates is conducted to validate the correlation. This method provides a simple way to estimate thermal performance of the battery pack when the battery pack is large and full transient simulation is not viable.