Headline

CFD Engineer (3 YOE) | EV Battery & Powertrain Thermal Management | CHT, Multiphase (VOF), Turbulence Modeling | ANSYS Fluent, STAR-CCM+ | Automotive OEM (GM via TCS)

About

CFD Engineer with 3 years of experience in EV battery, powertrain, and thermal management systems, solving complex fluid-flow and heat transfer problems using physics-driven simulation. My work focuses on conjugate heat transfer (CHT), multiphase flows (VOF), and system-level thermal management, applying strong fundamentals in fluid dynamics and heat transfer to improve performance, reliability, and design efficiency. At Tata Consultancy Services (Client: General Motors), I have worked on: • EV battery and ICE cooling systems (coolant flow distribution, fill & drain analysis)• E-motor thermal management (rotor and stator cooling optimization) • Turbocharger thermal analysis (CHT, oil & coolant interaction) • Crankcase ventilation and fuel tank slosh simulations (multiphase behavior) Worked closely with design teams to translate simulation insights into geometry and system-level improvements, enhancing cooling performance and resolving flow-related issues.Some key outcomes: • Reduced peak rotor temperature by 10°C, improving durability • Increased stator heat transfer coefficient by 22%, enhancing thermal performance • Developed ML-based surrogate models for centrifugal pumps with 92% prediction accuracy, reducing design cycle time by 30% Technical expertise: • ANSYS Fluent, STAR-CCM+, Simerics • Turbulence models (k-ε, k-ω SST), multiphase (VOF), rotating flows (MRF) • Mesh optimization, y+ control, and convergence strategies • Python (NumPy, Pandas, Scikit-learn) I enjoy solving engineering problems that require a balance of physics understanding, numerical accuracy, and system-level thinking, particularly in battery cooling, powertrain thermal systems, and multiphysics simulations. I’m currently open to opportunities in product-based companies where I can contribute to advanced CFD, thermal management, and simulation-driven design in EV, automotive, or energy systems.

Location

Bengaluru

AI stack

ChatGPT

Glean

Work experience

CFD Engineer at Tata Consultancy Services, Sep 2023 - Present · 3 y, Bengaluru, Karnataka, India, Working within the Powertrain & Thermal Systems domain, delivering CFD-driven solutions for EV battery cooling, e-motor thermal management, and automotive fluid systems, focusing on physics-based modeling, numerical accuracy, and design optimization. 🔹 Key Contributions: • Performed system-level CFD simulations for EV and ICE cooling systems, analyzing coolant flow distribution, fill & drain behavior, and thermal performance to improve system reliability and efficiency. • Conducted conjugate heat transfer (CHT) simulations of turbocharger assemblies using appropriate turbulence models (k-ε, k-ω SST), identifying coolant boiling risks and mitigating oil coking issues. • Optimized e-motor cooling (rotor & stator) through flow and geometry modifications, achieving: • 10°C reduction in peak rotor temperature • 22% improvement in stator heat transfer coefficient (HTC) • Simulated multiphase flows (VOF) for coolant systems and fuel tank slosh analysis, identifying air entrainment, flow instabilities, and pump inlet exposure issues. • Developed high-quality computational domains with mesh optimization (inflation layers, y+ control, polyhedral/trimmed cells), ensuring solution stability and accuracy. • Ensured numerical reliability through mesh independence studies, residual convergence monitoring, and solver parameter tuning. • Executed simulations involving rotating machinery (MRF/rotating reference frames) for pumps and thermal systems. • Developed Python-based AI/ML surrogate models (Scikit-learn) for centrifugal pump performance prediction, achieving 92% accuracy and reducing design cycle time by 30%. • Collaborated with cross-functional design teams to translate CFD insights into geometry and system-level design improvements, enhancing cooling performance, reducing NVH issues, and improving product reliability.

Summer Intern at Micro Turners Group - India, Jun 2017 - Jul 2017 · 2 mos, Nalagarh, Himachal Pradesh, India, • Gained hands-on exposure to the end-to-end manufacturing process of gears and shafts, from raw materialGained exposure to end-to-end manufacturing of automotive components (gears and shafts), including machining, heat treatment, and quality control processes. • Studied heat treatment processes (annealing, quenching, tempering) to enhance material strength and durability. • Observed integration of CNC machining and automation in precision manufacturing. • Applied mechanical engineering fundamentals to understand process optimization and defect reduction in production environments. preparation to final quality inspection. - Worked on heat treatment processes including annealing, quenching, and tempering to enhance component strength and durability. - Learned about automation and CNC machining integration in precision manufacturing. - Applied material science & mechanical engineering concepts to real-world challenges in process optimization and defect reduction.

Education

M.tech, Industrial design, National Institute of Technology Rourkela

Bachelor of Engineering - BE, Mechanical Engineering, UIETH, Panjab University