Anubhav Choudhary

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.

• 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.

Project: Foot Drop Splint Redesign & Optimization • Designed and optimized a foot drop splint using a simulation-driven design approach, focusing on material selection, structural performance, and thermal comfort. • Evaluated 50+ material options based on mechanical strength, durability, and heat retention characteristics to improve long-duration usability. • Applied design optimization techniques to refine geometry and enhance ergonomics while maintaining structural integrity. • Achieved ~95% functional compliance and reduced manufacturing cost by 50% (~₹500 per unit) through engineering optimization.

Project: Educational Abrasive Jet Machining Prototype • Designed and developed a working abrasive jet machining (AJM) prototype, applying principles of fluid dynamics and jet flow behavior. • Analyzed nozzle design, flow velocity, and abrasive particle interaction to improve cutting efficiency and process stability. • Conducted parametric evaluation of flow conditions and material properties, optimizing machining performance. • Successfully validated the prototype against expected performance benchmarks and deployed it for educational demonstration purposes.