ANSYS CFD Simulation Engineer

The Incumbent will be responsible for-

Simulation Execution-

1. Set up and perform CFD simulations using ANSYS Fluent, CFX, or similar tools based on defined design requirements and boundary conditions.

2. Conduct steady-state and transient simulations to capture various operating conditions and thermal behaviors.

3. Validate simulation results with experimental data or benchmark cases to ensure accuracy.

Perform sensitivity analysis and parametric studies to assess the impact of design changes.

Pre-processing and Model Development-

1. Create and refine 3D geometries of components or systems using CAD tools; clean and simplify geometry as needed for simulation.

2. Generate high-quality computational meshes using ANSYS Meshing, ICEM CFD, or equivalent, ensuring appropriate resolution in critical regions.

3. Develop accurate CFD models of systems involving fluid flow and heat transfer (e.g., battery packs, enclosures, HVAC).

4. Apply suitable material properties, initial conditions, and boundary conditions based on system requirements and physical phenomena.

5. Ensure model stability and fidelity by selecting appropriate turbulence models, solver settings, and convergence criteria.

Post-processing and Analysis-

1. Extract and visualize key flow and thermal parameters such as temperature distribution, pressure drop, velocity profiles, and heat flux using ANSYS Fluent/CFX post-processing tools.

2. Interpret simulation results to assess system performance, identify hotspots, flow separation zones, and potential areas of design concern.

3. Compare simulation outputs with design targets or experimental data to validate model accuracy and refine input parameters as needed.

4. Conduct root cause analysis in case of performance deviations and propose corrective design actions.

5. Generate clear plots, contour maps, vector fields, and animation sequences to communicate technical findings effectively.

6. Collaborate with design and engineering teams to translate analysis insights into actionable product improvements.

Documentation and Reporting-

Prepare technical reports, presentations, and documentation of analysis results and recommendations.

Automation and Optimization-

Utilize scripting tools (e.g., Python, MATLAB) to automate simulation workflows and explore design optimization.

Skills & Capabilities

• Experience with battery management systems (BMS) and their integration with mechanical components.
• Knowledge of manufacturing processes for battery packs and modules.
• Experience with thermal management system design for batteries (e.g., liquid cooling, air cooling).

• Familiarity with DFMEA (Design Failure Mode and Effects Analysis) and other reliability engineering methodologies.
• Project management skills and experience.