Thermal CFD Analyst (Internal Combustion Engine)

Qualification:

Experience Range:

Roles & Responsibilities:

• Perform detailed 3D CFD simulations of internal combustion engines across multiple combustion modes: Diesel, Spark-Ignition (SI), and Hydrogen.
• Handle the complete simulation lifecycle:

a) Pre-processing: Geometry cleanup, mesh generation (sector/full-cylinder), boundary condition definition.

b) Simulation Setup & Execution: Selection of appropriate physics modeling(Turbulence,combustion,spray, emission, etc), solver control, simulation execution and troubleshooting.

c) Post-processing & Analysis: In-cylinder pressure analysis, heat release rate, emissions prediction (NOx, soot), flame propagation, flow field interpretation and result interpretation.

• Conduct test correlation and validation using experimental/system simulation data to ensure model accuracy.
• Provide design and performance recommendations based on CFD insights to support engine development and optimization.
• Collaborate closely with global counterparts, engine design teams, and test engineers for simulation planning, result interpretation, and design proposals.
• Ensure best practices, template management, and continuous method improvements aligned with evolving engine technologies and regulatory trends
• Document simulation procedures, assumptions, model limitations, and publish internal reports and presentations.

Must Have:

• 2+ years of hands-on experience in 3D CFD combustion simulation for internal combustion engines (Diesel/SI/Hydrogen).
• Proficiency in simulation tools: STAR-CCM+, CONVERGE CFD, AVL FIRE or equivalent.
• Strong understanding of combustion physics (premixed/non-premixed, spray, ignition), emissions formation, and turbulence-combustion interactions.
• Exposure to test data correlation and understanding of engine instrumentation (e.g., pressure sensors, emissions analyzers).
• Ability to define realistic boundary conditions (e.g., injector profiles, wall temperatures, initial conditions) based on engine operating points.
• Knowledge of combustion strategies (e.g., split injection, EGR effects, H2 mixing).
• Strong fundamentals in fluid dynamics, thermodynamics, and heat transfer.
• Excellent analytical skills, communication, and cross-functional collaboration.
• Willingness to adapt to dynamic simulation demands and collaborate across global teams and time zones.
• Self-driven personality with a research-oriented mindset and a desire to solve complex combustion challenges.
• A strong grasp of CFD theory, solver numerics, and model limitations.
• Flexibility for international travel and and cross-site engagements.

Good to Have:

• Exposure to GT-SUITE for system-level engine performance and boundary condition mapping.
• Experience in simulation automation and scripting (e.g., Java macros in STAR-CCM+, Python).
• Experience with post-processing tools (e.g., Tecplot, ParaView, STAR-CCM+ scenes) and report preparation.
• Understanding of current and future emission regulations and their CFD implications.
• Automotive or engine OEM experience preferred.
• Experience with method development, template building, and simulation governance practices.