Agenda

Novel Multi-Physics Simulation Strategy For Stringent Aero-MIL Relay Requirements

Presented By
Sandeep Santhanagopal (TE Connectivity)

Authored By
Sandeep Santhanagopal (TE Connectivity)
Sandeep Santhanagopal (TE Connectivity)

This abstract outlines the simulation-driven development of a high-endurance electromechanical relay designed to meet Aero-MIL qualification standards, emphasizing how advanced multiphysics modelling and data-driven optimization enabled significant performance improvements while maintaining SWaP (Size, Weight, and Power) constraints. Accelerated Product Development Through Simulation: Traditional design methods followed a linear path, relying on design freeze, prototyping, and final qualification testing. This process, though effective, was time-consuming and often resulted in a trial-and-error loop. A novel approach now integrates advanced simulations early on, creating a virtual design loop between concept refinement and detailed design. This reduces reliance on physical testing, accelerates development by about 50%, and improves design accuracy. Novel Multi-Physics Simulation Strategy: Traditionally, relay design was manual and iterative, optimizing the contact system through static analysis and refining coil and magnet parameters via trial and error. The force-vs-stroke curve was derived solely from physical testing, making the process slow and prototype-dependent. Today, a comprehensive multi-physics simulation strategy integrates the contact system and electromagnetic performance into a unified model. Using ANSYS Mechanical Workbench, the contact system is optimized, while Maxwell Workbench assesses coil and magnet performance. These simulations are linked, enabling the creation of an accurate force-vs-stroke curve prior to prototype testing. This integrated approach led to a 28% increase in contact gap and a 17.6% increase in minimum contact force, alongside a 54% increase in contact area. The improvements also enhanced the contact system's performance by increasing A-spots, reducing contact resistance, and improving electrical performance. When prototypes were tested, the simulations demonstrated 90% accuracy. Using ANSYS optiSLang for Design of Experiments (DoE), these parameters were fine-tuned early in the design process, accelerating development and minimizing physical prototyping. This simulation-led approach enabled rapid iterations and successful qualification to Aero-MIL standards, showcasing the power of integrated simulation tools in optimizing high-reliability electromechanical systems.

Experimental Validation of a Three Dimensional Numerical Model of an Annular Linear Induction Pump

Presented By
Avijit Chakraborty (Indira Gandhi Centre for Atomic Research, Kalpakkam)

Authored By
Avijit Chakraborty (Indira Gandhi Centre for Atomic Research
Kalpakkam)
Prashant Sharma (Indira Gandhi Centre for Atomic Research) Sarat Kumar Dash (Indira Gandhi Centre for Atomic Research) G. Vijayakumar (Indira Gandhi Centre for Atomic Research) B.K. Sreedhar (Indira Gandhi Centre for Atomic Research)

Fast nuclear reactors use liquid metals, such as liquid sodium, as coolants. To circulate the coolant through auxiliary circuits, electromagnetic pumps (EM pumps), which operate under the influence of magnetic field, are commonly employed. The most widely used EM pump is Annular Linear Induction Pump (ALIP). Performance of an ALIP is assessed based on various characteristics, including pressure versus flow rate and input power versus flow rate. To predict the performance of an ALIP across a wide range of operating conditions, several computational models such as electrical equivalent circuit models and two-dimensional numerical models have been reported in the literature. However, a more accurate analysis of an ALIP requires solving both the fluid dynamics and electromagnetic equations to account for the interaction between the fluid and magnetic field. This computation is highly complex and challenging; as a result, many of the reported numerical models have relied on simplifying assumptions. To further improve the performance prediction, a three-dimensional finite element method (FEM) based computational model was implemented in the multiphysics software COMSOL for a small ALIP with a nominal flow rate of 5 m³/h. This model incorporates the pump’s asymmetric components, considers the interaction between fluid sodium and the magnetic field, and utilizes a voltage source for excitation. The model was validated against experimental data obtained from testing the pump in a sodium loop. Possible reasons for any observed deviations have also been explained.

High Fidelity Coupled Analysis of Component Loss and Temperature in Power Electronics

Presented By
Sandeep Roy (Altair)

Authored By
Sandeep Roy (Altair)
Abinash Baruah (Altair) Farhad Behafarid (Altair)

Over the past decade, electrification has transformed numerous industries, offering substantial benefits while introducing complex new challenges. Among these, thermal management has emerged as a critical concern, as thermal issues remain the number one cause of failures in electronic systems, often resulting in costly consequences. Design teams frequently provide rough estimates of component heat generation to thermal engineers. However, as thermal challenges intensify, more accurate methods for identifying and quantifying heat sources are essential. This is particularly true in power modules, where power loss in a component is not constant and depends on the temperature of the component. Both overestimation—leading to over-engineered and inefficient solutions—and underestimation—risking system failure—are no longer acceptable in modern design practices. High-fidelity simulations offer a cost-effective and efficient solution for the thermal management of power electronic components and systems. This paper presents a novel methodology in which conduction and switching losses of MOSFETs are calculated using a one-dimensional simulation tool (Altair PSIM). These loss values are dynamically linked to a Computational Fluid Dynamics (CFD) and thermal analysis tool (Altair SimLab – Electronics Thermal) to accurately predict temperature rise. The results from this fully coupled simulation approach are validated against experimental data, showing strong correlation and demonstrating the effectiveness of the method.

Electro-Thermal Co-Simulation Framework for High-Frequency Busbar Design in Aerospace Applications

Authored & Presented By
Advait Tikle (TE Connectivity)

Traditional busbar design methodologies, developed for low-frequency electrical systems (50–400 Hz), are increasingly obsolete for next-generation aerospace applications operating at 1500–4000 Hz. These legacy approaches fail to account for high-frequency electromagnetic effects—specifically skin and proximity phenomena—that significantly increase AC resistance, power loss, and thermal hotspots, impacting system safety and efficiency. This study introduces a frequency-aware, electro-thermal co-simulation methodology that integrates electromagnetic loss prediction with thermal modeling through a feedback-driven, parametric design framework. Electrical resistance is dynamically updated using temperature-dependent material properties, enabling accurate prediction of Joule heating and temperature rise under high-frequency, high-current operation. The method captures the nonlinear interaction between frequency, geometry, and thermal behavior, eliminating the need for repeated physical prototyping. A comprehensive design study involving 128 cases was conducted to evaluate how key parameters—such as conductor dimensions, material type, frequency, current, and ambient conditions—influence thermal performance. Regression analysis was applied to derive predictive equations for temperature rise, which were implemented in a user-accessible design sheet. This enables rapid, first-pass validation of copper and aluminum busbar designs without requiring detailed simulations or thermal testing. Validation against experimental results showed high correlation, with less than 3% error in predicted temperatures. The methodology reduced design effort by 85% and simulation time by over 94%, offering a scalable, cost-effective solution for high-frequency electrical system design. This innovation supports faster design cycles, enhances design accuracy, and improves accessibility for both engineers and non-specialists. It is highly applicable to aerospace, rail, automotive, and electrified mobility sectors where high-frequency electrical distribution systems demand efficient thermal management and rapid validation workflows.

Dynamic Performance Analysis of Relay/Contactor using Ansys Maxwell + Simplorer

Presented By
Pooja G (TE connectivity)

Authored By
Pooja G (TE connectivity)
Sandeep Santhanagopal (TE Connectivity)

Contactors are electrically controlled switching devices widely used in industrial and power systems to manage electrical loads ranging from a few kilowatts to several megawatts. These devices are predominantly actuated electromagnetically, with the actuator assembly comprising key components such as coils, moving contacts, and return springs. A crucial advancement in modern contactor design is integration of economizers, which are electronic control circuits that reduce coil power consumption during the holding phase after initial actuation. This not only enhances energy efficiency but also improves thermal performance and extends the mechanical and electrical lifespan of the device. Traditional simulation methodologies often rely solely on electromagnetic analysis tools such as Ansys Maxwell, supplemented by manual calculations which does not capture the circuit dynamics. However, these approaches are limited in their ability to accurately capture transient phenomena introduced by the economizer circuit, particularly during switching events. In this work, a co-simulation methodology is proposed using Ansys Maxwell for electromagnetic field simulation and Ansys Simplorer for system-level modeling of electrical and mechanical subsystems. Maxwell is used to compute spatially resolved magnetic fields, eddy currents, and coil behavior based on 3D actuator geometry. Simplorer simultaneously models the electrical characteristics of the economizer and the mechanical dynamics including mass-inertia systems, spring-damper elements, and motion constraints. Consequently, the methodology provides superior accuracy around 0.09%, compared to traditional decoupled analyses. Experimental testing of operate and release characteristics is inherently limited due to the high-speed motion of the armature, requiring sophisticated high-speed cameras to observe physical displacement. More critically, precise estimation of armature flight time during release is essential for predicting and mitigating contact arcing. The proposed co-simulation framework provides a powerful design and diagnostic tool that overcomes these limitations, yielding improved accuracy, better insight into transient behavior, and significant reduction in time and cost associated with iterative prototyping.

Fluid Structure Interaction with phase change modelling for e2W shock absorber design

Presented By
Soumik Ghatak (Ansys Inc.)

Authored By
Soumik Ghatak (Ansys Inc.)
Zeng Zhang (Ansys Inc.)

Electric 2W OEM customer is facing performance issues where fluid-structure interaction and cavitation in shock absorber fluid are likely playing crucial role due to intricate design. Accurate prediction of suspension system performance is critical for ensuring vehicle stability, comfort, and durability under dynamic loading conditions. One of the key performance-limiting phenomenon is Cavitation, which is an undesirable phenomenon that affects the essential functioning of the Suspension system i.e. Loss of Damping Performance, Noise and Vibration which leads to Damage and wear. CFD-structural 2-way coupling of solvers is challenging along with difficulty of dynamic meshing in thin gaps for traditional CFD solvers. This simple piston cylinder proof-of-concept work introduces a different compressible fluid solver which is called Conservation Element/Solution Element (CESE) to model a cavitating fluid with FSI. A special equation of state based phase change solver is used to incorporate cavitation in the fluid. In this work, we shall outline factors in selecting CESE solver and cover the various modelling aspects and challenges. The solution helps user to estimate force exerted by fluid on thin structures during each stroke of the shock absorber and hence they can optimize the material parameter of the structure.

Enhancing HEVs Battery Performance, Reliability & Lifespan Through A Novel Battery Thermal Management Concept By Leveraging CFD Simulation Techniques

Authored & Presented By
Vinay Kumar (MOBIS India Limited)

As we know the critical role of Battery thermal management system in Electric vehicles (EVs) and Hybrid electric vehicles (HEVs). It is also recognized that the batteries (Li-Ion) are highly sensitive to temperature fluctuations, requiring operation within a tightly defined thermal range to maintain optimal performance. However, often in peak load demand battery temperatures exceeds its safe operating limits. While existing cooling systems are employed to Lessen these risks, they often lack the precision and efficacy required to manage thermal loads uniformly across battery cells, particularly in extreme climates and peak load, which undermines battery performance and raises significant safety concerns. This paper introduces a unique solution to mitigate battery thermal issues for HEVs. The forced air-cooling thermal management system is developed where two Inlet air duct configuration have been used, first duct is configured to supply cabin air to the battery pack and the second duct is configured to supply cooled air from the HVAC (Heating ventilation & air conditioning) unit to the battery pack and a blower unit is installed at the outlet side of the duct which suck the air from both inlet ducts through the battery pack. This research work emphasizes primary methodologies, including building a 3D virtual prototype of BTMS (Battery thermal management system) and performing detailed CFD simulations to enable iterative testing and refinement of the system. To demonstrate the positive impact of two inlet duct configuration with HVAC air flow, following parameters have been analyzed such as heat dissipation and temperature distribution across the battery pack; Impact of positive air pressure at HVAC-inlet duct on blower efficiency; Air mass flow ratio at the inlet ducts and optimization of the ducts to increase the heat dissipation, mass flow rate and minimize the pressure drop across the battery pack.

Model based systems engineering of electromechanical devices

Presented By
Jagdish Goswami (Stryker Global Technology center)

Authored By
Jagdish Goswami (Stryker Global Technology center)
Venkateswaran Perumal (Stryker Global Technology Center)

This paper presents a Model-Based Systems Engineering (MBSE) approach to the design and validation of a robotic arm. The simulation model serves as a proof of concept, demonstrating how system-level modeling can be used to capture functional requirements, simulate behavior, and guide engineering decisions early in the design cycle. The robotic arm model can execute user-defined trajectories—either input manually or extracted from historical data—to replicate precise cutting paths using a blade mounted on the end-effector. The system dynamically adapts to changes in the trajectory input, enabling customizable incision shapes tailored to patient needs. Through the MBSE methodology, we systematically analyzed joint-level dynamics, allowing accurate estimation of torque and power requirements across the arm’s degrees of freedom. These insights directly inform motor selection and control strategy design. Additionally, the model predicts resistive forces such as friction and back forces. The system responds to these forces by adjusting joint torques in real-time, maintaining smooth and accurate motion. Simulation results validate the model’s ability to track complex trajectories with minimal error and provide quantitative data on actuator sizing and force compensation. This work demonstrates the effectiveness of MBSE in robotic systems functional modeling.

Energy Efficiency in Domestic Appliances: A System-Level Approach

Presented By
Ajay Naiknaware (Whirlpool Corporation)

Authored By
Ajay Naiknaware (Whirlpool Corporation)
Avinash Chandra (Whirlpool Corporation) Siddhi Marathe (Whirlpool Corporation)

Whirlpool Corporation is a leading American multinational manufacturer of home appliances, headquartered in Benton Harbor, Michigan. Founded in 1911, it owns globally recognized brands such as Whirlpool, KitchenAid, Maytag, and Amana, and operates in more than 170 countries. Its product portfolio includes a wide range of home and commercial appliances. For consumer products, cost and performance of appliances are vital parameters. System-level simulation predicts emergent behavior in terms of the cost and performance of the product. The famous “V-Model” of system engineering starts with stakeholder analysis to provide requirements for architectural concepts. This multidisciplinary optimization model can be obtained using system-level simulation, which provides key inputs for prototype manufacturing in the concept stage. The outcome of system-level simulation includes system integration, performance management, verification and validation, and life cycle management. The system-level model further disintegrated into the subsystem level model and component-level model. Verification and validation must be done at the component level, sub-subsystem level, and system level. This study investigates a horizontal axis washer-dryer combination, focusing on the integration of 1D simulation and 3D flow analysis. 3D flow analysis using ANSYS-Fluent for optimizing air management, enhancing clothes interaction, reducing bypass, and improving flow paths. A 1D simulation with Dymola is used for system performance parameter calculation. Various component and subsystem-level models are integrated, and a workflow in Mode Frontier is developed to perform optimization studies, aiming to predict energy savings by applying constraints to design parameters. Appliance performance is assessed by evaluating the trade-off between Remaining Moisture Content (RMC) and energy consumption under full-load and half-load conditions. The study demonstrates a 24% reduction in energy consumption for full load, a 27% reduction for half load, and a 3% improvement in RMC, highlighting the importance of system-level integration for optimizing energy efficiency and achieving new energy label (NEL) trade-offs.

1D Thermal Modelling and Testing of Rack Power Distribution Unit

Presented By
Richie Garg (Schneider Electric)

Authored By
Richie Garg (Schneider Electric)
Divakara Rao (Schneider Electric) Akhilesh Rao Borra (Schneider Electric) Santhosh Kumar Vijayan (Schneider Electric)

Rack Power Distribution Unit (rPDU) supplies critical power to servers in data centres reliably. It optimizes usage of energy and prevents overload. It can easily be scaled up and facilitates remote access to maintain uptime. Understanding thermal trends and behaviour is very important when it comes to the product functionality and safety. Predicting the critical temperatures of the product by using the one-dimensional (1D) model is simple, cost-effective, and saves the time as it runs in about a minute on a standard computer compared to the conventional computational fluid dynamics method requiring high computational resources. Testing is conducted on 1U (unit) rPDU equipped with twelve circuit breakers (CBs). The objective is to compare the measured CB temperature in test with 1D modelling. AC source and resistive load banks are used to power the CBs and to mimic the load in real applications. Thermocouples are used to measure the steady state temperature of the CBs and the ambient air of rPDU. Identical conditions are replicated in the 1D thermal model developed using MATLAB Simscape. The CBs are modelled taking care of radiative and convective heat transfer for thermal mass of body as well as air present inside the rPDU. The cables, compression lugs, terminals, and screws of CBs are considered in detail. Thermal and electric current paths are defined and solved. Predicted temperatures by simulation varied by 8.7 °C from 208 V test and 16.9 °C from 239 V test results. These preliminary simulations can be improved by detailing CB inner construction and sensitivity analysis of CB resistance. The 1D model provides extra information like temperature of air inside the CBs, temperature of the rPDU components, which are not measured in test.

Future-oriented lab data empowering Digital Twins

Authored & Presented By
Sridhar K (Schneider electric private limited)

In the rapidly evolving landscape of digital transformation, the integration of future-oriented lab data with Digital Twins presents a significant advancement in predictive modeling and real-time system optimization. This paper explores the methodologies for optimizing lab data to meet future demands, ensuring its relevance and utility in enhancing Digital Twin technologies. By leveraging advanced data analytics, machine learning, and IoT integration, we demonstrate how future-ready lab data can empower Digital Twins to provide more accurate simulations, predictive maintenance, and improved decision-making processes. The synergy between optimized lab data and Digital Twins not only enhances operational efficiency but also drives innovation across various industries. This study highlights the critical role of data integrity, real-time data processing, and cross-disciplinary collaboration in achieving a seamless integration that propels Digital Twin capabilities to new heights. Furthermore, it emphasizes the importance of adopting a holistic approach that encompasses technological advancements, strategic planning, and continuous improvement to fully realize the potential of Digital Twins in transforming industry practices and outcomes. By addressing these key aspects, we aim to provide a comprehensive framework for leveraging future-oriented lab data to empower Digital Twins, ultimately contributing to the advancement of digital transformation initiatives across diverse sectors.

Numerical Simulation Methodology For Thermoforming Manufacturing Process For Precisely Evaluating Thickness Variation

Presented By
Dheeraj Kapse (CNH Industrial Technology Services India Pvt Ltd)

Authored By
Dheeraj Kapse (CNH Industrial Technology Services India Pvt Ltd)
Raffaele Caggiano (CNH Industrial Italia SPA) Stefano Largo (CNH Industrial Italia SPA) Alessio Serracca (CNH Industrial Italia SPA)

Thermoforming is a widely used manufacturing process for shaping plastic sheets into various 3-Dimensional products. Ensuring uniform thickness distribution is crucial to achieve high-quality end products with consistent mechanical properties. In this research, we present a comprehensive investigation of thermoforming simulation techniques and their application to study thickness variation during the process. The primary objective of this study is to develop a reliable and efficient thermoforming simulation model capable of accurately predicting thickness variations in the formed parts. We begin by reviewing the existing literature on thermoforming. Next, we collaboratively build a simulation approach that considers various process parameters: material properties, and tooling conditions to simulate the thermoforming process more accurately. To validate the proposed simulation model, actual thermoforming products are 3D scanned. The 3D scan measured the thickness at various regions of the part. Comparisons between the simulation results and 3D scan results are then performed by averaging method to assess the precision, accuracy, and reliability of the developed simulation model. The study evaluates the thickness variation which guides designers and engineers to make informed decisions during the product development stage. Overall, this research aims to contribute significantly to the understanding of thermoforming simulations for thickness variation, paving the way for enhanced product quality, reduced material waste, and increased manufacturing efficiency. The findings from this investigation serve as a valuable resource for design engineers seeking to improve their thermoforming processes and ultimately advance the state-of-the-art in plastic manufacturing technology. Keywords: Thermoforming, Plastic, Manufacturing Simulation, Precision

Aero-Vibroacoustic Noise Prediction and Design Optimization of Blower for Acoustic Performance Improvement

Presented By
Pushpendra Mahajan (Whirlpool Corporation)

Authored By
Pushpendra Mahajan (Whirlpool Corporation)
Avinash Chandra (Whirlpool Corporation)

Whirlpool Corporation is a global leader in home appliances, with over 110 years of innovation. Known for its iconic brands like Whirlpool, KitchenAid, and Maytag, the company offers a wide range of products, including washing machines, refrigerators, dishwashers, and ovens. As consumer demand for quieter household appliances continues to rise, reducing noise in devices such as dryers has emerged as a critical area of focus in appliance design and development.. The high turbulence is the primary contributor to airborne noise, which induces flow separation from the blower blades. Flow separation, where the boundary layer detaches from the surface, leads to intense pressure fluctuations and unsteady vortex shedding, which in turn generates aerodynamic noise, including significant airborne acoustics. This necessitates a coupled approach that combines unsteady-state flow field calculations with aero-vibro-acoustic evaluations of the structure. The flow analysis is conducted using transient incompressible Reynolds-averaged Navier-Stokes (RANS) equations, which provide fluctuating surface pressure fields on both the blower and casing surfaces. The resulting aero-vibro-acoustic noise is then evaluated using the Multi-Domain Boundary Element Method (MDBEM). Although the incompressible CFD approach ensures faster computations, it only captures convective components of pressure fluctuations. To derive acoustic pressure fluctuations from the CFD data, this study uses a new derivation of acoustic analogy based on Curle’s integral formulation and Lighthill’s equation. The coupled methodology enables precise prediction of blower noise and its contributing factors, facilitating the optimization of blower design through systematic virtual experiments employing Design of Experiments (DOE). This approach led to a 6-8 dBA reduction in blower noise, highlighting the effectiveness of the optimized design in improving appliance performance.

A Brief Study Of Parametrization In CFD For Optimized Results

Authored & Presented By
Prem Chinna Polamada (Mobis india limited)

Thermal and flow simulations using CFD is becoming increasingly vital for analyzing heat and flow characteristics during both the conceptual and detailed design stages. These simulations enhance performance while reducing product development time and costs. This article delves into the impact of design parameters on design exploration studies in CFD. When conducting defrosting simulations, the complexity is heightened by internal turbulence, induced pressures, and pressure drops between subsystems, making it challenging, time-consuming, and costly to achieve meaningful results. However, by adjusting the variable parameters, we can significantly improve the outcomes. This paper provides a comprehensive review comparing the direction, velocity, and turbulence levels of flow optimization, which showed significant improvements. It also explores methods for optimizing the design of defroster nozzles. Various techniques for enhancing performance by modifying either the solid or fluid domain are discussed. The aim is to summarize the utilization and efforts dedicated to improving the performance of demisters and nozzles. For a quick estimation of defroster duct performance in the automobile industry, well-known correlations based on geometry and flow properties can be employed. This methodology can also be applied to other domains, such as electronics cooling, with proposed solutions.

Drag Prediction of Qargos F09 Electric Cargo Vehicle using CFD

Presented By
Pranav Shinde (QARGOS)

Authored By
Pranav Shinde (QARGOS)
Alok Das (QARGOS) Karthik Balachandran (Dassault Systemes)

The Drag prediction of an electric cargo scooter is a very important stage in the design of an electric cargo scooter. Early knowledge of the drag forces will enable the designers to accurately estimate the motor power, battery pack size, vehicle range, and lastly the vehicle maximum speed and dynamics. In the present paper we are presenting a simulation based methodology to estimate the drag forces and drag coefficient of an Electric Cargo Scooter that is designed for use in cargo logistics application. The Computational Fluid Dynamics approach allows for estimating the drag forces and drag coefficient as a function of vehicle velocity accurately. CFD simulation based flow visualization enables to identify high pressure stagnation zones and propose design changes to reduce the drag force and hence the drag coefficient. The main advantage of simulation based method is reducing the number of prototypes built during the initial design stages and reducing wind tunnel tests. Future variants will also not require any wind tunnel measurements as they will be accurately predicted using the established process. Reynolds Averaged Navier Stokes (RANS) based steady state Computational method is utilized. The Study includes mesh independence and Turbulence model independence studies.

Non-dimensional model for pressure drop prediction across spring loaded valve

Authored & Presented By
Vivek Tripathi (Atmus Filtration Technologies)

Atmus Filtration Technologies is a global leader in filtration solutions for on-highway commercial vehicles and off-highway vehicles and equipment. These filtration solutions use spring loaded valves extensively for multiple applications. Behavior of these spring-loaded valves is very complex phenomenon. Hence, performing detailed simulations to predict pressure drop across these valves is quite time consuming and resource intensive. To address this, extensive CFD analyses were performed to generate validated results on a wide range of valve configurations and applications. A non-dimensional 1D model was then developed using machine learning and data training from these CFD simulations. This model was implemented as an excel based tool to increase technical productivity in product development process. It is understood that the valve pressure drop is dominated by spring force which determines the valve displacement, resulting maximum velocity and associated inertial head. The pressure drop across the valve is function of Reynolds number. This tool predicts the pressure drop with root mean square percentage error of around 10% with respect to CFD simulation. Product teams leverage this tool during the concept phase, thereby reducing the overall product development cycle.

Virtual Assessment of Rotating Spray Arm Performance Using Multiphase CFD Simulation

Presented By
Vaibhav Gulakhe (Whirlpool Corporation)

Authored By
Vaibhav Gulakhe (Whirlpool Corporation)
Aswin R (Whirlpool Corporation)

The utilization of virtual product development has become increasingly crucial in modern industry, enabling accelerated design conceptualization and final product realization. This study investigates the efficacy of engineering simulation, specifically computational fluid dynamics (CFD), in evaluating the performance of a dishwasher spray arm for soil removal. Employing a multiphase approach, the simulation assesses the spray arm's performance by quantifying wall shear stress, which is then correlated with the soil removal rate. This methodology provides a quantitative measure of the spray arm's effectiveness in a virtual environment. The study involves developing a CFD model of the dishwasher spray arm, incorporating relevant fluid dynamics principles and boundary conditions. The simulation results are analyzed to determine the distribution of wall shear stress and its correlation with soil removal efficiency. To validate the proposed approach, the simulation findings are compared with experimental data obtained from physical testing of the spray arm. The comparative analysis demonstrates a good correlation between the simulation results and the physical test outcomes, confirming the reliability and accuracy of the virtual assessment method. This study highlights the potential of CFD simulation in optimizing dishwasher spray arm design and performance, reducing the need for extensive physical prototyping and testing. The findings contribute to the advancement of virtual product development techniques and provide valuable insights for enhancing the efficiency and effectiveness of household appliances.

CFD investigation of Princess Royal propeller cavitation and acoustics: A benchmark study

Authored & Presented By
Madhan Kumar (Simerics Inc)

This paper discusses the CFD investigation to estimate the cavitation characteristics of the Princess Royal propeller using the RANS-based CFD code Simerics-MP+. The propeller used in the Princess Royal research vessel at Newcastle University was chosen for the present cavitation benchmark study. Accurate prediction of propeller cavitation characteristics is of paramount importance to avoid its adverse effects, such as reduced propulsive efficiency, erosion, and increased noise. Initially, the propeller performance was validated in open water conditions, and then cavitation studies were conducted for different flow conditions based on the advanced coefficient and cavitation number. The equilibrium dissolved gas model [1] which accounts for both aeration and cavitation effects, is used to model the cavitation characteristics. The gas present in the fluid can be in various states, such as free, dissolved, or mixed, based on the local pressure. The cavitation bubbles and the propeller performance characteristics obtained from the CFD simulation showed good agreement with the available experiment and numerical data. In addition, the noise characteristics of the propeller at different cavitation conditions were obtained and reported to elucidate the influence of cavitation on the propeller noise. The Ffowcs-Williams-Hawkings (FW-H) acoustic analogy is used to predict the noise propagation to the receivers and then compared against the test data for validation. It was found that the noise data from the present study showed good agreement with the test data

Evaluation of operational characteristics of Hydrocyclones to enhance performance using numerical studies

Presented By
Vaideeswarasubramanian Kannan (Flsmidth)

Authored By
Vaideeswarasubramanian Kannan (Flsmidth)
Saminathan Karumbayiram (FLSmidth)

A hydrocyclone is a device used to separate particles in a slurry based on their size and density, playing a crucial role in the mining industry for efficient mineral separation. The slurry feed enters the hydrocyclone, creating centrifugal force that separates the particles. The heavier particles move to the outer wall and exits as underflow, while the lighter particles move to the core and exits as overflow due to back pressure. This study presents a comprehensive analysis of hydrocyclone performance using finite element analysis and computational fluid dynamics in accordance with ASME guidelines. A commercial numerical simulation software is utilized to highlight the benefits of performing analysis in determining stress distribution, fluid flow patterns, and potential improvement areas. The evaluation of various operational characteristics is significant to enhance the separation performance, and the utilization of simulation studies is emphasized. These analyses include the integration of cloud computing to enhance computational efficiency for large-scale models. This paper provides insights into optimizing design and operational parameters, to improve reliability and performance.

Aid of CFD simulations in safe and efficient thermal management of IT servers in data centre cooling

Presented By
Ankit Khandelwal (ITB Engineering services private limited)

Authored By
Ankit Khandelwal (ITB Engineering services private limited)
Yannick Lattner (ITB Ingenieurgesellschaft Technische Berechnungen mbH)

Modern world electronics are seeing a rapid change and still accelerating development. Fundamental physics pose great challenged to engineers trying the maintain thermally safe operations. These challenges are additionally complicated by the need to enable continuous operations. CFD-Simulations are essential to predict and analyse the thermal system's behaviour. CFD results precisely predict all relevant thermal and flow properties under controlled conditions. Data centre thermal management systems - Are we really awake to combat a safe and sustained thermal management with rapid shift of IT Servers heat load requirements? The thermal handling of radiations emerging through newly digitised smart phones or any electronics appliances? There is a pressing need for designs that ensure lasting thermal comfort for users and device cooling, backed by validated CFD simulations. Thermal management in data centre cooling involves controlling key parameters like coolant flow rate, room humidity, and air quality indices (PMV, PEV). Simulations help identify hotspots and evaluate worst-case scenarios such as power outages. CFD simulations reveal critical flow zones like stagnation or recirculation areas that may cause hotspots near server racks. Whether air, water, or immersion cooled, CFD is key to optimizing thermal infrastructure. CFD being a powerful way to model and optimise thermal air flow in data centres, is on other hand typically challenging and requires domain experts. It requires critical thinking & detailed layout to comprehend correct input parameter. High-fidelity CFD simulations require significant computing power and expertise plays to balance between the two which is vital for any critical simulation. Domain expertise helps correct mesh models, avoiding numerical instabilities, interpret simulation results with engineering judgments, suggesting design fixes that actually work in practice, not just in the simulation, validating cooling redundancy scenarios, etc.

Tractor muffler design and simulation for transmission Loss (TL) evaluation and Back Pressure

Presented By
Vinay Yadav (Tafe Motors and Tractors Limited (TMTL))

Authored By
Vinay Yadav (Tafe Motors and Tractors Limited (TMTL))
Tarun Nema (Tafe Motors and Tractors Limited (TMTL) Pawan Singh (Tafe Motors and Tractors Limited (TMTL) Sanjiv Pathak (Tafe Motors and Tractors Limited (TMTL) Hemant Shrikhande (Tafe Motors and Tractors Limited (TMTL)

Technology brings success and growth but it has undesirable side effects such as pollution. A type of pollution predominant on the agricultural and industrial divisions is noise. There are a lot of noise sources around us primarily automotive vehicle, machine and industry. These noise sources lead to dangerous diseases and also able to do permanent hearing loss for a person. Tractor engine is one of the unwanted noise sources. It produces high amplitude noise due to vibration. These vibrations lead to fatigue failure of other components. To control noise of engine, silencer is used. So, there is a need to design silencers more accurately. Silencers have a lot of design parameters based on aero-dynamic criterion, mechanical criterion, geometrical criterion and economical criterion. Some of the primary parameters are backpressure loss, insertion loss and transmission loss. This paper is about simulation of finite element analysis (FEA) to know the transmission loss and back-pressure in round (cylindrical) and elliptical tractor’s mufflers for a given frequency range. Finite element modelling of the problem has been performed in ANSYS Workbench 2020R2 for transmission loss. The result obtained from round muffler is compared with elliptical muffler. Analytical solution and traditional laboratory methods are discussed. These traditional methods are the four-pole transfer matrix method and three-point method. Computational Fluid Dynamic (CFD) analysis is performed using Hyper works CFD and AcuSolve CFD for determination of back-pressure in elliptical and round muffler. Results of round muffler is compared with elliptical muffler. It is observed that elliptical muffler is better in TL and backpressure.

Design Insights for Efficient Ventilation: A CFD-Based Sensitivity Analysis of Factors Influencing CO₂ Levels in a Washer/Dryer

Presented By
Mahendra Wankhede (Whirlpool of India Ltd.)

Authored By
Mahendra Wankhede (Whirlpool of India Ltd.)
Ketan Parashar (Whirlpool of India Ltd.)

Whirlpool Corporation, a global leader in home appliances with more than 110 years of innovation, is renowned for its iconic brands such as Whirlpool, KitchenAid, and Maytag. The company offers a diverse range of products, including refrigerators, washing machines, dishwashers and ovens. As consumer preferences increasingly lean toward safer and reliable home environments, enhancing the safety in appliances—particularly washers and dryers—has become a key priority in product design and development. Ventilation performance thus becomes a critical design parameter, particularly when CO₂ concentrations approach safety thresholds—a key concern in scenarios such as accidental child entrapment inside the drum. In an effort to enhance ventilation performance and identify cost-reduction opportunities without compromising system efficacy, a detailed investigation was conducted on a drum assembly exhibiting CO₂ levels near the upper permissible limit. A baseline Computational Fluid Dynamics (CFD) simulation was developed and experimentally validated to quantify the existing CO₂ distribution. Subsequently, a Design of Experiments (DOE) methodology was implemented, incorporating eight design variables—such as flapper positioning, dry channel state, inlet/outlet hose diameters, blower shell openings, condenser integration, exhaust hose presence, and drum perforations—across sixteen simulation runs. The parametric study enabled a systematic sensitivity analysis, revealing that the inclusion of a condenser subsystem was a dominant factor influencing CO₂ accumulation. This approach facilitated the identification of critical interactions and latent knowledge gaps in the current architecture. The insights gained not only informed ventilation system optimization but also supported design rationalization aligned with cost-reduction objectives, establishing a data-driven foundation for future design iterations. Keywords: Ventilation performance, Washer, Dryer, CO₂ concentration, O₂ levels, Computational Fluid Dynamics (CFD), Design of Experiments (DOE)

Terminal Replacement in a 4000 A Circuit Breaker using Experimentation Aided by Thermal and Electromagnetic Modeling: A Study Case

Presented By
Richie Garg (Schneider Electric)

Authored By
Richie Garg (Schneider Electric)
Efrain Gutierrez (Schneider Electric) Ezequiel Salas (Schneider Electric) Michel Romero (Schneider Electric)

A 4000 A circuit breaker was tested for temperature rise under different setups. The main objective was to replace casted copper terminals with integrated heat sinks by extruded copper terminals with external aluminum heat sinks, which have a lower carbon footprint. However, a significant temperature variation was observed after repeating the same setups (up to 11°C), which difficulted to accurately assess the performance of the new terminals. To diagnose the issue, thermal and electromagnetic simulations were performed. From the simulations results, it was found that temperature variations could be caused by external air currents. This was supported by further in field investigation. Different air currents caused by opening doors and the laboratory ventilation system were causing air flow disruptions at random intervals producing natural convection mitigation on the circuit breaker busbars. The random nature of these effects made it difficult to identify the cause of the temperature variations. Moreover, the vertical configuration of the busbars of the breaker made them more susceptible to air flow disruptions. Finally, to avoid these effects, physical barriers and a horizontal busbar configuration were used in the circuit breaker. By using horizontal busbars and physical barriers (curtains and cardboards), a better air control was achieved. Moreover, this is also applicable for the standard vertical busbar configuration included in UL 489 and ANSI C37.50 standard. If we ensure a good air control, any busbar configuration should give consistent results.

A Physics-based Tool for the Design and Simulation of Motors for Electric Vehicles

Presented By
Srinivas Tangirala (Pilabz Electro Mechanical Systems Pvt. Ltd)

Authored By
Srinivas Tangirala (Pilabz Electro Mechanical Systems Pvt. Ltd)
Radhakrishnan Ramdasa
Kannan Lakshminarayanana
Supreet Sultanpura
Surya Narayan (Center for Excellence in Energy and Telecommunications (CEET))

The design of electric motors for electric vehicles (EVs) presents unique challenges due to the direct interdependence between motor performance parameters and vehicle dynamic requirements. Traditional motor design approaches typically begin with an assumed motor geometry, which is iteratively refined through successive simulations to meet target speed and torque specifications. This method, however, can be time-consuming, resource-intensive, and susceptible to suboptimal outcomes. To address this, a physics-based, vehicle dynamics-driven methodology is proposed, wherein key motor performance parameters — including torque and speed demands — are directly derived from the assumed vehicle specifications which include its gross weight, wheel radius, the battery voltage, and the frontal area to achieve the target gradeability as per Automotive research association of India (ARAI). The resulting envelope of torque-speed values forms the boundary conditions and constraints for the subsequent motor design process. A case study involving the dynamic performance simulation of a commercial electric vehicle, the Tata Nexon EV, was conducted to benchmark the proposed methodology. The simulated torque and speed demands showed good agreement with the datasheet specifications of the vehicle’s production motor. Based on these performance requirements, an internal permanent magnet synchronous motor (IPMSM) was designed whose geometry was derived from the results of vehicle dynamic simulations tailored to encompass the torque-speed envelope. A detailed two-dimensional axisymmetric finite element method magnetic (FEMM) simulation of the designed IPMSM was performed to estimate its efficiency, the winding temperature, and its torque-speed curve. Maximum torque trajectory and the maximum torque per Ampere (MTPA) table was derived to help facilitate the development of a control system for the designed motor.

Advanced Equalization and Signal Integrity Simulation Techniques for High-Speed PCB Design

Presented By
Vishal Mahajan (Mobis India Limited)

Authored By
Vishal Mahajan (Mobis India Limited)
Upendra Chilakamarri (Mobis India Limited)

In the realm of high-speed printed circuit board (PCB) design, maintaining signal integrity and ensuring reliable data transmission are paramount. This paper explores the integration of advanced equalization techniques with signal integrity simulation methods to address the challenges posed by high-speed data communication. Advanced equalization techniques, such as Feedforward Equalization (FFE), Decision-Feedback Equalization (DFE), and Continuous-Time Linear Equalization (CTLE), are critical for mitigating signal degradation and noise in high-speed PCBs. These techniques enhance the performance of communication channels by compensating for losses and distortions, thereby improving signal quality and reliability. Complementing these techniques, signal integrity simulation plays a vital role in predicting and analysing the behaviour of high-speed signals. By employing simulation tools, designers can evaluate the effectiveness of various equalization methods and optimize PCB layouts to minimize signal integrity issues such as crosstalk, reflection, and electromagnetic interference (EMI). This paper presents a comprehensive study of the combined application of advanced equalization and signal integrity simulation techniques. Through detailed analysis and practical case studies, we demonstrate how these methods can be synergistically employed to enhance the performance of high-speed PCBs.

Electromagnetic Noise Prediction of Washing Machine BLDC Motor

Presented By
Nagaraja Jade (Whirlpool of India)

Authored By
Nagaraja Jade (Whirlpool of India)
Amit Nikam (Whirlpool of India)

Whirlpool Corporation is a global leader in home appliances, with over 110 years of innovation. Known for its iconic brands like Whirlpool, KitchenAid, and Maytag, the company offers a wide range of products, including washing machines, refrigerators, dishwashers, and ovens. Brushless DC (BLDC) motors are widely used in modern washing machines due to their high efficiency, compact size, and precise speed control. However, electromagnetic noise generated during motor operation can contribute significantly to acoustic noise and affect the appliance’s performance and user comfort. This study focuses on the prediction and analysis of electromagnetic noise in a washing machine BLDC motor using finite element analysis (FEA) and electromagnetic simulation techniques. Multi-physics simulation methodology has been developed to predict the noise radiation from the motor. This case study presents a multidisciplinary methodology to predict the electromagnetic noise of a BLDC motor by coupling Electromagnetics and Vibro-acoustics. The study also explores mitigation strategies by considering the controllable electrical, physical and mechanical properties of the rotor and stator assembly. The parameters such as Magnet RFD, Magnet thickness, Winding resistance, Slot opening of stator and rotor, and Motor mass are considered. Design of Experiment (DOE) analysis has been performed with two-level settings to understand the effect of potential factors on the sound power level (SWL) of the motor. The different statistical tools, such as the Pareto chart and interaction effect plots used to understand the factors having higher and lower effects on the SWL of the Motor. The optimized solution has been calculated using Regression Analysis and Monte Carlo simulations. This proposed optimized solution has a reduction of 5 dBA in motor noise level compared to the baseline design. This work provides valuable insights for designers aiming to develop quieter and more efficient motor-driven appliances.