Sagar Kumar
Email-id: sagar985263@[Link]
Mobile No: 8709191881
Summary
Dedicated CFD Simulation Engineer with robust expertise in thermal and fluid flow analysis, leveraging
industry-standard tools like Ansys Fluent, Icepak, FloEFD and STAR-CCM+. Skilled in designing and
optimizing simulation workflows across automotive, electronics, and industrial sectors, with strong
competencies in electronic cooling, conjugate heat transfer, and EM-thermal coupling. Armed with an
[Link] in Thermal Engineering from NIT Kurukshetra and a solid blend of academic excellence and
practical project experience, I excel at delivering precise, optimized simulation solutions and clear,
effective client communication.
Tools / Skills
CFD & Simulation Tools: Ansys Fluent, Ansys Icepak, FloEFD, STAR-CCM+, Simcenter 3D,
AEDT, Ansys Workbench, Ansys Discovery
Modeling & CAD Tools: SpaceClaim, SolidWorks
Core Competencies: Heat Transfer, Thermodynamics, Fluid Mechanics, CHT (Conjugate Heat
Transfer), Steady-State Simulation, Transient Simulation, Electronics Cooling, Thermal analysis,
Flow Analysis, Radiation, Rotating Domain, Porous Media Modeling, Multiphase Flow
Work Experience
Simulation Engineer | CADFEM India Pvt. Ltd., Hyderabad, Telangana
July 2023 – Present
Role & Responsibility
Employing Ansys ICEPAK and FloEFD for electronic cooling, Ansys Fluent and STAR-CCM+
for Thermal and Flow analyses across diverse projects.
Leading key phases of CFD projects, including geometry simplification, meshing, simulation,
and post-processing.
Contributing to improved pre-processing efficiency through streamlined geometry simplification
techniques.
Conducting in-depth data analysis during post-processing to derive meaningful insights.
Preparing and delivering client presentations, effectively communicating complex simulation
results.
Projects
1. CFD Analysis of PRS (Pressure Reduction Station)
Conducted 3D CFD analysis of a PRS device using Ansys Fluent to evaluate mass flow,
velocity, and pressure distribution at the inlet, outlet, and pressure controller.
2. CFD Analysis of High-Pressure Nozzle
Performed 3D CFD analysis of a high-pressure nozzle using Ansys Fluent, focusing on
airflow dynamics to determine variations in critical flow parameters such as pressure and
velocity around the O-ring.
3. CFD (Thermal) Analysis of Head Lamp
Conducted 3D thermal CFD analysis of a headlamp using Ansys Icepak with ECAD for the
PCB to assess the temperature distribution across all critical components.
4. CFD Analysis of Card Cage Assembly
Performed 3D CFD analysis of a fully loaded card cage assembly (20 sets of cards) using
Ansys Icepak to evaluate temperature distribution and airflow between the boards.
5. CFD Analysis of Submersible Motor
Conducted a 3D steady-state thermal CFD analysis of a submersible motor using Ansys
Fluent. Utilized electromagnetic (EM) output (power losses) as input to evaluate the
temperature distribution across critical components, including copper windings, core, shaft,
sleeve, and magnets.
6. CFD Analysis of Bus Duct
Performed a 3D steady-state thermal CFD analysis of a bus duct using Ansys Fluent. Utilized
electromagnetic (EM) output (power losses) as input to evaluate the temperature distribution
across all three-phase conductors and their enclosure, ensuring both remain within allowable
temperature limits.
7. Thermal Analysis of Electric Oven
Conducted thermal and fluid flow simulations in STAR-CCM+ for various oven modules.
Analyzed airflow in the cavity, ventilation, and door regions to identify hotspots and
recommend performance-enhancing design changes. Performed both steady and transient
analyses, incorporating MRF, porous media, tags, filters, and Java macros for efficient post-
processing and HPC job submission.
8. CFD Analysis of Radar
Performed a 3D steady-state thermal CFD analysis of a 12V car radar using Ansys Icepak
with ECAD for the PCB. Incorporated thermal interface material (TIM) to enhance heat
transfer and analyzed the temperature distribution across the heat source, heat sink, and
mounting plate under three different ambient temperature conditions.
9. CFD Thermal Analysis of FLACS OCT Module
Investigated the thermal performance of the FLACS (Femtosecond Laser-Assisted Cataract
Surgery) OCT (Optical Coherence Tomography) module of an eye surgical device. Explored
alternate heatsink designs for optimal thermal performance and compact integration. This
CFD analysis was performed using Ansys Icepak.
10. Flow and Thermal Analysis of an Eye Device
Performed comprehensive flow and thermal analysis of an eye-care device using FloEFD.
Simulated key components including porous media, internal fan, and multiple heat sources to
evaluate airflow distribution and temperature profiles. Identified recirculation zones and
potential hotspots affecting device performance. Based on CFD insights, provided detailed
recommendations to enhance thermal management and ensure uniform cooling across the
device for improved reliability and user comfort.
Awards / Certifications
Got the course completion certificate on “INTRODUCTION TO CAE SIMULATIONS USING
SIMCENTER STAR CCM+” from Siemens Centre of Excellence, NIT Kurukshetra.
Got the course completion certificate on “INTRODUCTION TO SIMCENTER-3D” from
Siemens Centre of Excellence, NIT Kurukshetra.
Got the course completion certificate on “SOLID WORKS” at Netaji Subhash Engineering
College.
Attended five days Training program on “Design and Simulation Workshop using Ansys” at
National Institute of Technology Kurukshetra
Attended “7th National Workshop on Research Methodology in Fluid Mechanics: Challenges in
CFD” at IIT Roorkee.
Education
[Link] (Thermal Engineering) – NIT Kurukshetra (2023) | CGPA: 8.53
[Link] (Mechanical Engineering) – NSEC, Kolkata (2020) | CGPA: 8.57
Senior Secondary (12th) – BSEB (2014) | 68.6%
Secondary (10th) – BSEB (2012) | 77%
[Link] Project
CFD Simulation of a Single Cylinder Four-Stroke Dual-Fuel Engine using Ansys Forte. Focus
on spray parameters, performance metrics (pressure, temperature, efficiency), and emissions
(NOx, UHC, CO).
Accomplishments
“Effects of Spray Cone Angle on Dual Fuel Gasoline-Diesel Engine Using CFD Simulation”.
Paper presented in 1st International Conference on Mechanical Engineering: Researches and
Evolutionary Challenges (ICMech-REC-2023) organized by National Institute of Technology
Warangal on 23-26th June 2023 at NIT Warangal, Telangana, India.
“Effects of Spray Nozzle Area on Dual Fuel Gasoline-Diesel Engine Using CFD Simulation”.
Paper presented in 3rd International Conference on Advancement in Materials Processing
Technology (AMPT-2023) organized by National Institute of Technology Jamshedpur on 13-14th
July 2023 at NIT Jamshedpur, Jharkhand, India.