INTRODUCTION
Good morning! My name is Prasad Varnekar, and I have recently completed my [Link] in
Mechanical Engineering from Vishwakarma Institute of Technology, Pune, with a CGPA of
8.53. I completed my HSC from R.R. Shind e Jr. College, Pune, securing 83%, and my SSC
from Sadhana Vidyalaya, Pune, with 89%.
Talking about my family, we are a family of [number of members], and my father is [father’s
occupation], while my mother is [mother’s occupation]. My family has always supported
and encouraged me to pursue my passion for engineering and technology.
During my academics, I gained practical exposure to CAD design, CFD analysis, and thermal
simulations. I have worked on multiple projects, including the Design of a Supercharger,
Thermal Management System for EV Battery Packs, and a Vapour Chamber Heat Sink for
efficient cooling.
I also completed an internship at Bharat Forge as a 3D Visualization Intern, where I
developed photorealistic 3D models using Autodesk VRED and created a Digital Twin of
defence vehicle sub-systems, integrating real-time sensor feedback for predictive
maintenance.
Additionally, I was part of the BAJA SAEINDIA team as a Vehicle Dynamics Engineer, where
we secured an All India Rank of 6 overall in 2024, including AIR 2nd in Cost Presentation
and AIR 4th in Endurance & Suspension.
I am passionate about design, simulation, and product development and always eager to
learn and adapt to new technologies. I’m looking forward to applying my skills and
knowledge to contribute effectively to this role.
Project Details
1) Design of supercharger:-
For this project, I designed a supercharger system for a Ford Raptor R equipped with a 5.2L
V8 engine, aiming to enhance its stock performance from 450 hp and 691 Nm torque to
approximately 700 hp. I started by calculating the natural airflow requirement without
boost, which was around 750 CFM, and then determined the required pressure ratio of
about 1.55 using the relation between desired and existing horsepower. Based on this, the
target airflow was calculated to be approximately 1,162.5 CFM. Using these parameters, I
estimated the supercharger speed required to achieve this airflow, which came out to nearly
2,143 RPM. I also calculated the displacement per revolution of the supercharger to be
around 0.35 ft³, ensuring the blower could deliver the desired volume of air efficiently.
The rotor design was a critical part of this project. Based on the airflow requirement and
speed ratio, I finalized the rotor length, diameter, and number of lobes to achieve optimal
efficiency and smooth operation. A helical lobe profile was selected to improve volumetric
efficiency, reduce turbulence, and minimize noise while maintaining tight clearances
between the rotors and housing to prevent leakage. CFD simulations were considered to
optimize airflow paths, while FEA was used to validate the rotor’s structural integrity and
thermal stability under high-speed operation.
For the drive mechanism, I calculated the pulley ratio by relating the maximum engine rpm
to the required supercharger rpm. A belt-driven system was chosen for its balance of
efficiency, cost-effectiveness, and reliability. Lightweight aluminum alloy pulleys were
designed to reduce rotational inertia, and a tensioner mechanism was included to maintain
proper belt tension under varying loads. Additionally, high-strength bearings capable of
withstanding both radial and axial forces were selected to ensure durability at high rpm.
Finally, the entire design was validated by cross-verifying the calculated supercharger rpm,
airflow delivery, boost pressure, and engine performance to ensure that the system could
reliably achieve the target of 700 hp without compromising efficiency, safety, or long-term
reliability. This project helped me gain strong practical knowledge in forced induction system
design, rotor optimization, and drive mechanism integration.
2) Thermal Management System for EV Battery Packs
In this project, I designed a thermal management system for lithium-ion battery packs used in
electric vehicles to maintain their operating temperature within a safe range and improve
performance.
I started by collecting the battery specifications, including cell capacity, number of cells, pack
configuration, and safe temperature limits. Using these inputs, I calculated the heat
generated during different operating conditions such as charging, discharging, and peak
loads.
Next, I studied different cooling methods and compared forced air cooling and phase change
material (PCM)-based cooling. I created a 3D CAD model of the battery pack and designed
the cooling system in SolidWorks.
To evaluate the system, I performed CFD-based thermal simulations using ANSYS Fluent. I
analyzed temperature distribution, airflow patterns, and heat transfer efficiency under
different load conditions. Based on these results, I optimized the cooling design to achieve
uniform temperature control and prevent thermal runaway.
3) Design and Analysis of Vapour Chamber with Heat Sink
This project focused on improving thermal management for high-power electronic components by
designing a vapour chamber integrated with a heat sink. The objective was to enhance heat
dissipation and avoid hotspots in compact electronics.
I started by calculating the heat load generated by the components and studied the
feasibility of using a vapour chamber. A vapour chamber works on the phase change
principle, where liquid inside evaporates, spreads heat evenly, and condenses back, thus
maintaining uniform temperature.
After understanding the concept, I designed the vapour chamber geometry and optimized
the heat sink fins — considering fin height, thickness, spacing, and material to improve heat
transfer. I created the 3D CAD models using SolidWorks.
Then, I performed CFD simulations in ANSYS Fluent to analyze temperature profiles, heat
flux, and airflow distribution. I iterated the design to minimize hotspots and maximize
cooling efficiency.
The final design showed a significant improvement in thermal performance compared to a
conventional heat sink. Through this project, I gained practical experience in thermal design,
CFD-based analysis, and component optimization techniques.
OOP (Object-Oriented Programming)
A programming approach where we organize code into objects that contain data and
methods.
Four Pillars of OOP
1. Encapsulation → Hiding data by wrapping variables and methods inside a class and
controlling access using getters and setters.
Example: Private variables in a class.
2. Inheritance → Reusing code by creating a new class (child) from an existing class
(parent).
Example: Car class inheriting from Vehicle class.
3. Polymorphism → Same name, different behavior.
o Compile-time (Overloading) → Same method name, different parameters.
o Runtime (Overriding) → Child class changes parent’s method
implementation.
4. Abstraction → Hiding implementation details and showing only necessary
information.
Achieved using abstract classes and interfaces.
Other Basics
• Class → Blueprint or template.
• Object → Instance of a class.
• Constructor → Special method to initialize objects.
• this → Refers to the current object.
• super → Refers to parent class properties or constructors.
• You should hire me because I have a strong foundation in mechanical engineering
along with hands-on experience in CAD tools like Creo and exposure to Windchill. I
also have a keen interest in programming and understand the basics of OOP
concepts, which will help me quickly learn and apply NXOpen automation for CAD
customization.
• I am a fast learner, adaptable to new tools and technologies, and eager to take up
challenging projects. I believe my combination of mechanical design knowledge,
CAD skills, and programming interest makes me a good fit for this role and I am
confident that I can contribute effectively while growing with the organization."*