Mridhul

Pole Crash Test Simulation (Automotive Safety)

Client Work

Nov 2025 - Jan 2026 • 2 mos

The project involved simulating a pole crash test in LS Dyna to evaluate structural behaviour under both frontal and side impacts, with particular focus on the pole vehicle interaction. The objective was to benchmark performance against Euro NCAP style requirements and provide reinforcement strategies to improve safety compliance. Detailed CAD models of the vehicle structure and pole barrier were developed in SolidWorks and prepared for explicit crash simulation, with calibrated material definitions, contact models, and boundary conditions replicating regulatory standards. Results showed intrusion depths of 210-220 mm, peak occupant loading of 28 g, and total energy absorption above 65 kJ. Acceleration time histories confirmed controlled load transfer throughout the event, while quantified load paths revealed critical stress channels in the side sill and floorpan. Deformation occurred within 61 ms, highlighting localized failures and guiding targeted reinforcement concepts.

Pump Impeller Design & Hydraulic Optimization

Government backed energy project

Jul 2025 - Oct 2025 • 3 mos

Commissioned within a government backed energy program, this project delivered a centrifugal pump impeller for large scale pumping operations. The mandate was to increase efficiency and reliability while ensuring the design remained practical for industrial manufacturing and long term operation. The impeller was developed in SolidWorks with multiple design iterations refining blade geometry and hub configuration. Performance was validated through CFD simulations in Ansys Fluent and StarCCM+, with a focus on reducing hydraulic losses, improving velocity balance, and extending cavitation resistance under demanding duty cycles. The optimized design achieved a 14% efficiency improvement, a 20% reduction in hydraulic losses, and a 30% improvement in flow uniformity, while extending cavitation margin by 12% compared to baseline. These results directly supported project targets for lower energy consumption and stable long term operation.

Intake Manifold CFD Optimization (Dual Inlet)

Independent European Motorsport Team

Mar 2025 - Jun 2025 • 3 mos

This project addressed uneven flow distribution in a dual inlet intake manifold intended for high-performance automotive applications. The goal: deliver consistent air fuel balance across all cylinders while minimizing pressure losses. A baseline model was developed in SolidWorks and iteratively refined. CFD simulations in StarCCM+ evaluated velocity distribution, pressure drop, and turbulence intensity across design variants. Runner geometry and inlet angles were systematically optimized to achieve uniform flow delivery. The optimized design achieved a 4× reduction in velocity scatter, reduced pressure drop to 236 Pa, and secured <0.1% mass flow imbalance ensuring stable and efficient combustion conditions. Deliverables included a complete CAD package, CFD reports with contour and streamline visualizations, and a validation dossier suitable for integration into performance engine programs.