ADARSH VIJI ELANGO

As a Senior Product Engineer CAE at Honda Development and Manufacturing of America LLC, leads advanced CAE initiatives within the Digital Innovations Division to optimize automotive crash models and product performance through MDO techniques.

• Pioneered and implemented best practices for CAE methods, scripts, and processes, significantly enhancing reliability and robustness in FEA-based automotive crash model optimization.
• Automated complex CAE workflows and scripting for Design of Experiments (DOE), Robustness Optimization, and Multi-Disciplinary Design Optimization (MDO), leading to improved product performance and reliability.
• Developed and standardized advanced engineering design tool methodologies, streamlining product development cycles and optimizing designs for superior performance.
• Completed a proof-of-concept MDO study projecting a mass saving of ~5kg per vehicle, conservatively estimated to save ~$2 million in material and manufacturing costs per vehicle program.
• Spearheaded CAE methods development across diverse multi-physics disciplines, including External Aerodynamics, Thermal performance, Powertrain energy usage, HVAC, NVH, Crash Safety, and Vehicle Body-in-white structural rigidity.

Member of the application engineering team at Hexagon Design & Engineering, contributions include creating proof of concept projects, demonstrations, presentations and benchmarks using Hexagon’s portfolio of simulation products (Cradle CFD and ODYSSEE), leveraging expertise in computational modeling techniques.

• Streamlined external aerodynamics workflows using Cradle CFD's Voxel Fitting Mesh methodology, effectively handling 'dirty' CAD geometries and improving efficiency for OEM customers.
• Developed and applied automated scripts and enhanced workflows, directly benefiting various OEM customers in their adoption of advanced simulation techniques.
• Created compelling proof-of-concept studies showcasing the ODYSSEE platform's benefits for reduced order modeling (ROM) and machine learning (ML) applications in product development.
• Developed multi-fidelity CFD simulation methodology for automotive battery packs in thermal runaway condition, achieving a 6X to 10X speedup of simulation run time using empirical modeling based on experimental battery ARC data, P2D and Equivalent Circuit Models (ECM) for individual cells in the battery pack.
• Contributed to a commercial services engagement, developing rapid prediction methods for Finite Element Analysis (FEA) stress and strain fields in new automotive assemblies, leveraging existing data.
• Conducted Gearbox oil-air sloshing simulation using Cradle CFD multiphase flow simulation (overset mesh, VOF fluid surface capturing and moving elements).

Provided expert pre and post-sales consulting for automotive, aerospace, and energy sectors, implementing simulation automation, design optimization, and multiphysics studies using modeFRONTIER.

• Advised a Master's thesis on 'Shape Optimisation in Fluid Dynamics,' translating Ansys Fluent CFD adjoint solver results to ANSA mesh morphing for gradient-based optimization.
• Executed and presented medical device FEA optimization case studies, including minimizing dilation stresses in cardiovascular stents and potting stress in femoral implants.
• Performed fighter aircraft outer mold line optimization, maximizing range and endurance using Lockheed Martin EXPEDITE model data.
• Provided external supervision and support on a Master’s thesis, ‘Analysis of Mooring cable behavior for floating offshore wind platforms in deep sea deployments’

Delivered technical expertise in simulation automation, design optimization, and multiphysics studies, supporting clients across automotive, aerospace, and energy industries with modeFRONTIER.

• Conducted training sessions for various OEMs on simulation process integration, surrogate modeling, and optimization, enhancing client capabilities.
• Developed macros and scripts in multiple programming languages to automate simulation processes, improving efficiency and repeatability.
• Streamlined process automation and data for a one-way Fluid Structure Interaction (FSI) automotive water-wading simulation, including auto-compilation of pressure results into structural load decks.
• Provided expert consultation to aero-acoustic engineers, successfully optimizing and reducing fluid flow noise produced by the fluid flow between side mirrors and automotive glass windows.
• Developed a systematic method for statistical analysis of automotive aerodynamic drag coefficients' sensitivity, informing future derivative vehicle programs.
• Automated simulation workflows using Sculptor mesh morphing and Ansys Fluent, reducing IC engine performance variation by 66% and increasing exhaust manifold flow uniformity by 40%.
• Optimized automotive HVAC systems for component sizing, achieving cabin comfort with minimal energy expense.
• Automated simulations to optimize electric traction motor performance, minimizing torque ripple and maximizing output, while meeting structural stress constraints.
• Automated fluid simulations using CAESES and Ansys CFX, establishing efficient workflows for complex geometries like the turbocharger shroud volute.
• Automated simulation and job execution on cloud HPC and distributed execution environments (Linux and Windows).

As a Systems Engineer, contributed to the design and engineering of luxury yachts through 3D CAD modeling, structural analysis, and preliminary design calculations.

• Created comprehensive 3D CAD models, production, and structural drawings for luxury yacht designs, ensuring accuracy and manufacturability.
• Conducted preliminary design hand calculations, mass estimations, and FEA simulations to validate and optimize next-generation product designs.

Presented on the optimization techniques for high-power electric traction machines, showcasing advanced simulation and design methodologies.

Presented on leveraging model-based design automation and collaborative MDO to accelerate aircraft design processes.

Presented on simulation-based design exploration strategies for optimizing medical devices like cardiovascular stents and femoral implants.

Presented on cloud-based optimization techniques applied to mixer design for urea/SCR aftertreatment systems.

Published a paper on optimizing HVAC systems to reduce energy consumption and enhance cabin comfort.

Authored a journal article on methods for identifying optimal designs within highly constrained design optimization problems with infeasible data sets.

Published a journal article detailing multidisciplinary design optimization strategies for achieving significant vehicle weight reduction.

Authored a technical paper on applying hybrid optimization algorithms to automotive design problems and comparing their performance with standard optimizers.