Although Electric Vehicles have several advantages compared to their ICE counterparts, EV related fires and thermal runaways have caused widespread concerns!

Vishwas Kulkarni, our next pathbreaker, Research Engineer at Virtual Vehicle Research GmbH (Graz, Austria), is responsible for carrying out thermal and fluid simulations of e-Powertrain components and optimizing them.

Vishwas talks to Shyam Krishnamurthy from The Interview Portal about his master’s thesis on In-orbit refuelling simulation for future deep space and long term missions, that played a vital role in solidifying his interest in fundamental and practical Fluid Dynamics.

For students, the most effective way to have a fundamental understanding of what you study is by gaining practical knowledge through hands-on projects.

Vishwas,  what were your growing up years like?

I’m from Nashik, Maharashtra, grew up in Nashik itself. My father is a Civil engineer, and Mother is a teacher (BSc Physics). Due to the technical background of my parents, I always had an interest in Math and Science, a strong urge to know everything around me – what they are and how they work. In my school, I did not quite excessively participate in extracurricular activities, but now and then I used to participate in some competitions and sports events but not much.

As I said I liked science but during the period of 8-10th grade, I knew I didn’t quite like biology, chemistry or electro chemistry. But I felt, as compared to these subjects, I was a little better in solving equations and understanding the Physical concepts. This may have played a part in why I did not choose to pursue medical or electrical/E&TC engineering.

What did you do for graduation/post graduation?

After my 10th, I did a Diploma in Mechanical engineering from GGSP Polytechnic, Nashik then I did my BE in Mechanical engineering from Pune University and Master’s in Aerospace engineering from University of Bremen, Germany.

What were some of the influences that led you to a DeepTech, Research intensive career in Core Engineering?

As I said earlier, my interests were in understanding Physical and Mathematical concepts. As a kid, I had the curiosity to open a random toy at home and play around.

My father played a vital role in guiding me to choose subjects and make me understand the real world. One of my Professors in my bachelors made me really understand the subjects, not just study for exams per se.

An acquaintance of mine who was working at National Chemical Laboratory in Pune, introduced and encouraged me to do a masters in Germany. This helped me secure a Masters position with full Scholarship in a German University.

Tell us about your career path

My first internship was at Sharda Motors in Nashik during my diploma. The company manufactures and assembles various parts from emission systems to suspension systems, supply chain, concluding at seating frames and trims. My job was just to study the supply chain for the suspension systems right from manufacturing to quality control. Though I had already studied these things in my curriculum, a month-long internship helped me to really understand that it takes much more than studying to understand things. This motivated me even more to have a strong basic understanding of what I study, not just theoretical but also practical.

This helped in my final year diploma project at Lear Corporations in Nashik as well. The project was focused on improving manufacturing processes. The Industry was unable to manufacture a driver and co-driver seat component ‘RISER’ used in ‘Mahindra Scorpio’ within specifications due to a problem in the tool insert of the 150 ton Hydraulic Press. Studies were carried out by applying the ‘Fishbone method of root cause analysis’ and ‘Why-Why analysis’ on planning and manufacturing processes of the Riser component. This project helped me understand corporate culture and inter-team collaborations. 

My final year bachelors project was in Finolex Plasson Pvt. Ltd in Pune. This project was based on Product Design, Development and Manufacturing of an Irrigation dripper. An irrigation dripper is a component of a drip irrigation system that slowly releases water in small drops directly to the plant’s root zone, minimizing water loss from evaporation and runoff

We had to apply a generic design process to develop a new irrigation dripper. This was the first time I was introduced to the field of Computational Fluid dynamics and it was quite interesting to study the subject in depth, not just in theory.

After my bachelors, I worked as a Design Engineer for a year at Strama Summit Machinery in Nashik. My role was to develop and design the automated machinery and mechatronic system from a mechanical point of view using Solidworks and Autocad. My job was not just technical but to develop and work on new projects and tenders as well. Apart from this, I conducted workshops for students and interns as well as collaborated with an international team in Germany. This all helped me to expand my work ethics. Overall, this job helped me improve not just technical skills but also managerial and leadership skills. 

From all the above internships and jobs, it was clear to me that I wanted to do something that involved Structural Design engineering in future as a career. I already had a BTech in Mechanical Engineering. As I saw this interesting master’s program in Aerospace which had interesting courses and study structure, I just applied to it.

But in my masters in Germany, I could not find any Structural Design internships. One of my Fluid Dynamics professors had a student position open in his department, so I applied to it. This internship solidified my interest in fundamental and practical Fluid Dynamics. It was in this same department where I did my Master’s thesis which was a joint project of NASA-German Aerospace Center-University Bremen regarding development and simulation of an in-orbit refuelling of spacecraft. In this student position and master’s thesis, I learnt more than I could from any other textbook or course or internship or job. It shaped me in every possible way as a student to always keep learning, as a person to always be good and humble, and be a good team member.  

In-orbit refuelling plays a vital role for future deep space and long term missions. Zero Boil-Off Tanks (ZBOT) are significant in preventing any propellant loss which are caused due to repeated venting of the tank to maintain the pressure. NASA, DLR and University of Bremen are jointly working on the project `ZBOT-FT’ where filling and transfer of propellant from donor tank (space depot) to the receiver tank (spacecraft tank) is investigated.

This master’s thesis aims at numerical modelling and simulation of the no-vent fill process of a tank in zero gravity using a similitude fluid of Perfluoro-n-pentane C5F12. The interfacial mass transfer rate and the flow behaviour at different volumetric flow rates were observed by filling the liquid C5F12 at a saturation state of 10 000Pa into a completely or partially vapour filled adiabatic tank at the same saturation state. Capabilities of ANSYS Fluent was extended using a user-defined function (UDF) whose purpose was to model the interfacial mass transfer. The 0D equilibrium model was developed by solving equation systems for the equilibrium state with a non-linear solver of Python in order to cross-check the CFD simulations. Further, a dimensional analysis onto the problem was done to have a better understanding of the physical phenomenon involved in this fill process as well as to test the potential of the similitude fluid.

You can find more here: https://ntrs.nasa.gov/citations/20220016412

How did you get your first break?

My student position/master’s thesis in my Masters was my break. Getting the job in Austria was kinda hard. HR considered all the knowledge and experience from my bachelors. As I said, my masters’ thesis and student job made a difference.

What were some of the challenges you faced? How did you address them?

Challenge 1: I didn’t get admitted to my dream University for my bachelors. I was down for a long time even after I started my engineering. But after some point, I accepted it and worked harder from that point.

Challenge 2: After coming to Germany, it was hard to be alone in an unknown place. Different language, different people, cold winter. It felt strange for my 1st semester. I just tried to connect with other people, family, and make new friends. This helped to get rid of my anxiety.

Challenge 3: I face many challenges everyday where things don’t work at all. Not just professional but also personal. When I feel this, I just take a long walk in nature to free my mind and relax.

Where do you work now? 

I currently work at Virtual Vehicle Research Center (Austria) which is a nonprofit research center. It’s a public funded research institute. Research topics are ADAS systems, Battery Development, Rail Engineering, Human Centric Design etc. We do EU funded research projects and some service-based projects for the automotive OEMs.

I’m responsible for carrying out the thermal and fluid simulations of e-Powertrain components and optimizing them. So basically, numerical model development & design of automobile battery/inverter cooling and power electronics cooling components.

What are the skills required for your role? How did you acquire them?

Skills required are understanding and knowledge of thermodynamics, fluid mechanics and mathematics, as well as knowledge in Fluid Simulation software OpenFOAM and coding skills.

I think what I love about my job is that it is not monotonous, every now and then I have to work on new designs and simulation concepts and try to improve them. 

How does your work benefit society? 

I’m developing the components for EV automobiles. So, I’m satisfied that I do something for the environment and aspire to keep the society pollution free.

Tell us an example of a specific memorable work you did that is very close to you!

During my bachelors, I worked on the student racing team. Developing, design and manufacturing all on our own was quite memorable. 

Your advice to students based on your experience?

I suggest students to have the fundamental understanding of what you study. Try to gain more practical knowledge by working on hands-on projects. Sometimes things may not go the way you planned but still don’t lose hope; you’ll get back into it and achieve greater things.

Future Plans?

I’m planning to work in the same field I’m working in now. Try to contribute fruitfully in my research field. And let’s see what comes in the way.