Working Details

• Phase 1: Model Scoping & Baseline Analysis: Established the analytical framework for a critical electric turbo-charger sub-assembly, defining the boundary conditions and preparing the CAD geometry for a multi-physics environment. 

• Phase 2: Electro-Thermal Simulation: Developed a detailed thermal model to simulate the Joule heating effect resulting from a continuous 265 A, 3-phase electrical load, accurately predicting heat generation within the conductors. 

• Phase 3: Conjugate Heat Transfer (CHT) Analysis: Executed a comprehensive fluid dynamics simulation (Fluent/CFX) to characterize the heat rejection capabilities of the integrated fluid-cooling circuit, quantifying the heat transfer between the solid components and the coolant. 

• Phase 4: Coupled-Field Integration: Mapped electro‑thermal and CFD results to deliver a comprehensive temperature field for structural assessment. 

• Phase 5: Thermomechanical Structural Assessment: Performed high‑fidelity static analysis including thermal contact resistance and potting behavior to evaluate stresses and deflections. 

• Phase 6: Validation and Verification: Executed mesh‑convergence studies and benchmarked predictions against test data, confirming insulation temperatures and mechanical stresses within design limits.